78' Dura-Lok Plank and Support Manual Owner’s Manual PNEG-1834 Date: 01-04-12 PNEG-1834
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 26-41, 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 78' 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 45 and plank length chart on Page 46.) 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 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 78'-14" Monorail Spacing Layout 78' Diameter 14" Spacing Bill of Materials Length Qty Measurement in Inches Measurement in Centimeters A-22MONO 264 96 Rail # Section 1 Section 2 Section 3 Section 4 Rail # Section 1 Section 2 Section 3 Section 4 A-21.58MONO 259 2 Part # * NOTE: This special monorail run is used to support the floor plank at the split.
6. Layouts 78'-15" Monorail Spacing Layout Bill of Materials Part # A-22MONO A-21.33MONO A-21.25MONO NOTE: Eighty (80) total outer perimeter 3' monorail pieces. See Page 17 for leg support details. Part # Description Qty FL-404-15 15" Monorail Tie Bar 370 S-280 #10-16 x 5/8" Zinc Self-Drilling Screw 1270 FL-7411 Monorail Strap 1-1/2" x 30" x 0.061" Measurement in Inches 264 82 Rail # Section 1 Section 2 Section 3 Section 4 256 255 4 197 264 264 197 1 500.38 670.56 670.56 500.
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.) 30 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 78'-16" Monorail Spacing Layout Bill of Materials 78' Diameter 16" Spacing 23.77 m Diameter 40.64 cm Spacing Length Qty Measurement in Inches Measurement in Centimeters A-22MONO 264 92 Rail # Section 1 Section 2 Section 3 Section 4 Rail # Section 1 Section 2 Section 3 Section 4 A-21.25MONO 255 4 1 197 264 264 197 1 500.38 670.56 670.56 500.38 A-20.42MONO 245 4 2 196 264 264 196 2 497.84 670.56 670.56 497.84 A-20MONO 240 4 * 2A 52 0 0 52 * 2A 132.
6. Layouts 78'-17" Monorail Spacing Layout Bill of Materials Part # A-22MONO A-21.33MONO NOTE: Eighty (80) 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 FL-404-17 17" Monorail Tie Bar 330 FL-7411 Monorail Strap 1-1/2" x 30" x 0.061" 110 S-280 #10-16 x 5/8" Zinc Self-Drilling Screw 1130 78' Diameter 17" Spacing 23.77 m Diameter 43.
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 strap (See Page 16 for installation detail.) 34 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 78'-18" Monorail Spacing Layout Bill of Materials * NOTE: This special monorail run is used to support the floor plank at the split. Part # Description Qty 23.77 m Diameter 45.72 cm Spacing Length Qty Measurement in Inches Measurement in Centimeters A-22MONO 264 76 Rail # Section 1 Section 2 Section 3 Section 4 Rail # Section 1 Section 2 Section 3 Section 4 A-21.58MONO 259 2 1 197 264 264 197 1 500.38 670.56 670.56 500.38 A-21.
6. Layouts 78'-20" Monorail Spacing Layout Bill of Materials * NOTE: This special monorail run is used to support the floor plank at the split. Part # Description Qty 23.77 m Diameter 50.80 cm Spacing Length Qty Measurement in Inches Measurement in Centimeters A-22MONO 264 70 Rail # Section 1 Section 2 Section 3 Section 4 Rail # Section 1 Section 2 Section 3 Section 4 A-21.16MONO 254 4 1 197 264 264 197 1 500.38 670.56 670.56 500.38 A-20.
Tie straps (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.) 38 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 78'-22" Monorail Spacing Layout Bill of Materials * NOTE: This special monorail run is used to support the floor plank at the split. Part # Description Qty 23.77 m Diameter 55.88 cm Spacing Length Qty Measurement in Inches Measurement in Centimeters A-22MONO 264 66 Rail # Section 1 Section 2 Section 3 Section 4 Rail # Section 1 Section 2 Section 3 Section 4 A-21MONO 252 4 1 197 264 264 197 1 500.38 670.56 670.56 500.
6. Layouts 78'-26" Monorail Spacing Layout Bill of Materials * NOTE: This special monorail run is used to support the floor plank at the split. Part # Description Qty FL-404-26 26" Monorail Tie Bar 220 FL-7411 Monorail Strap 1-1/2" x 30" x 0.061" 120 S-280 #10-16 x 5/8" Zinc Self-Drilling Screw 770 23.77 m Diameter 66.
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 78' Floor Bundle Layout NOTE: 78' Floor is split up into four (4) different bundles. Two (2) AB1 planks are identical to each other and one AB2, C1 and C2 planks. The split of the floor is staggered from one 7" plank to the next. The bundle is arranged, so that AB1 planks are installed together, AB2 planks are installed together and each C1 and C2 are installed separately. The first plank installed will be out of bundle C1, plank 1.
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6. Layouts 78' Plank Layout for Manual Plank # 46 Length Plank A In Inch In Metric Plank # Length Plank B In Inch In Metric Plank # Length Plank C In Inch In Metric Plank # Length Plank A In Inch In Metric Plank # Length Plank B In Inch In Metric Plank # Length Plank C In Inch In Metric 1 13'-4" 160 406.4 34A 24'-2" 290 736.6 34B 23'-2" 278 706.12 34C 20'-0" 240 609.6 2A 6'-5" 77 195.58 2B 12'-5" 149 378.46 2C 35A 23'-6" 282 716.28 35B 24'-6" 294 746.
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.
