Page 1
Roof Stairs
Models:
12 FT. – 156 FT. DIAMETER BINS
Installation Manual
PNEG-2062
Version 6.0
Date: 05-02-19
PNEG-2062
Page 2
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.
2
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Contents
Chapter 1 Safety Precautions ....................................................................................................................5
Safety Guidelines ........................................................................................................................5
Cautionary Symbol Definitions......................................................................................................6
Safety Cautions...........................................................................................................................7
Safety Decals ........................................................................................................................... 11
Safety Sign-off Sheet.................................................................................................................13
Chapter 2 Roof Stairs ..............................................................................................................................15
General Information...................................................................................................................15
Assembling the 3-Step Stairs Section .........................................................................................16
Assembling the 4-Step Stairs Section .........................................................................................17
Assembling the 8-Step Stairs Section .........................................................................................18
Assembling the Roof Stair Sections ............................................................................................19
Installing the Roof Stairs ............................................................................................................24
Installing the Handrails ..............................................................................................................26
Limited Warranty — N.A. Grain Products ................................................................................ 29
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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NOTES
4
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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1 Safety Precautions
Topics Covered in this Chapter
▪ Safety Guidelines
▪ Cautionary Symbol Definitions
▪ Safety Cautions
▪ Safety Decals
▪ Safety Sign-off Sheet
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating procedures and problems that can be encountered by the
operator and other personnel when using this equipment. Read and save these instructions.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all
times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable regulations, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must 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.
ST-0001–4
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Chapter 1: Safety Precautions
Cautionary Symbol Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we
use the symbols that are defined below.
Table 1-1 Description of the different cautionary symbols
Symbol Description
This symbol indicates an imminently hazardous situation which, if
not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not
avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to personal
injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005–2
6
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Safety Cautions
Use Personal Protective Equipment
• Use appropriate personal protective equipment:
Chapter 1: Safety Precautions
Eye
Protection
Hearing
Protection
Hand
Protection
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
Follow Safety Instructions
Respiratory
Protection
Head
Protection
Foot
Protection
Fall
Protection
ST-0004–1
• 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.
• If you do not understand any part of this manual or need
assistance, contact your dealer.
ST-0002–1
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Chapter 1: Safety Precautions
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep
area clean and dry.
• Never service equipment while it is operating. Keep hands,
feet, and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace
worn or broken parts immediately.
Sharp Edge Hazard
• This product has sharp edges, which can cause serious
injury.
• To avoid injury, handle sharp edges with caution and always
use proper protective clothing and equipment.
ST-0003–1
Fall Hazard
• Ladders, stairways and platforms are for use by competent
and trained personnel only. Do not allow children or other
unauthorized persons to have access to the equipment.
• Access to the equipment must be restricted by the use of
security fencing and lockable gates.
• Lower sections of ladders must be fitted with a lockable
safety gate to prevent unauthorized access.
• Make sure that hot surfaces have had adequate time to cool
before working on or in the equipment.
• Lock out and tag out power supplies and fuel supplies to all
equipment.
• Do not attach lifting equipment to ladders or platforms.
• Do not go outside of the safety rails provided on elevated
platforms.
• Do not work at heights during high winds, rain, snow, or ice
storms.
ST-0036–2
ST-0056–1
8
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Do Not Enter Bin
• Rotating flighting will kill or dismember.
• Flowing material will trap and suffocate.
• Crusted material will collapse and suffocate.
— If you must enter the bin:
1. Shut off and lock out all power sources.
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.
Chapter 1: Safety Precautions
ST-0061–1
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Chapter 1: Safety Precautions
Confined Space Hazards and Entry Procedures
• Note that the interior of this equipment is considered a confined space. Maintenance of this equipment can require
access to the confined space.
• Access doors must be shut and locked except when access
is required.
• Doors giving access to dangerous equipment must be safety
interlocked.
• The following entry procedures must be followed:
— Be aware of all possible hazards present inside the con-
fined space and wear personal protective equipment
(PPE) as needed.
— Complete a permit to work and follow all permit required
confined space entry procedures defined by the site
manager.
— Make sure that the area has been purged of any hazard-
ous products or gases. Check the atmosphere for harmful gases or vapors with a suitable gas analyzer and
make sure levels are safe before entering.
— Do not smoke or use naked flames.
— Lock out and tag out power supplies and fuel supplies to
all equipment.
— Do not work alone. Work in teams of at least three so
that help is immediately available in the event of an
emergency.
— Confirm that all personnel have safely exited the equip-
ment and tools have been recovered once work is
complete.
ST-0055–1
10
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Chapter 1: Safety Precautions
Safety Decals
The safety decals on your equipment are safety indicators which must be carefully read and understood
by all personnel involved in the installation, operation, service and maintenance of the equipment.
To replace a damaged of missing decal, contact us to receive a free replacement.
GSI Decals
1004 E. Illinois Street
Assumption, IL 62510
Phone: 1–217–226–4421
Location Decal No. Decal Description
Located next to
aeration system.
DC-969
Caution Vacuum Pressure
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Chapter 1: Safety Precautions
Location Decal No. Decal Description
On bin door
covers
On bin door
covers
DC-GBC-1A
DC-GBC-2A
Danger Keep Clear of
Augers
Warning Unload Instructions
12
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Chapter 1: Safety Precautions
Safety Sign-off Sheet
Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name
Supervisor Name
PNEG-2062 12'-156' Diameter Bin Roof Stairs
ST-0007
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NOTES
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2 Roof Stairs
Topics Covered in this Chapter
▪ General Information
▪ Assembling the 3-Step Stairs Section
▪ Assembling the 4-Step Stairs Section
▪ Assembling the 8-Step Stairs Section
▪ Assembling the Roof Stair Sections
▪ Installing the Roof Stairs
▪ Installing the Handrails
General Information
Roof Stairs may consist of a combination of 3-step, 4-step and 8-step sections (varies with diameter)
which are spliced together before being installed onto the roof.
Refer to the table for stair step sections used for different bin diameters.
Table 2-1 Stair step sections
Bin Diameter (ft.)
12 1
15
18 2
21 1 1
24 3
27 2 1
30 1 2
33 0 3
36
42 3
48
54 3 1 1
60
66 3
72
75
78
90 2
105 3 1 4
135 2 1 6
156
No. of 3-step stair
Section
*
–
2 2
–
– –
–
2
1 1
–
No. of 4-step stair
Section
– –
1
– –
– –
–
1 2
–
1 3
–
–
1 8**
No. of 8-step Stair
Section
–
–
–
–
–
–
1
3
2
3
3
4
* RFS-1012 is a 3-step stair section used only for 12 ft. diameter bin.
** RFS-1005 is a 8-step stair section used only for 156 ft. diameter bin.
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Chapter 2: Roof Stairs
Assembling the 3-Step Stairs Section
1. Place a left 3-step stringer section (35) and a right 3-step stringer section (36) at a distance and
assemble the three stair steps (34) in between using flange bolts (2) and flange nuts (3).
NOTE:
• Install the flange bolts (2) from the outside of the stringer sections and flange nuts (3)
on the inside.
• Place the stringers with flanges at the bottom and towards the inside.
Figure 2-1 Assembling the 3-step stair section
16
2
3
34
5/16 x 3/4 in. flange bolt (S-6606)
5/16 in. flange nut (S-3611)
Stair step (WBS-0007)
35
36
Left 3-step stringer section (RFS-0013)
Right 3-step stringer section (RFS-0014)
2. Repeat the above step to assemble the multiple sets of 3-step stair sections (if required).
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Chapter 2: Roof Stairs
Assembling the 4-Step Stairs Section
1. Place a left 4-step stringer section (61) and a right 4-step stringer section (62) at a distance and
assemble the four stair steps (34) in between using flange bolts (2) and flange nuts (3).
NOTE:
• Install the flange bolts (2) from the outside of the stringer sections and flange nuts (3)
on the inside.
• Place the stringers with flanges at the bottom and towards the inside.
Figure 2-2 Assembling the 4-step stair section
2
3
34
5/16 x 3/4 in. flange bolt (S-6606)
5/16 in. flange nut (S-3611)
Stair step (WBS-0007)
61
62
Left 4-step stringer section (RFS-0015)
Right 4-step stringer section (RFS-0016)
2. Repeat the above step to assemble the multiple sets of 4-step stair sections (if required).
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Chapter 2: Roof Stairs
Assembling the 8-Step Stairs Section
1. Place a left 8-step stringer section (32) and a right 8-step stringer section (33) at a distance and
assemble the eight stair steps (34) in between using flange bolts (2) and flange nuts (3).
NOTE:
• Install the flange bolts (2) from the outside of the stringer sections and flange nuts (3)
on the inside.
• Place the stringers with flanges at the bottom and towards the inside.
Figure 2-3 Assembling the 8-step stair section
18
2
3
32
5/16 x 3/4 in. flange bolt (S-6606)
5/16 in. flange nut (S-3611)
Left 8-step stringer section (RFS-0017)
33
34
Right 8-step stringer section (RFS-0018)
Stair step (WBS-0007)
2. Repeat the above step to assemble the multiple sets of 8-step stair sections (if required).
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Chapter 2: Roof Stairs
Assembling the Roof Stair Sections
Roof Stairs may consist of a combination of 3-step, 4-step and 8-step sections (varies with diameter)
which are spliced together before being installed onto the roof.
Before You Begin
The following assembly instructions are for splicing three 8-step sections to form a roof stair section.
Refer to the table in General Information, page 15, for the number of stair step sections required for each
diameter bin.
1. Connect the assembled sets of stair sections (O) together using stringer splice plates (37), bolts (2)
and nuts (3).
Figure 2-4 Assembling the stair sections
2
5/16 x 3/4 in. flange bolt (S-6606)
3
5/16 in. flange nut (S-3611) O
PNEG-2062 12'-156' Diameter Bin Roof Stairs
37
Splice plates (RFS-0019)
8-step stair section
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Chapter 2: Roof Stairs
2. Align and install the handrail posts (38) to the stair sections using the flange bolts (2) and flange
nuts (3).
NOTE:
• Determine the location of the handrail posts (38) for each diameter (see Figure 2-7,
page 22 and Figure 2-8, page 23).
• The handrail post connections should have the bolts oriented so the nut is outside the
walking area to eliminate a trip hazard.
• Do not tighten the flange bolts (2), leave hand tight until the stairs assembly is installed
onto the roof.
Figure 2-5 Assembling the roof stair handrail posts
20
2
3
5/16 x 3/4 in. flange bolt (S-6606)
5/16 in. flange nut (S-3611) O
38
Roof stair handrail post (RFS-0048)
8-step stair section
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Chapter 2: Roof Stairs
3. Assemble the platform mount bracket (39) to the first handrail post set (38) using the flange bolts (2)
and flange nuts (3).
NOTE: The panel mount bracket (39) must be installed to the first handrail post set only.
NOTE: Do not tighten the flange bolts (2), leave hand tight until the stairs assembly is installed onto
the roof.
4. Assemble the panel support brackets (40) to the remaining handrail post sets (38) using the flange
bolts (2) and flange nuts (3).
NOTE: The panel support bracket (40) must be installed on all the handrail post sets other than the
first handrail post set.
NOTE: Tighten the panel support brackets (40).
Figure 2-6 Assembling the platform mount and panel support brackets
5/16 x 3/4 in. flange bolt (S-6606)
2
5/16 in. flange nut (S-3611)
3
38
* Used only for 8-step stair sections on 156 ft. diameter bin.
Handrail post (RFS-0048) Panel support bracket (RFS-0049)*
39
40
Platform mount bracket (RFS-0009)
Panel support bracket (RFS-0002)
5. Tighten all stair steps and all splice bolts after ensuring the stair sections are straight. That is, the
top surfaces of all the stringers and splice plates should be flush with each others.
NOTE: Leave the handrail posts loose until the stairs assembly is installed onto the roof.
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Chapter 2: Roof Stairs
For each diameter, refer to the following images for the required sets of stair step section and the
locations for the handrail post sets.
Figure 2-7 For 12 ft. - 72 ft. diameter bins
22
A
B
3-step stair section (RFS-1000) C 8-step stair section (RFS-1002)
4-step stair section (RFS-1001)
D
3-step stair section (RFS-1012)
**
* If the 33, 48 , 60 or 72 ft. diameter bin is not connecting to a peak walkaround or peak handrail, shift
the handrail post locations up one step to make sure there are posts at the first and last stair step.
** RFS-1012 is a 3-step stair section used only for 12 ft. diameter bin.
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Figure 2-8 For 75 ft. - 156 ft. diameter bins
Chapter 2: Roof Stairs
A
3-step stair section (RFS-1000) C 8-step stair section (RFS-1002)
B
4-step stair section (RFS-1001)
E
8-step stair section (RFS-1005)***
*** RFS-1005 is a 8-step stair section used only for 156 ft. diameter bin.
PNEG-2062 12'-156' Diameter Bin Roof Stairs
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Chapter 2: Roof Stairs
Installing the Roof Stairs
Before You Begin
Remove the three truss head bolts on the inside edge of platform where the roof stairs will be attached.
1. Lift and position the assembled roof stairs assembly (Q) on the panel adjacent to the manway hole.
2. Attach the platform mount bracket (39) at the bottom of the roof stair assembly (Q) to the platform
(G) at the eave using the truss head bolts (1) and flange nuts (3), which were removed earlier.
NOTE: Leave the truss head bolts (1) loose until the roof stair assembly (Q) is centered and
attached to the roof panel (R).
3. Field drill holes on the roof panel ribs and install the panel support brackets (40) in the roof stair
assembly (Q) to the roof panel (R) using the standard bin roof bolts (S) and flange nuts (T).
IMPORTANT:
• The roof stair assembly (Q) should be centered on the panel before field drilling
the holes.
• If two slots in the panel mount bracket align on a roof panel rib, field drill one
hole in the slot that is closer to the center line of the roof panel rib.
NOTE:
• Install the standard roof bolts (S) with the bolt head from the inside of the bin.
• As the roof panel narrows near the top, the stair steps may need to be removed to
allow a hole to be drilled.
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Figure 2-9 Installing the roof stairs assembly
Chapter 2: Roof Stairs
5/16 x 3/4 in. truss head bolt (S-10267)
1
5/16 in. flange nut (S-3611)
3
Platform mount bracket (RFS-0009)
39
Panel support bracket (RFS-0002)
40
Platform assembly
G
Roof stair assembly
Q
Roof panel
R
S Standard roof bolt
Flange nut
T
4. Tighten all the truss head bolts (1) and the standard roof bolts (S) after installing the roof stairs
assembly onto the roof panel (R).
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Chapter 2: Roof Stairs
Installing the Handrails
The following procedure is for the installation of handrails for the roof stair assembly.
Before You Begin
NOTE: If peak handrail is to be installed, then start installing the stairs handrail at the top and work down
from peak to eave.
1. Install the handrail brackets (17) to the end of handrail posts (38) using flange bolts (2) and flange
nuts (3).
NOTE: Install the flange bolts (2) from the inside of the stairs assembly and flange nuts (3) on the
outside.
2. Starting at the bottom of the roof stair assembly, orient the first upper handrail (41) with the swaged
end up and secure it to the handrail brackets (17) using two self-drilling screws (4) per bracket.
NOTE: Install the self-drilling screws (4) from the outside of the handrail brackets (17).
3. Install the next upper handrail (41) over the installed handrail and secure it to the handrail brackets
(17) using two self-drilling screws (4) per bracket with swaged end up.
NOTE: Install the self-drilling screws (4) from the outside of the handrail brackets (17).
4. Orient and align the first lower handrail (42) to the holes located in the middle of the handrail posts
(38) and secure using self-drilling screws (4).
NOTE: Install the self-drilling screws (4) from the outside of the roof handrail posts (38).
5. Align the next lower handrail (42) to the holes located in the middle of the handrail posts (38) over
the installed handrail and secure using self-drilling screws (4) with swaged end up.
NOTE: Install the self-drilling screws (4) from the outside of the roof handrail posts (38).
6. At the bottom, trim the handrails and cap them with the provided plastic caps.
26
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Figure 2-10 Installing the handrails
Chapter 2: Roof Stairs
5/16 x 3/4 in. flange bolt (S-6606)
2
5/16 in. flange nut (S-3611)
3
1/4 x 1 in. self-drilling screw
4
17
PNEG-2062 12'-156' Diameter Bin Roof Stairs
Handrail brackets (WBS-0319)
38
41
42
Handrail post (RFS-0048)
Upper handrail (RFS-0007)
Lower handrail (RFS-0008)
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NOTES
28
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Chapter 2: Roof Stairs
Limited Warranty — N.A. Grain Products
The GSI Group, LLC. (“GSI”) warrants products which it manufactures, to be free of defects in materials and workmanship
under normal usage and conditions for a period of 12 months from the date of shipment (or, if shipped by vessel, 14
months from the date of arrival at the port of discharge). If, in GSI’s sole judgment, a product is found to have a defect in
materials and/or workmanship, GSI will, at its own option and expense, repair or replace the product or refund the
purchase price. This Limited Warranty is subject to extension and other terms as set forth below.
Warranty Enhancements: The warranty period for the following products is enhanced as shown below and is in
lieu of (and not in addition to) the above stated warranty period. (Warranty Period is from date of shipment.)
Product Warranty Period
Grain Bin Structural Design
Storage
Conditioning
Material
Handling
▪ Roof, doors, platforms and walk arounds
▪ Flooring (when installed using GSI specified floor support system for that floor)
▪ Hopper tanks
Dryer Structural Design – (Tower, Portable and TopDry)
▪ Includes (frame, portable dryer screens, ladders, access doors and platforms)
All other Dryer parts including:
▪ Electrical (controls, sensors, switches & internal wiring)
Bullseye Controllers
Bucket Elevators Structural Design
Towers Structural Design
Catwalks Structural Design
Accessories (stairs, ladders and platforms) Structural Design
5 Years
5 Years
2 Years
2 Years
5 Years
5 Years
5 Years
5 Years
Conditions and Limitations:
THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH
HEREIN; SPECIFICALLY, GSI DISCLAIMS ANY AND ALL OTHER WARRANTIES OF ANY KIND, EXPRESS OR
IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) ANY PRODUCT MANUFACTURED OR SOLD BY GSI,
OR (II) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT,
REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION,
LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS.
The sole and exclusive remedy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paid
for the product purchased. This Warranty only covers the value of the warranted parts and equipment, and does not cover
labor charges for removing or installing defective parts, shipping charges with respect to such parts, any applicable sales
or other taxes, or any other charges or expenses not specified in this Warranty. GSI shall not be liable for any other direct,
indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits or benefits. Expenses
incurred by or on behalf of a claimant without prior written authorization from the GSI warranty department shall not be
reimbursed. This warranty is not transferable and applies only to the original end-user. GSI shall have no obligation or
responsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor. Prior to
installation, the end-user bears all responsibility to comply with federal, state and local codes which apply to the location
and installation of the products.
This Limited Warranty extends solely to products sold by GSI and does not cover any parts, components or materials used in conjunction with the
product, that are not sold by GSI. GSI assumes no responsibility for claims resulting from construction defects, unauthorized modifications,
corrosion or other cosmetic issues caused by storage, application or environmental conditions. Modifications to products not specifically
delineated in the manual accompanying the product at initial sale will void all warranties. This Limited Warranty shall not extend to products or
parts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained.
Notice Procedure:
In order to make a valid warranty claim a written notice of the claim must be submitted, using the RMA form, within 60 days of discovery of a
warrantable nonconformance. The RMA form is found on the OneGSI portal.
Service Parts:
GSI warrants, subject to all other conditions described in this Warranty, Service Parts which it manufactures for a period of 12 months from the
date of purchase unless specified in Enhancements above.
(Limited Warranty - N.A. Grain Products_ revised 19 October 2018)
PNEG-2062 12'-156' Diameter Bin Roof Stairs
29
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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.
1004 E. Illinois St.
Assumption, IL 62510-0020
Phone: 1-217-226-4421
Fax: 1-217-226-4420
www.gsiag.com
Copyright © 2019 by The GSI Group, LLC
Printed in the USA
GSI is a worldwide brand of AGCO Corporation.
CN #342710
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