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PNEG-1400
User Manual
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GSI PNEG-1400 User Manual

PNEG-1400
WCL Commercial 4" Corrugation Externally Stiffened Grain Bin
Assembly Manual
PNEG-1400
Version: 2.0 Date: 12-06-11
All information, illustrations, photos, and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
Table of Contents

Contents

Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines .................................................................................................................................. 4
General Safety Statement ..................................................................................................................... 5
Safety Instructions ..................... ... .... .......................................... ... ........................................................ 6
Safety Sign-Off Sheet ........................................................................................................................... 8
Proper Storage of Grain Bin/Silo Materials Prior to Construction ......................................................... 9
Chapter 2 Decals ..................................................................................................................................................10
Chapter 3 Bin Assembly ......................................................................................................................................13
General Information ............................................................................................................................ 13
Construction Procedures and Lifting Jack Usage ............................................................................... 14
Decal Sheet Placement ....................................................................................................................... 15
Bolting Requirements - 2 Stiffeners per Sidewall Sheet ..................................................................... 16
Bolting Requirements - 3 Stiffeners per Sidewall Sheet ..................................................................... 17
Hardware ...................................... ................ ................. ................ ................ ...................................... 18
Caulking Detail .................................................................................................................................... 19
Laminated Sheet Illustration ................................................................................................................ 20
Base Angle Installation ........................................................................................................................ 21
Anchor Bolt Washer Installation .......................................................................................................... 22
Bolt Identification ................................................................................................................................. 23
Chapter 4 4" WCL Commercial Tank Stiffener Instructions ............................................................................29
4" WCL Corrugation WCL Commercial Stiffener Splice Details .......... ............................................. ... 29
Commercial Stiffeners for 4" Corrugation ...................................... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ...... 30
Stiffener Splice Details ........................... ... ... .... ... ... .......................................... ... ................................ 31
Laminated Stiffener Splice .................................................................................................................. 34
Stiffeners to Sidewall Sheet Details .................................................................................................... 35
Chapter 5 Wind Ring and Access Door Assembly ...........................................................................................43
Wind Ring Assembly .................................... .... ... ... .......................................... ... ................................ 43
Access Door Weldment Assembly Hardware Package (PLS-41985) ..................... ... ... ... ... .... ... ... ... ... 44
Chapter 6 Sidedraw Accessory Instructions .....................................................................................................45
Installation and Management of Sidedraw Systems ........................................................................... 45
1" Diameter Anchor Bolt Requirements for Sidedraw Systems .......................................................... 46
Sidedraw System Installation .................................... .... ... ... ... .......................................... ... ................ 47
Wind Rings Sidedraw Usage - WCL 2 Post Stiffened Tanks .............................................................. 48
Wind Rings Sidedraw Usage - WCL 3 Post Stiffened Tanks .............................................................. 49
Sidedraw Installation .................................... .... ... ... ... .... ... ... .......................................... ... ................... 50
Chapter 7 Warranty ..............................................................................................................................................53
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 3

1. Safety

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to personal injury.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Safety Guidelines
This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections. Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death.
DANGER
WARNING
CAUTION
NOTICE
1. Safety
This product has sharp edges, which may cause serious injury. To avoid injury, handle sharp edges with caution and always use proper protective clothing and equipment.
General Safety Statement
Our foremost concern is your safety and the safety of others associated with grain handling equipment. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.
As owner and/or operator, you are responsible to know what requirements, hazard s, and precautions exist and inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment, which may produce a very dangerous situation, where SERIOUS INJURY or DEATH may occur.
You should consider the location of the bin site relative to power line locations or electrical transmission equipment. Contact your local power company to review your installation plan or for information concerning required equipment clearance. Clearance of portable equipment that may be taken to the bin site should also be reviewed and considered. Any electrical control equipment in contact with the bin should be properly grounded and installed in accordance with National Electric Code provisions and other local or national codes.
This product is intended for the use of grain storage only. Any other use is a misuse of the product.
Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall bundles is laying horizontally with the arch of the sheet upward, like a dome. Sidewall sheets stored on edge must be secured so that they cannot fall over and cause injury. Use care when handling and moving sidewall bundles.
Personnel operating or working around equipment should read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 5
1. Safety
Follow Safety Instructions
Carefully read all safety messages in this manual and safety signs on your machine. Keep signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from the manufacturer.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machinery in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.
If you do not understand any part of this manual or need assistance, contact your dealer.
Read and Understand Manual
Practice Safe Maintenance
Understand service procedures before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is in operation. Keep hands, feet, and clothing away from rotating parts.
Keep all parts in good condition and properly installed. Fix damage immediately . Replace worn or broken p arts. Remove any built-up grease, oil, and debris.
Maintain Equipment and Work Area
Safety Instructions
Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.
As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment. Such alterations may p roduce a very dangerous situation where SERIOUS INJURY or DEATH may occur.
This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
1. Safety
Prepare for Emergencies
Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Keep Emergency Equipment Quickly Accessible
Wear Protective Clothing
Wear close-fitting clothing and safety equipment appropriate to the job.
Remove all jewelry.
Tie long hair up and back.
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharp edges on plastic or steel parts.
Wear steel-toed boots to help protect your feet from falling debris. Tuck in any loose or dangling shoestrings.
A respirator may be needed to prevent breathing potentially toxic fumes and dust.
Wear a hard hat to help protect your head.
Wear appropriate fall protection equipment when working at elevations greater than six feet (6').
Eye Protection
Gloves
Steel-Toed Boots
Respirator
Hard Hat
Fall Protection
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 7
1. Safety
Safety Sign-Off Sheet
As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe operating and safety procedures for this auger. This sign-off sheet is provided for your convenience and personal record keeping. All unqualified persons are to stay out of the work area at all times. It is strongly recommended that another qualified person who knows the shut down procedure be in the area in the event of an emergency.
Date Employee Name Supervisor Name
1. Safety
Proper Storage of Grain Bin/Silo Materials Prior to Construction
Wet storage stain (rust) will develop when closely packed bundles of galvanized material, such as sidewall and roof sheets, have moisture present. Inspect roof and sidewall bundles on arrival for any moisture. If moisture is present, it must not be allowed to remain between the sheets. Separate the sheets or panels immediately and wipe them down. Spray with a light oil or diesel fuel.
If possible, sidewall bundles, roof sheets and other closely packed galvanized materials should be stored in a dry, climate controlled building. If outdoor storage is unavoidable, the materials should be stored so that they are raised above the ground and vegetation. Any stacking and spacing materials should not be corrosive or wet. Be sure to protect materials from the weather, but permit air movement around the bundles if possible.
Storing roof bundles and sidewall sheets at a slight incline can also help minimize the presence of moisture. Storing the bundles with the center of the dome up (like an arch) is one option for minimizing moisture during storage. Sidewall bundles can also be stored on edge but must be secured so that they do not fall over and cause injury.
If “white rust” or “wet storage stain” occurs, contact the manufacturer immediately about ways to minimize the adverse effect upon the galvanized coating.
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 9

2. Decals

Excessive vacuum (or pressure) may damage roof. Use positive aeration system. Make sure all roof vents are open and unobstructed. Start roof fans when supply fans are started. Do not operate when conditions exist that may cause roof vent icing.
DC-969
CAUTION!
The manufacturer does not warrant an y roof damage caused by excessive vacuum or internal pressure from fans or other air moving system s. Ade quate v entilation and/o r “make up air” dev ices should be provided for all powered air handling systems. The manufacturer does not recommend the use of downward flow systems (suction). Severe roof damage can result from any blockag e of air passages. Running fans during high humid ity/co ld w ea ther co nditio ns can ca us e air ex haust or intake ports to freeze.
2. Decals
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
Keep clear of all augers. DO NOT ENTER this bin!
Failure to heed these
warnings will result in
serious injury or death.
If you must enter the bin:
1. Shut off and lock out all power.
2. Use a safety harness and safety line.
3. Station another person outside the bin.
4. Avoid the center of the bin.
5. Wear proper breathing equipment or respirator.
DC-GBC-1A
ATTENTION: The decal shown below should be present on the inside of the outside door cover of the 2 ring, 24" porthole door cover and roof manway cover. If a decal has been damage d or is missing in any of these locations, contact the manufacturer for a free replacement decal.
GSI Decals
1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 11
2. Decals
Failure to heed these warnings
could result in serious injury, death,
structural damage or collapse of tank.
1. Use CENTER FLOOR OUTLET ONLY until NO grain remains above this outlet.
2. Side floor outlets to be used ONLY when above condition is satisfied.
3. Lock all side floor outlets to avoid accidental premature use.
4. See manufacturers instructions for proper use of factory supplied sidedraw (wall) discharge systems.
UNLOADING INSTRUCTIONS:
DC-GBC-2A
WARNING
DON’T
DO
ATTENTION: The decal shown below should be present on the inside of the outside door cover of the 2 ring, 24" porthole door cover and roof manway cover. If a decal has been damaged or is missing in any of these locations, contact the manufacturer for a free replacement decal.
GSI Decals
1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421

3. Bin Assembly

General Information
INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct. Report any damage or shortages by recording a detailed description on the bill of lading to justify the customer’s claim from the transport firm. Our responsibility for damage to the equipment ends with acceptance by the delivering carrier. Save all paperwork and documentation furnished with any of the equipment/components.
This manual should be considered a permanent part of the equipment and should be easily accessible when needed.
Read this manual carefully. This manual will provide instructions on building the sidewall. Other instructions and manuals are required to build this tank. Some of the additional materials needed are detailed below.
A stiffener and sidewall gauge layout chart is needed. If such a chart is not included with this manual, contact GSI.
Roof instructions are required and must be followed. The roof construction manual (PNEG-1092) will contain instructions for 60' diameter and smaller bins. See appropriate individual diameter instructions for other diameters.
Ladders, roof stairs, roof handrails and other products are covered by separate instruction manuals. Consult the appropriate accessory manual.
Aeration systems and transitions are to be installed according to the instruct ions provided with the system or transition.
Anchor bolt placement details are provided in the GSI Concrete Recommendation Manual (PNEG-318).
Tools for construction:
• Combination wrench set 7/16" to 1".
• Alignment punches 12" long.
• Hammer.
• Screw drivers - standard and phillips.
• 3/8" Drive socket set and ratchet.
• 1/2" Drive socket set and ratchet.
• Nail aprons or tool pouches to hold supplies.
• Gloves for hand protection.
• Tape measure.
• 1/2" Drive electric or pneumatic impact gun.
• 1/2" Drive impact socket set.
• Lifting jacks.
• Center pole roof support.
• Step ladders.
• Large C-clamp or welding V-grip for clamping.
Quantities required depends on the number of workers and size of the bin/silo.
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 13
3. Bin Assembly
Construction Procedures and Lifting Jack Usage
NOTE: The roof and top ring or two (2) rings will be installed prior to the beginning of bin lifting/jacking
procedures. Refer to all other procedures on sidewall and stiffener installation prior to the start of construction.
1. Consider the starting location of the bin, as it relates to the location of doors and other accessories. Proper placement of lifting jacks in relationship to anchor bolts could influence final locations. Note that the sidewall sheets will be staggered.
2. Lifting jacks are used to slowly and evenly lift the bin during construction. Lifting jacks must be properly sized and designed to carry all dead and live loads and meet all job site conditions associated with the construction of the bin.
The number of lifting jacks required is best determined by personal experience and expertise. Factors such as bin size, jack design, construction conditions, support surface, etc. are all to be considered when deciding how many to use. If in doubt, use one jack on every sheet. The lifting jack must be adequate to carry all loads. Heavy duty jacks, generally hydraulic or electric powered in the case of large bins, should be used for commercial installation. All jacks should be secured with braces or otherwise maintained in a stable condition.
Do not lift bins under windy conditions. Follow the jack manufacturer’s recommendations on capacity and operations.
3. Lifting brackets must be attached through the stiffener bolt holes. Normally at least four (4) bolts per stiffener are required.
4. Raise the bin just high enough to assemble the next ring. When lifting the bin, all jacks must lift at an equal rate. Monitor the process to ensure that even lifting is occurring.
5. Bolt the next ring to the inside of the first ring. Be sure to stagger the sheets and select the prope r gauge material.
6. After assembling and tightening the bolts on the new ring (or rings), lower the bin onto the foundation.
7. Attach stiffeners to the body sheets every two (2) tiers on the external surface of the bin. Consider leaving the sheets loose to make the attachment of the stiffeners easier.
8. Re-bolt the lifting brackets to the lowest ring in place thus far. Continue ring additions by repeating
Step 5 and Step 6.
9. Add inside and outside ladders as you continue to raise the bin. (Refer to the manual supplied with the ladder.)
10. Lower the tank and secure to the foundation before leaving the job site.
11. At the completion of the tank, set stiffeners over the anchor bolts and measure the tank to ensure it is in a round condition. Consult with GSI for questions on tolerances.
NOTE: For 2 ring doors or vehicle traffic doors, special placement issues may apply. Consult the special
instructions provided with 2 ring doors or vehicle traffic doors for these options.
3. Bin Assembly
Decal Sheet Placement
NOTE: The decal sheets are located in the second ring from the top. They are to be spaced evenly around
the diameter of the bin.
Figure 3A 2 Post
Figure 3B 3 Post
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 15
3. Bin Assembly
Bolting Requirements - 2 Stiffeners per Sidewall Sheet
Sidewall Gauge Horizontal Seam Vertical Seam Stiffener to Sidewall Overlap Seam
20-15
14-12
11-9
8
13L-6L
(Laminated)
5/16" x 3/4" (S-275)
[8]
3/8" x 1" (S-455)
[20]
7/16" x 1" (S-9312)
[20]
7/16" x 1" (S-9312)
[20]
7/16" x 1-1/2" (S-3885)
[20]
5/16" x 3/4" (S-275)
[42]
3/8" x 1" (S-455)
[42]
7/16" x 1" (S-9312)
[42]
1/2" x 1-1/2" (S-9307)
[42]
1/2" x 1-1/2" (S-9307)
[63]
3/8" x 1" (S-455)
[22]
3/8" x 1" (S-455)
[22]
3/8" x 1" (S-455)
[22]
3/8" x 1-1/2" (S-5060)
[22]
3/8” x 1-1/2" (S-5060)
[22]
5/16" x 3/4" (S-275)
[2]
3/8" x 1" (S-455)
[2]
7/16" x 1-1/2" (S-3885)
[2]
7/16" x 1-1/2" (S-3885)
[2]
7/16" x 1-1/2" (S-3885)
[4]
• Use 3/8" x 1-1/2" (S-5060) bin bolts at splice locations to attach the stiffener/splice plate to the sidewall. Use 3/8" x 1-1/2" (S-5060) bin bolts on laminated stiffeners to attach stiffeners to the sidewall sheet.
•
• Refer to Stiffener Assembly Details on Page 35 and the Caulking Detail on Page 19 for stiffener
assembly hardware usage and caulking details. Refer to Hardware identification section
on Page 18 for aid in hardware identification.
Figure 3C As Viewed from Outside
3. Bin Assembly
Bolting Requirements - 3 Stiffeners per Sidewall Sheet
Sidewall Gauge Horizontal Seam Vertical Seam Stiffener to Sidewall Overlap Seam
20-15
14-12
11-9
8
13L-6L
(Laminated)
5/16” x 3/4" (S-275)
[8]
3/8" x 1" (S-455)
[20]
7/16" x 1" (S-9312)
[20]
7/16" x 1" (S-9312)
[20]
7/16" x 1-1/2" (S-3885)
[20]
5/16" x 3/4" (S-275)
[42]
3/8" x 1" (S-455)
[42]
7/16" x 1" (S-9312)
[42]
1/2" x 1-1/2" (S-9307)
[42]
1/2" x 1-1/2" (S-9307)
[63]
3/8" x 1" (S-455)
[21]
3/8" x 1" (S-455)
[21]
3/8" x 1" (S-455)
[21]
3/8" x 1-1/2" (S-5060)
[21]
3/8" x 1-1/2" (S-5060)
[33]
5/16" x 3/4" (S-275)
[2]
3/8" x 1" (S-455)
[2]
7/16" x 1-1/2" (S-3885)
[2]
7/16" x 1-1/2" (S-3885)
[2]
7/16" x 1-1/2" (S-3885)
[4]
• Use 3/8" x 1-1/2" (S-5060) bin bolts at splice location s to attach the stiffen er/splice plate to the sidewall.
• Use 3/8" x 1-1/2" (S-5060) bin bolts on laminated stiffeners to attach stiffeners to the sidewall sheet.
• Refer to Stiffener Assembly Details on Page 35 and the Caulking Detail on Page 19 for stiffener assembly hardware usage and caulking details. Refer to Hardware identification section on Page 18 for aid in hardware identification.
Figure 3D As Viewed from Outside
PNEG-1400 WCL Commercial 4" Corrugation Externally Stiffened Grain Bin 17
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