How it Works
GSI
Loading...
PNEG-805
User Manual
74 pgs2.82 Mb0
Table of contents
Loading...

GSI PNEG-805 User Manual

PNEG-805
36' Diameter 40°/45° NCHT Commercial Hopper Tanks
Installation Manual
PNEG-805
Date: 10-07-13
2PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
Table of Contents

Contents

Chapter 1 Introduction ..........................................................................................................................................5
Chapter 2 Safety .....................................................................................................................................................6
Safety Guidelines .................................................................................................................................. 6
Safety Instructions ..................... ... .... .......................................... ... ... ..................................................... 7
Safety Sign-Off Sheet ........................................................................................................................... 9
General Safety Statement ................................................................................................................... 10
Proper Storage of Grain Bin/Silo Materials Prior to Construction ....................................................... 11
Chapter 3 Decals ..................................................................................................................................................12
Chapter 4 Foundations ........................................................................................................................................16
36' Diameter Commercial Hopper Tank Foundation up to 18 Rings ................................................... 16
36' Diameter Commercial Hopper Tank Foundation 19-22 Rings ....................................................... 19
Chapter 5 Column Heights ..................................................................................................................................22
Standard Commercial Hopper Tank Column Heights ......................................................................... 22
Chapter 6 Substructure Part List ........................................................................................................................23
Substructure Part List for 36' Commercial Hopper Tanks ................................................................... 23
Typical NCHT36 Column .................................................................................................................... 24
Chapter 7 Hopper Section Assembly ................................ .................................................... .............................25
Hopper Section Assembly 36' Diameter Hopper Tanks ...................................................................... 25
Bracing Assembly ............................................................................................................................... 26
Install Compression Angle .................................................................................................................. 27
Install Compression Channel .............................................................................................................. 28
Install Hopper Panels .......................................................................................................................... 29
Tighten All Bolted Connections ........................................................................................................... 31
Install Rack and Pinion Roller Gate .................................................................................................... 32
Chapter 8 Sidewall Assembly .............................................................................................................................33
Sidewall Erection Instructions ... ... .......................................... .... ... ... ... ... .... ... ... ... ................................ 33
Caulking Detail .................................................................................................................................... 34
Decal Sheet Placement ....................................................................................................................... 35
Chapter 9 Lifting Jack .........................................................................................................................................36
Lifting Jack Usage .................................. ... ... .... ... ... ... .......................................... .... ... ... ...................... 36
Chapter 10 Color Code Charts ............................................................................................................................37
Color Code Chart 2.66" Commercial Stiffeners ........................ ......................................................... 37
Color Code Chart 2.66" Sidewall Gauges ......................................................................................... 37
Chapter 11 Hardware ...........................................................................................................................................38
Identifying Bolt Grades ...................................................................................................................... 38
Hardware Identification Notes ........................................................................................................... 39
Color Chart for Bin Hardware Bucket Lids ......................................................................................... 42
2.66" Commercial Tank Bolting Requirements - 2 Stiffeners per Sidewall Sheet ............................. 43
Chapter 12 Stiffeners ...........................................................................................................................................44
Universal Stiffener and Splice Hardware ..................... ................................................ ..................
Commercial Stiffeners for 2.66" Corrugation ..................................................................................... 45
2.66" Corrugation Commercial Stiffener Splice Details ..................................................................... 46
Non-Laminated Stiffener to Sidewall Detail ....................................................................................... 52
Laminated Stiffener to Sidewall Detail ......................................... ...................................................... 53
Universal Stiffener Starting Location - 2.66" Reverse Corrugation Outside Stiffener Only ............... 54
.... 44
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 3
Table of Contents
Chapter 13 Roof Rafter Installation ....................................................................................................................55
Standard Roof Stiffener Detail - 2.66" Corrugation Outside Stiffener Only ....................................... 55
Special Roof Instructions for 36' Diameter Commercial Hopper Tank .............................................. 56
Chapter 14 Wind Ring ..........................................................................................................................................59
Wind Ring Assembly ......................................................................................................................... 59
Chapter 15 Base Stiffener ...................................................................................................................................60
Stiffener Shim Plate Detail (Use when Necessary) ........................................................................... 60
Chapter 16 Doors .................................................................................................................................................61
Access Door Weldment Assembly Hardware Package (PLS-41985) ................................................ 61
Chapter 17 Aeration .............................................................................................................................................62
Aeration Package (Optional) ............................................................................................................. 62
Chapter 18 Ladders .............................................................................................................................................66
Hopper Ladder Supports ................................................................................................................... 66
Chapter 19 Hoisting .............................................................................................................................................67
Hoist Instructions ............................................................................................................................... 67
Chapter 20 Flashing .............................................................................................................................................70
Flashing Installation ........................................................................................................................... 70
Chapter 21 Warranty ............................................................................................................................................73
4PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks

1. Introduction

READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage.
INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct. The customer should report and note any damage or shortage on the bill of lading to justify their claim to the transport company.
THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be easily accessible when needed.
This warranty provides you the assurance that the company will back its products when defects appear within the warranty period. In some circumstances, the company also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the factory specifications, the warranty will become void and field improvements may be denied.
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 5

2. 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
6PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
2. 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 produce 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.
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 7
2. 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
8PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
2. 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 equipment. 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
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 9
2. 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, hazards, and precau tions 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.
10 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
2. 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 rema in 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-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 11

3. 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
GSI Group, Inc. 217-226-4421
The manufacturer does not warrant any roof damage caused by excessive vacuum or internal pressure from fans or other air moving systems. Adequate ventilation and/or “makeup air” devices should be provided for all powered air handling systems. The manufacturer does not reco mmend the use of downward flow systems (suction). Severe roof damage can result from any block age of air passages. Running fans during high humidity/cold weather conditions can cause air exhaust or intake ports to freeze.
12 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
3. Decals
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
DANGER
Keep clear of all augers.
DO NOT ENTER this bin!
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.
Failure to heed these
warnings will result in
serious injury or death.
DC-GBC-1A
GSI GROUP, INC. 217-226-4421
ATTENTION: The decal shown below should be present on the outside of the 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
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 13
3. Decals
WARNING
GSI GROUP, INC. 217-226-4421
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:
Failure to heed these warnings
could result in serious injury, death,
structural damage or collapse of tank.
DC-GBC-2A
ATTENTION: The decal shown below should be present on the outside of the 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
14 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
Sidewall and stiffener gauge sheets are
not included in this manual. They may
be obtained by calling GSI if they are
not attached to the front of this manual.
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 15

4. Foundations

36' Diameter Commercial Hopper Tank Foundation up to 18 Rings
Figure 4A
Ref # Description
A 18'-9" Radius B 18' - 2-5/8" Radius C 17' - 10-5/8" Radius D 17'-5" Radius E “C” Radius F “D” Radius G Footing Detail (NOTE: Not to scale.) H 1/2" Expansion Joint
I 6 x 6 - 6/6 Wire Mesh
J 1 Extra #4 Hoop at 3" c/c Each Face at Top K 4-#4 Hoops Evenly Spaced Each Face L “P” Bars Spacing at Center of Footing
M #4 Bars at 12" c/c Each Face with 12" Hook at Bottom N 6" Maximum O “N” #5 Hoops Evenly Spaced
P 1" Diameter Anchor Bolt 96 Required. (See section detail on Page 18.)
16 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
4. Foundations
36' Diameter Commercial Hopper Tank Foundation up to 18 Rings (Continued)
# of Rings Up to 10 14 18
A 1'-4" 1'-4" 1'-8" B 6'-0" 7'-6" 9'-2" C 14'-11" 13'-11" 12'-11" D 20'-11" 21'-5" 22'-1" N #5 at 12" c/c #5 at 10" c/c #5 at 9" c/c
P #5 at 10" c/c #6 at 10" c/c #7 at 8-1/2" c/c #4 Rebar (Ft.) 2400 2400 2400 #5 Rebar (Ft.) 1500 1000 1400 #6 Rebar (Ft.) 0 1000 0 #7 Rebar (Ft.) 0 0 1400
6 x 6 - 6/6 Wire Mesh (Ft.2)
Concrete (Cu. Yds.) 75 80 110
960 960 960
NOTES:
1. The foundation design is based on a minimum allowable soil bearing capacity of 3000 PSF. Bearing capacity of the soils should be determined by geotechnical investigation and be of uniform bearing capacity.
2. The foundation site must be free of vegetation and debris and well drained.
3. The foundation must be founded below the frost line or placed on non-expansive frost free fill.
4. All material used for backfill inside the ring wall should be clean, well graded, crushed rock or a sand-gravel mixture. Backfill should be placed in 6" lifts, 95% compaction.
5. All reinforcement must meet the requirements of ASTM A615 grade 60 deformed bars.
6. Lap all circumferential bars 35 bar diameters and stagger all laps in plans 3'-0". Estimates for material do not include end laps.
7. Concrete must have a minimum compressive strength of 3000 PSI at 28 days, 6%-8% air entrainment, 4" slump.
8. Codes: UBC 97, ACI 318-95.
9. Interior top slab may be crowned 2" to provide water drainage away from foundation. Crowning the slab will reduce the clearance under the discharge.
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 17
4. Foundations
36' Diameter Commercial Hopper Tank Foundation up to 18 Rings (Continued)
Chord dimensions shown from center of base plate to center of base plate. Anchor bolts must be set with a template, not be hand. All anchor bolts must be AISI1018 cold rolled steel. (Fy. = 60 KSI, Ft. = 70 KSI). Nuts and washers must
be a grade 5. Washers must be a minimum of 1" diameter 96 anchor bolts required. (See Figure 4B.)
Figure 4B
Ref # Description
A Anchor Bolt Plan B R 17' - 10-5/8" Inner Anchor Bolt C R 18'-5/8" Base Pl ate Center D R 18' - 2-5/8" Outer Anchor Bolt E Section Detail F 1" Diameter G 3" Projection H Plan Detail
18 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
4. Foundations
36' Diameter Commercial Hopper Tank Foundation 19-22 Rings
Figure 4C
Ref # Description
A 18'-9" Radius B 18'-2-5/8" Radius C 17'-10-5/8" Radius D 17'-5" Radius E “C” Radius
F “D” Radius G Footing Detail (NOTE: Not to scale.) H 1/2" Expansion Joint
I 6 x 6 - 6/6 Wire Mesh
J 1 Extra #4 Hoop at 3" c/c Each Face at Top K #4 Hoops Evenly Spaced Each Face
L “P” Bars Spacing at Center of Footing M #4 Bars at 12" c/c Each Face with 12" Hook at Bottom N 6" Maximum O “N” #5 Hoops Evenly Spaced Top and Bottom P #5 Bars at 18" c/c
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 19
4. Foundations
36' Diameter Commercial Hopper Tank Foundation 19-22 Rings (Continued)
# of Rings 20 22
A 2'-0" 2'-0"
B 10'-2" 11'-2" C 11'-7" 11'-7" D 22'-5" 22'-9" N #5 at 12" c/c #5 at 12" c/c
P #5 at 6" c/c #6 at 5" c/c
#4 Rebar (Ft.) 2400 2400 #5 Rebar (Ft.) 3000 3300 #6 Rebar (Ft.) 2300 3000
6 x 6 - 6/6 Wire Mesh (Ft.2)
Concrete (Cu. Yds.) 122 128
960 960
NOTES:
1. The foundation design is based on a minimum allowable soil bearing capacity of 3000 PSF. Bearing capacity of the soils should be determined by geotechnical investigation and be of uniform bearing capacity.
2. The foundation site must be free of vegetation and debris and well drained.
3. The foundation must be founded below the frost line or placed on non-expansive frost free fill.
4. All material used for backfill inside the ring wall should be clean, well graded, crushed rock or a sand-gravel mixture. Backfill should be placed in 6" lifts, 95% compaction.
5. All reinforcement must meet the requirements of ASTM A615 grade 60 deformed bars.
6. Lap all circumferential bars 35 bar diameters and stagger all laps in plans 3'-0". Estimates for material do not include end laps.
7. Concrete must have a minimum compressive strength of 3000 PSI at 28 days, 6%-8% air entrainment, 4" slump.
8. Codes: UBC 97, ACI 318-95.
9. Interior top slab may be crowned 2" to provide water drainage away from foundation. Crowning the slab will reduce the clearance under the discharge.
20 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks
4. Foundations
36' Diameter Commercial Hopper Tank Foundation 19-22 Rings (Continued)
Chord dimensions shown from center of base plate to center of base plate. Anchor bolts must be set with a template, not be hand. All anchor bolts must be AISI1018 cold rolled steel. (Fy. = 60 KSI, Ft. = 70 KSI). Nuts and washers must
be a grade 5. Washers must be a minimum of 1" diameter 96 anchor bolts required. (See Figure 4D.)
Figure 4D
Ref # Description
A Anchor Bolt Plan B R 17' - 10-5/8" Inner Anchor Bolt C R 18'-5/8" Base Plate Center D R 18' - 2-5/8" Outer Anchor Bolt E Section Detail F 1" Diameter G 3" Projection H Plan Detail
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 21

5. Column Heights

Standard Commercial Hopper Tank Column Heights
Figure 5A
“A” Dimension “B” Dimension
Tank Diameter Hopper Slope
Feet Meters Inches Millimeters
36' 40 15' - 11-1/2" 4.86 32 813 36' 45 20' - 1-1/2" 6.13 32 813
22 PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks

6. Substructure Part List

Substructure Part List for 36' Commercial Hopper Tanks
Tank Size 36'-40° 36'-45°
Color Code White Light Blue Column Weldment CHT-1580 (24) CHT-1566 (24) Compression Angle Weldment CHT-1532 (24) CHT-1568 (24) Compression Channel Weldment CHT-1535 (24) CHT-1535 (24) Diagonal Column Brace CHT-1538 (96) CHT-1570 (144) Horizontal Column Brace CHT-1539 (48) CHT-1539 (96) Top Hopper Panel CHT-1540 (24) CHT-1571 (24) Middle L.H. Hopper Panel CHT-1541 (24) CHT-1572 (24) Middle R.H. Hopper Panel CHT-1542 (24) CHT-1573 (24) Bottom Hopper Panel CHT-1543 (24) CHT-1574 (24) Collar Weldment CHT-1445 (1) CHT-1577 (1) Support Hardware CHT-1427 New (1) CHT-1578 (1)
PNEG-805 36' Diameter 40°/45° NCHT Commercial Hopper Tanks 23
Loading...
+ 51 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use