42' Dura-Lok Plank and Support Manual Owner’s Manual PNEG-1828 Date: 01-10-12 PNEG-1828
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 Introduction ..........................................................................................................................................4 Chapter 2 Safety .....................................................................................................................................................5 Safety Guidelines ..................................................................................................................................
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.
2. Safety 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.
2. Safety 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 precautions exist and inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel.
2. Safety 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.
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. Eye Protection Remove all jewelry. Gloves Tie long hair up and back. Wear safety glasses at all times to protect eyes from debris.
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.
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 remain between the sheets. Separate the sheets or panels immediately and wipe them down. Spray with a light oil or diesel fuel.
3. Decals Roof Damage Warning and Disclaimer 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 recommend the use of downward flow systems (suction). Severe roof damage can result from any blockage of air passages.
3. Decals ATTENTION: The decal shown below should be present on the outside of the door cover of the 2 ring, 24" porthole door cover and the 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 Rotating flighting will kill or dismember. Flowing material will trap and suffocate. Crusted material will collapse and suffocate.
3. Decals ATTENTION: The decal shown below should be present on the outside of the door cover of the 2 ring, 24" porthole door cover and the 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 WARNING DON’T DO UNLOADING INSTRUCTIONS: 1. Use CENTER FLOOR OUTLET ONLY until NO grain remains above this outlet. 2.
4. Monorail Installation Fan Placement Diagram For uniform air flow, place the fans in relation to the unloading tube as shown in Figure 4A. Floor planks should be perpendicular to the unloading tube.
4. Monorail Installation Tie Bar Detail 1. Locate the tie bars between the rails. (Spaced evenly throughout the system.) NOTE: Tie bars are to be placed at the end of monorail, at each splice and in the middle of the rail if it is over 16' long. (Not necessarily evenly spaced.) Rail spacing details on Pages 26-38, detail tie bar placements in each layout. 2. A single #10 x 5/8" self-drilling screws may be used to fasten the tie bars at each end to the rails as necessary. (See Figure 4B.
4. Monorail Installation Tie Strap Detail 1. Tie straps should be used when a tie bar cannot be used to connect rails together due to special spacing of monorail. Tie strap should be connected to all three (3) rails using self-drilling screws. (See Figure 4D.) 2. Tie straps are to be located in the same places as a tie bar would be used. NOTE: Some tie straps will be used to support center well and intermediate well assembly. (See Figure 5F on Page 24 and Figure 5G on Page 25.
4. Monorail Installation Assembling Legs to Rail 1. Place two (2) corners of the monorail leg into the rails as shown. 2. By twisting the leg it will spread the rail enough to get the other corners inside. 3. The leg can then be pushed down into the rail until the tabs lock it into place. (See Figure 4E.) See chart on Page 18. Spacing depends on eave height.
4. Monorail Installation Monorail “Rail and Leg Spacing”/“Full Floor Leg Quantity” for 42' Bin Diameter 18 4.00" Ring 2.66" Ring Eave Height (ft.
4. Monorail Installation Outer Perimeter Rail Details 3' Sections of monorail should be placed around the perimeter of the bin. Monorail legs for perimeter rails should be spaced 16" apart on center. (See Figure 4F.
4. Monorail Installation Splicing Rails 1. A leg must be centered at each rail splice. 2. The closest leg may be moved a few inches over to center it under the splice. If more than 3" of movement is required to center the leg under the splice, add an additional leg. 3. Fasten the rail to the leg with two (2) #10 self-drilling screws (splice locations only). (See Figure 4G.
5. Flooring - Planks Floor Splice Details Two (2) splices located at each splice location. (See Figure 5B on Page 22.) Some of the floor planks will need to be spliced together. (See Figure 5F on Page 24 and plank layout on Page 43 and plank length chart on Page 44.) Install plank length A first, then install the corresponding plank length B. Continue until floor is complete. Center and install two (2) splices (PCL-7009) at each plank splice location using self-drilling screws.
5. Flooring - Planks Figure 5B Splice Assembly View Flashing Installation Figure 5C Formed Flashing Installation If bin sweep auger is to be used, overlap flashing such that rotation (usually clockwise) of the sweep will climb up on the next flashing section. (See detail C in Figure 5C.) This will prevent the rotating/slipping outer wheel of the sweep from catching on the flashing edges. After the floor is in place, lay the flashing pieces on top of the floor place over the 1-1/4" bin bolts.
5. Flooring - Planks Flashing Installation (Continued) Figure 5D 2.66" Corrugation Figure 5E 4.
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Tie bar (See Page 15 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
6. Layouts 42'-15" Monorail Spacing Layout Bill of Materials Part # Description 12.80 m Diameter 38.10 cm Spacing Measurement in Inches Measurement in Centimeters Length Qty A-20.5MONO 246 4 Rail # Section 1 Section 2 Rail # Section 1 Section 2 A-20.3MONO 244 4 1 246 246 1 624.84 624.84 A-20.25MONO 243 4 2 244 244 2 619.76 619.76 A-20MONO 240 4 3 243 243 3 617.22 617.22 A-19.67MONO 236 4 4 240 240 4 609.6 609.6 A-19.25MONO 231 4 5 236 236 5 599.
6. Layouts 42'-16" Monorail Spacing Layout Bill of Materials Part # Measurement in Centimeters Qty Measurement in Inches A-20.5MONO 246 4 Rail # Section 1 Section 2 A-20.3MONO 244 4 1 246 A-20.25MONO 243 8 2 A-19.9MONO 239 4 A-19.58MONO 235 4 A-19.25MONO 231 2 A-19.08MONO 229 4 A-18.5MONO 222 4 A-17.8MONO 214 4 A-17MONO 204 4 A-16MONO 192 4 A-14.83MONO 178 4 Qty A-13.
Tie bar (See Page 15 for installation detail.) Tie strap (See Page 16 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
Tie bar (See Page 15 for installation detail.) Tie strap (See Page 16 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
6. Layouts 42'-17" Monorail Spacing Layout Bill of Materials Part # 42' Diameter 17" Spacing 12.80 m Diameter 43.18 cm Spacing Length Qty Measurement in Inches A-20.5MONO 246 4 Rail # Section 1 Section 2 A-20.3MONO 244 6 1 246 A-20.25MONO 243 4 2 A-20.2MONO 242 4 A-19.83MONO 238 4 A-19.5MONO 234 4 A-18.92MONO 227 4 A-18.25MONO 219 4 A-17.42MONO 209 4 NOTE: Forty three (43) total outer perimeter 3' monorail pieces. See Page 17 for leg support details. A-16.
6. Layouts 42'-18" Monorail Spacing Layout Bill of Materials Part # NOTE: Forty three (43) total outer perimeter 3' monorail pieces. See Page 17 for leg support details. * NOTE: This special monorail run is used to support the floor plank at the split. Part # Description 42' Diameter 18" Spacing 12.80 m Diameter 45.72 cm Spacing Length Qty Measurement in Inches A-20.5MONO 246 4 Rail # Section 1 Section 2 A-20.33MONO 244 4 1 246 A-20.25MONO 243 4 2 A-20.17MONO 242 4 A-19.
Tie bar (See Page 15 for installation detail.) Tie strap (See Page 16 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
Tie bar (See Page 15 for installation detail.) Tie strap (See Page 16 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
6. Layouts 42'-20" Monorail Spacing Layout 42' Diameter 20" Spacing 12.80 m Diameter 50.80 cm Spacing Bill of Materials Length Qty Measurement in Inches A-21MONO 252 2 Rail # Section 1 Section 2 A-20.5MONO 246 4 1 246 A-20.33MONO 244 4 *2 A-20.25MONO 243 4 A-20MONO 240 A-19.58MONO Part # NOTE: Forty three (43) total outer perimeter 3' monorail pieces. See Page 17 for leg support details. * NOTE: This special monorail run is used to support the floor plank at the split.
6. Layouts 42'-22" Monorail Spacing Layout 42' Diameter 22" Spacing 12.80 m Diameter 55.88 cm Spacing Bill of Materials Length Qty Measurement in Inches A-21.25MONO 255 2 Rail # Section 1 Section 2 A-20.5MONO 246 4 A-20.25MONO 243 8 A-19.92MONO 239 4 A-19.42MONO 233 4 A-18.67MONO 224 4 A-17.75MONO 213 4 A-16.58MONO 199 4 Qty A-15.08MONO 181 4 Part # NOTE: Forty three (43) total outer perimeter 3' monorail pieces. See Page 17 for leg support details.
Tie strap (See Page 16 for installation detail.) Tie bar (See Page 15 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
Tie strap (See Page 16 for installation detail.) Tie bar (See Page 15 for installation detail.) NOTE: This depicts monorail spacings only. Leg spacing is dependant on eave height. See Page 18 for leg and rail spacing chart. 6.
6. Layouts 42'-26" Monorail Spacing Layout 42' Diameter 26" Spacing 12.80 m Diameter 66.04 cm Spacing Bill of Materials Part # NOTE: Forty three (43) total outer perimeter 3' monorail pieces. See Page 17 for leg support details. * NOTE: This special monorail run is used to support the floor plank at the split. Part # Description Qty Length Qty A-20.5MONO 246 4 A-20.25MONO 243 8 A-19.67MONO 236 4 A-19MONO 228 4 A-18MONO 216 4 A-17.33MONO 208 2 A-16.
6. Layouts 42' Split Floor Bundle Layout NOTE: The 42' floor is split up into two (2) different bundles, two (2) of which are identical to each other. The split of the floor is staggered from one 7" plank to the next. The bundle is arranged so that the “A” plank is installed together with the “B” plank. Begin installation with plank 1 found in bundle.
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NOTES 42 PNEG-1828 42' Dura-Lok Plank and Support Manual
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6. Layouts 42' Split Plank Layout for Manual 44 Plank # Length Plank A In Inch In Metric Plank # Length Plank B In Inch In Metric 1 8'-5" 101 256.54 2A 3'-5" 41 104.14 2B 9'-5" 113 287.02 3A 11'-0" 132 335.28 3B 5'-0" 60 152.4 4A 6' - 3-1/2" 75-1/2 191.77 4B 12' - 3-1/2" 147-1/2 374.65 5A 13' - 4-1/2" 160-1/2 407.67 5B 7' - 4-1/2" 88-1/2 224.79 6A 8'-4" 100 254 6B 14'-4" 172 436.88 7A 15'-2" 182 462.28 7B 9'-2" 110 279.4 8A 9'-10" 118 299.
6. Layouts 42' Non-Split Floor Bundle Layout NOTE: The 42' floor is split up into two (2) different bundles, two (2) of which are identical to each other. The split of the floor is staggered from one 7" plank to the next. The bundle is arranged so that the “A” plank is installed together with the “B” plank. Begin installation with plank 1 found in bundle.
NOTES 46 PNEG-1828 42' Dura-Lok Plank and Support Manual
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6. Layouts 42' Non-Split Plank Layout for Manual 48 Plank # Plank Length In Inch In Metric 1 8'-4" 101 256.54 2 12'-8" 154 391.16 3 16'-0" 192 487.68 4 18'-6" 223 566.42 5 20'-8" 249 632.46 6 22'-7" 272 690.88 7 24'-3" 292 741.68 8 25'-7" 308 782.32 9 27'-1" 325 825.5 10 28'-3" 340 863.6 11 29'-6" 355 901.7 12 30'-7" 368 934.72 13 31'-7" 380 965.2 14 32'-7" 392 995.68 15 33'-5" 402 1021.08 16 34'-3" 412 1046.48 17 35'-2" 422 1071.
7. Warranty GSI Group, LLC Limited Warranty 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 after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
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. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
