15 ft. (4.57 m) diameter metric roof assembly - explosion panel (26 pages)
Summary of Contents for GSi 40 Series
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48' Diameter Unstiffened Bin 40-Series Bin - 4.00" Corrugation 6000 lbs. Peak Load Roof for IDC Construction Manual PNEG-2048 Version: 2.0 Date: 09-20-19 PNEG-2048...
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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. PNEG-2048 48' Diameter Unstiffened Bin with Special 6K Roof for IDC...
Table of Contents Contents Chapter 1 Safety ..............................5 Safety Guidelines ..........................5 Cautionary Symbols Definitions ......................6 Safety Cautions ............................. 7 Safety Sign-Off Sheet ......................... 11 Chapter 2 Decals ..............................12 Chapter 3 General Overview ..........................14 General Information ..........................14 Tools Required for Construction ......................
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Table of Contents Chapter 8 Roof Assembly ........................... 47 Installing the Roof Rafter Bracket to the Sidewall ................47 Installing the Eave Clip and Intermediate Eave Angle to the Sidewall Sheet ........48 Attaching the Roof Stiffener Clips to the Rafter .................. 49 Center Collar Placement ........................
1. Safety 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.
1. Safety Cautionary Symbols 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. This symbol indicates an imminently hazardous situation DANGER which, if not avoided, will result in serious injury or death.
1. Safety Safety Cautions Use Personal Protective Equipment • Use appropriate personal protective equipment: Foot Respiratory Protection Protection Protection Head Fall Hearing Protection Protection Protection Hand Protection • Wear clothing appropriate to the job. • Remove all jewelry. ST-0004-1 • Tie long hair up and back.
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1. Safety Prevent Roof Damage Due to Vacuum Pressure • Roof damage can result from excessive vacuum or internal pressure from fans or other air moving systems. The manufacturer does not warrant this type of roof damage. • Adequate ventilation or “makeup air” devices must be provided for all powered air handling systems.
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1. Safety Rotating Auger Hazard • Keep clear of rotating augers and moving parts. • Do not remove or modify guards or covers. • Lock-out power source before making adjustments, cleaning, or maintaining equipment. • Failure to follow these precautions will result in serious injury or death.
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1. Safety Stay Clear of Hoisted Equipment • Always use proper lifting or hoisting equipment when assembling or disassembling equipment. • Do not walk or stand under hoisted equipment. • Always use sturdy and stable supports when needed for installation. Not following these safety precautions creates the risk of falling equipment, which can crush personnel and cause serious injury or death.
1. Safety 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 ST-0007 PNEG-2048 48' Diameter Unstiffened Bin with Special 6K Roof for IDC...
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. GSI Group, Inc. 217-226-4421 DC-969 PNEG-2048 48' Diameter Unstiffened Bin with Special 6K Roof for IDC...
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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 could result in serious injury or death. GSI GROUP, INC. 217-226-4421 DC-GBC-1A WARNING On bin door Warning Unload DC-GBC-2A...
These include, but may not be limited to: 1. A sidewall gauge layout chart. If such a chart is not included with this manual, contact GSI. 2. Roof instructions must be followed. Roof instructions are included in this manual.
3. General Overview Guidelines for Proper Storage of Grain Bin Materials Prior to Construction Storage of the build materials prior to construction is important. Do not to allow moisture to remain between sheets or panels. Wet storage stain (rust) will develop when closely packed bundles of galvanized material, such as sidewall and roof sheets, have moisture present.
3. General Overview Guidelines for Construction Procedures and Lifting Jack Usage 1. Before constructing the bin, consider the location of the door and other accessories. Proper placement of lifting jacks in relationship to anchor bolts could make a difference on odd or even ring bins.
“standard” series bin. Any re-circulating device or system should be used in the “re-circulating” series bins. NOTE: For GSI bins larger than 48' diameter an alternate method of mounting is to attach suspension chain to intermediate center collar.
3. General Overview Guidelines for Placement of the Decal Sidewall Sheet Use the following as a general guideline the proper decal sheet placement. NOTE: Refer to sidewall attachment detail and specific gauge sheet for the bin. The decal sheets are located in the top ring.
4. Foundations Foundation Recommendations These are general foundation recommendations. Site conditions, system requirements and other factors may create foundation construction requirements not covered by this manual. Selecting the Proper Site Location 1. The selected site should be level, firm and free from underlying debris. The soil bearing capacity should be equal to or greater than required by the footing specifications.
4. Foundations Foundation Forms Circular foundation forms are commonly used for stiffened farm bins. Figure 4B Circular Form Ref # Description Footing Trench Carpenter’s Level Preparing the Foundation Forms 1. Having scribed the diameter of the foundation, proceed by digging the foundation’s footing, which consists of a large circular trench inside the foundation line.
4. Foundations Placing the Reinforcement 1. Once the forms and trench have been prepared, begin placing the reinforcement rods and mesh in the foundation’s footing. Make sure the reinforcement rods are properly lapped by wiring. 2. Place at least 2" of compacted sand on the inside section of the foundation to provide a good base for the concrete and to protect against rodents.
4. Foundations Anchor Bolt Charts Prior to setting any anchor bolts, you must be sure to have the correct anchor bolt placement. NOTE: Refer to proper chart to find the anchor chord dimensions that correspond to the bin that is being built.
4. Foundations Placement of the Vane Axial Fan Foundation If a fan or fan and heater combination is to be installed, determine the concrete foundation size. 1. The top of the fan foundation should be level with the top of the bin’s foundation. 2.
4. Foundations Placement of the Centrifugal Fan Foundation 1. A correct fan foundation should be poured 2" below the top of bin foundation for all centrifugal fans. 2. A foundation for heaters is not required, but is recommended. 3. Recommended foundation thickness is 4". 4.
4. Foundations Frost Free Foundation Recommendations The foundation design is based on a minimum allowable soil bearing capacity 3000 PSF. Bearing capacity of the soil should be determined by geotechnical investigation and be of uniform bearing capacity. 1. All reinforcement must meet the requirements of ASTM A615 grade 60 deformed bars. 2.
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4. Foundations NOTE: All foundation specifications are recommendations only. Due to many variable conditions in actual installation, the manufacturer assumes no liability for results arising from the use of such recommendations. NOTE: Make sure to contact the manufacturer’s engineering department for additional information for heights more than 6".
4. Foundations Inverted “T” Foundation (3000 PSF Soil Bearing Capacity) 1. Determine bearing capacity of soils by using geotechnical investigations. Found all footings on soils of uniform bearing capacity. 2. All bins with a diameter of 60' or larger must use ASTM A615 grade 60 deformed bars for concrete reinforcement.
4. Foundations NOTE: All foundation specifications are recommendations only. Due to many variable conditions in actual installation, the manufacturer assumes no liability for results arising from the use of such recommendations. Specifications for 48' Diameter Bin #4 Bar #5 Bar Cu.
5. Hardware Requirements Bolt and Nut Pairings This chart lists the correct nut to use with each size of bolt. Nut Part # Nut Size Type Hex or Flanged Bolt Size Bolt Part # 5/16" x 1" S-10260 S-396 5/16" 5/16"...
Under no condition shall any other bolts be substituted for those supplied by GSI. Grade 2 Bolts Grade 2 bolts are designated with a plain head and are not used in GSI grain bins. Grade 5 Bolts Grade 5 bolts are designated by three (3) slash marks on the head. All 5/16" diameter bolts are to be grade 5 or higher.
5. Hardware Requirements Bolt Identification Use the following information to identify the bolts and where each must be used during installation. Bolt (S-10260) An S-10260 is a 5/16" x 1" JS bolt that is pre-assembled with a sealing washer. Bolt (S-10260) is used in the following locations: 1.
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5. Hardware Requirements Bolt (S-7485) An S-7485 is a 3/8" x 1" JS hex bolt with flanged head and without a sealing washer. Bolt (S-7485) is used in the following locations: 1. Use in 48' farm roof only. 2. The color of bucket lid is light green. 1.350"...
5. Hardware Requirements Color Chart for Bin Hardware Bucket Lids For ease of identification, hardware is separated and identified by buckets with color coded lids. Use the following chart to help identify the correct hardware. Part # Color Bucket Count Lid Color Description S-10260...
6. Assembling Sidewall Sheets Guidelines for Constructing Sidewall Sheets 1. Before bolting the sidewall sheets together, check for the proper gauge of steel for the first ring. Higher gauge numbers denote the thinner materials. (For example, 20 gauge material is thinner than 14 gauge.) 2.
6. Assembling Sidewall Sheets Orientation Detail for Top Sidewall Sheets To avoid the misalignment of the holes, it is necessary to use the correct orientation of the sidewall sheet during installation. (See Figure 6A.) NOTE: Always assemble the top sidewall sheets with the orientation shown. Figure 6A Top Sidewall Sheet Orientation (Viewed from Outside of the Bin) Ref # Description...
6. Assembling Sidewall Sheets Caulking and Bolting Detail for Standard Sidewall Sheets To keep out moisture from overlapping the sheets, it is necessary to apply caulk to each sheet prior to installing. (See Figure 6B.) NOTE: Always assemble the sidewall sheets with the overlap in the same direction. Figure 6B Standard Sidewall Sheets as Viewed from the Outside of the Bin Ref # Description...
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6. Assembling Sidewall Sheets Caulking and Bolting Detail for Standard Sidewall Sheets (Continued) 1. Apply a strip of caulk near the outside edge of the outer sheet and between the outer two (2) rows of bolts (A), then apply a strip of caulk 10" (25.4 cm) long along the horizontal seams (B), as shown Figure Figure 6C Caulking and Bolting Details (Viewed from Inside of the Bin) Ref #...
7. Door Assembly Door Placement Consider the location of the door and other accessories before starting the bin. Proper placement of lifting jacks in relationship to the anchor bolts could make a difference on odd or even ring bins. (See Figure 7A.) NOTE: The walk-through diameter door must be centered between two (2) anchor bolts.
7. Door Assembly 2 Ring Door Installation Before You Begin Before starting to install, make sure the correct door has been received. Note that one ring doors are standard with some sizes of bins/silos. Refer to round access door installation instructions. General Information 1.
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7. Door Assembly 2 Ring Door Installation Instructions NOTE: Refer to PNEG-301 for detailed assembly instructions. 1.Remove the inner door panels (Q, R and S) and outer door cover (A) from the door assembly. NOTE: Place the top of the door frame to the inside of the sidewall and the bottom of the door frame to the outside of the sidewall.
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7. Door Assembly NOTE: 48' Diameter bins up to 8 rings. Figure 7C Standard 2 Ring Door PNEG-2048 48' Diameter Unstiffened Bin with Special 6K Roof for IDC...
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7. Door Assembly Ref # Part # Description WD-039 Outer Door Cover WD-6283 Outer Cover Latch Bracket WD-225 Outer Cover Hinge Bracket WD-035 Door Cover Brace Section WD-6066 Outer Cover Hinge Base WD-6055 Bottom Inner Door Hinge WD-6056 Middle Inner Door Hinge WD-6054 Top Inner Door Hinge S-4380...
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7. Door Assembly NOTE: 48' Diameter bins 9 rings (WD-6244 and WD-6248). Figure 7D Heavy 2 Ring Door PNEG-2048 48' Diameter Unstiffened Bin with Special 6K Roof for IDC...
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7. Door Assembly Ref # Part # Description WD-039 Outer Door Cover WD-6283 Outer Cover Latch Bracket WD-225 Outer Cover Hinge Bracket WD-035 Door Cover Brace Section WD-6066 Outer Cover Hinge Base WD-6055 Bottom Inner Door Hinge WD-6056 Middle Inner Door Hinge WD-6054 Top Inner Door Hinge S-4380...
7. Door Assembly Two-Ring Door Latch Assembly 1. Install outer door latch assembly (WD-6289) to the door frame lining up to the door latch mount (L) with the 6 bolt from the top and door latch mount (K) with the 6 bolt from the bottom.
7. Door Assembly Options for 2 Ring Door - Bin Step 1. Attach the left and right sides (B and C) to the sides of the bin door step (D) using bolts (E) and nuts (G). 2. Center the assembled step under the bin door and use it as a template to field drill the holes (F) in the sidewall sheet on the ridges of the corrugation.
8. Roof Assembly Installing the Roof Rafter Bracket to the Sidewall The roof rafter bracket is the vertical member which supports the rafter. It is installed to the inside perimeter of the sidewall sheet. What You Should Know Field drill 3/8" hole 4" below the center of horizontal seam holes over 9-3/8" from right side first horizontal seam hole.
8. Roof Assembly Installing the Eave Clip and Intermediate Eave Angle to the Sidewall Sheet The eave clips and intermediate eave angles are installed onto the sidewall sheet to assemble the roof panels. 1. Install the eave clips (B) to the sidewall sheet (E) with flange bolts (C) and flange nuts (D). NOTE: Make sure to install the eave clips (B) to the inside of the sidewall sheet.
8. Roof Assembly Attaching the Roof Stiffener Clips to the Rafter Roof stiffener clips secure the rafter to the center collar. What You Should Know Each roof rafter receives two (2) roof stiffener clips. 1. Determine the correct orientation of each rafter (A) by identifying the roof panel holes (E) located near the end of each rafter (A).
8. Roof Assembly Center Collar Placement The following figure gives the approximate height needed to install the center collar. With one sidewall ring in place, position the center collar at the height specified, measuring from the bottom of the center collar to the foundation as shown. If additional rings are required for construction purposes, add 44"...
8. Roof Assembly Assembling the Roof Flashing Angle 1. Position the roof flashing angles (B) as shown in Figure 8F. Field drill the center collar pieces (A) through the roof flashing angles (B) and install the flange bolts (C) and flange nuts (D). Tighten to the recommended torque specification.
8. Roof Assembly Assembling the Rafters What You Should Know Each rafter will consist of a three (3) piece design and will need to be spliced together for assembling the rafter onto the roof. 1. Locate an upper rafter (A) and a middle rafter (B) and find the series of holes on each end of the two (2) rafters.
8. Roof Assembly Attaching the Rafter Assembly to Roof Rafter Bracket Install the lower portion of the rafter assembly to the roof rafter bracket. 1. Position and align the lower portion of the rafter assembly (outside surface) (D) to the roof rafter bracket (A).
8. Roof Assembly Attaching the Rafter Assembly to Center Collar The rafter assembly must be installed to support the center collar weldment and main roof structure. Before You Begin The center collar should be assembled and secured to the support pole and the rafter assembly should be assembled.
8. Roof Assembly Assembling the Purlin Purlins are horizontal members between the rafters that give support to the roof structure. The length of the purlin determines its location on the rafter assembly. Before You Begin All roof rafter assemblies must be installed and secured to both the center collar and roof rafter brackets. What You Should Know Purlins are installed between two (2) rafters.
8. Roof Assembly Installing the Tension Rods Tension rods connect to the rafter brackets through the rafter and are installed around the inside of the bin. Before You Begin Make sure all the rafters are installed before proceeding the installation of tension rods. What You Should Know 1.
GSI is not responsible for the effectiveness or performance of any temperature cable monitoring system or layout.
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8. Roof Assembly 4. Install a quick link (C) to each cable bracket to support the temperature cables. IMPORTANT: Do not attach weights to the temperature cables; secure the bottom of cables to the floor with light twine. No roof rafter shall support more than one cable. Figure 8M Supplier Quick Link Ref # Description...
8. Roof Assembly Installing the Roof Panels Roof panels overlap the previous roof panel, giving protection from outside elements. Rafters and rib support clips will support to hold the roof panels. Before You Begin Ensure all roof rafter assemblies and purlins are installed and properly tightened. Pre-determine the manway access location.
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8. Roof Assembly 2. Secure the roof panel ribs to the rafter (J) with the flange bolts (G) and flange nuts (H). 3. Install the flange bolts (G) and flange nuts (H) securing the bottom portion of the roof panel (A) to the eave clip (K) and intermediate eave angle (F).
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8. Roof Assembly 4. Make sure that the roof panel ribs are supported on the rib support clips (M). 5. After the initial roof panels (A) are installed, fill in the exposed gaps (B). Working in a counterclockwise direction, install two (2) additional roof panels (as shown), overlapping each roof panel on the left.
8. Roof Assembly Installing the Roof Flashing The roof flashing will seal the area between the center collar and the roof panels. What You Should Know Each roof flashing section (A) overlaps and bolts together with the previously installed roof flashing section (A).
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8. Roof Assembly 5. Align the holes along the edge of the next roof flashing (A) with the holes of the previously installed roof flashing holes and with the roof flashing angle (C). 6. Install flange bolts (E) and flange nuts (F), securing the other two (2) roof flashing sections (A) together.
8. Roof Assembly Roof Ring Placement (Optional) The roof ring is a tubular ring bolted to the exterior of the roof. The placement location and quantity of roof ring kits vary with the size of each bin. The roof support ring (A) on the 48' bin will be installed in the seventh (7 ) roof panel rib hole from the eave.
8. Roof Assembly Installing a Roof Ring Quantity and part numbers of roof ring kits vary with the location placement and with the size of each bin. The following procedure will be similar for each kit. 1. Determine the quantity of roof ring clips (C) needed for the roof ring section (B) being installed. NOTE: Each roof panel rib must have a roof ring clip installed.
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8. Roof Assembly Installing a Roof Ring (Continued) 5. Locate a threaded stud (F) and install stud nuts (G) evenly and to the center of the threaded stud (F). 6. Install the threaded stud (F) with stud nuts (G) to the end of the roof ring section (B). NOTE: Install the threaded stud (F) to the side where the next roof ring section will be installed.
9. Accessories Assembling the Ladder Section The inside ladder package consists of the ladder, starter brackets, standoff brackets, reinforcement straps, and ending bracket. The ladder should to be assembled before installing it to the bin structure. What You Should Know When assembling the ladder sections, ensure all slip resistant ladder rungs are oriented in the same direction.
9. Accessories Installing the Platform Support 1. Attach the platform mounting angles (C) to the sidewall (F) of the grain bin using 5/16" x 1" flange bolts (D) and 5/16" flange nuts (E). NOTE: Use the platform mounting holes to attach the mounting angles. NOTE: Tighten all the hardware.
9. Accessories Installing the Eave Adjustable Braces to Extension Rails and Roof An eave adjustable brace assembly is comprised of one large diameter (center) tube (I) and two smaller diameter tubes (M). 1. Slide the smaller tubes (M) towards inside of the center tube (I) as shown. 2.
9. Accessories Assembling the Platform and Handrail 1. Install the platform (C) to the platform supports using 5/16" x 1" flange bolts (H) and 5/16" flange nuts (I). 2. Install the vertical entrance angle (F) to the left front corner of the platform (C) using 5/16" x 1" flange bolts (H) and 5/16"...
9. Accessories Assembling the Eave Safety Cage Hoop What You Should Know Before attaching any pieces to the ladders of platform, some pre-assembly is required. 1. Install two safety cage hoop brackets (A) to the 8' extension rail (I) and one safety cage hoop bracket (A) to the second ladder section (H).
9. Accessories Safety Cage Hoop Adjuster Plate Connection Details Refer the below figure to determine the proper holes used when attaching the hoop adapters to the safety cage hoop adjuster plate. Figure 9G Safety Cage Hoop Adjuster Plate Connection Details Installing the Vertical Supports Before You Begin Before installing vertical supports make sure the three hoop assemblies are in place.
9. Accessories Assembling the Safety Cage 1. Install the safety cage vertical supports (F) to the existing safety cage hoop halves (D) in the ladder (H) using the 5/16" x 1" flange bolts (G) and 5/16" flange nuts (C). NOTE: Install 5/16" x 1" flange bolts (G) with bolt heads on the inside of the safety cage. 2.
9. Accessories Assembling the 24" Safety Cage Bell Section 1. Install the safety cage vertical supports (A) to the hoop half assembly from the final safety cage installation using the 5/16" x 1" flange bolts (C) and 5/16" flange nuts (D). NOTE: Install 5/16"...
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NOTES PNEG-2048 48' Diameter Unstiffened Bin with Special 6K Roof for IDC...
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.
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