GSI Group PNEG-1276 User manual

PNEG-1276
Top Dry Autoflow Construction
Manual 24', 30' and 36'
Construction and Owner’s Manual
PNEG-1276
Date: 11-29-12

2 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'

Table of Contents
PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 3
Contents
Chapter 1 Safety .....................................................................................................................................................5
Safety Guidelines .................................................................................................................................. 5
Chapter 2 Decals ....................................................................................................................................................6
Roof Damage Warning and Disclaimer ................................................................................................. 6
Chapter 3 Foundation Requirements ...................................................................................................................9
Foundation Requirements for Top Dry Bins (4.00" Top Dry Bin Corrugation) ...................................... 9
Inline Centrifugal Fan Pad ................................................................................................................... 12
Duct and Drying Fan Pad Optional ..................................................................................................... 13
Anchor Bolt Placement ........................................................................................................................ 14
Frost Free Pad (Top Dry Bins) ............................................................................................................ 15
Frost Free Foundation (Top Dry Bins) ................................................................................................ 16
Chapter 4 Hardware .............................................................................................................................................17
Hardware/Bolting Requirements ......................................................................................................... 17
Location of Accessories ...................................................................................................................... 20
Very Important ..................................................................................................................................... 21
Chapter 5 Sidewall Construction ........................................................................................................................22
Sidewall Gauges ................................................................................................................................. 22
Sidewall Erection Instructions ............................................................................................................. 23
Caulking Detail .................................................................................................................................... 24
Lifting Jacks and Brackets .................................................................................................................. 25
Lifting Jack Usage ............................................................................................................................... 26
Chapter 6 Stiffener Details ..................................................................................................................................27
Stiffener Gauges ................................................................................................................................. 27
Outside Stiffeners ................................................................................................................................ 28
Top Stiffener Starting Location ............................................................................................................ 29
Stiffener Installation and Location ....................................................................................................... 30
Bolting Requirements .......................................................................................................................... 31
Stiffener and Seam Locations ............................................................................................................. 31
Chapter 7 “C” Channels ......................................................................................................................................32
Stiffener to “C” Channel Bracket Installation ....................................................................................... 32
“C” Channel Installation ....................................................................................................................... 33
Center Collar Assembly ...................................................................................................................... 34
Chapter 8 Installation ..........................................................................................................................................36
Rafter Installation and Floor Support Angle Attachment ..................................................................... 36
Purlin Installation ................................................................................................................................. 37
Dump Hopper Installation .................................................................................................................... 40
Floor Sheet Installation ....................................................................................................................... 40
Flashing Bolt Installation ..................................................................................................................... 41
Eave Flashing Installation ................................................................................................................... 41
Eave Flashing Splice ........................................................................................................................... 42
Outer Dump Chutes ............................................................................................................................ 43
24' Leveling Band Post Installation ..................................................................................................... 44
30' Leveling Band Post Installation ..................................................................................................... 45
36' Leveling Band Post Installation ..................................................................................................... 46
Leveling Band Installation ................................................................................................................... 46
24' Leveling Band Location ................................................................................................................. 47
30' Leveling Band Location ................................................................................................................. 48
36' Leveling Band Location ................................................................................................................. 50

Table of Contents
4 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Chapter 9 Assembly ............................................................................................................................................52
Pulley Assembly .................................................................................................................................. 52
Dump Chute Chain Assembly ............................................................................................................. 53
Center Cone Assembly ....................................................................................................................... 55
Center Cone Installation ...................................................................................................................... 55
Roof Assembly .................................................................................................................................... 56
Perforated Center Band ...................................................................................................................... 57
42" Fan Diffuser Instructions and Installation ...................................................................................... 58
Fan Entrance Sheets .......................................................................................................................... 60
Access Door Platform (TDP-5012) ...................................................................................................... 62
Small Platform Assembly .................................................................................................................... 63
Large Platform Assembly .................................................................................................................... 65
Cross Over Platform Assembly for Use with Stairs (TDP-5013) ......................................................... 67
Transition Installation (TR-4734) ......................................................................................................... 68
Transition Assembly (TR-4734) .......................................................................................................... 69
Top Dry Access Door Assembly (TD-100996) .................................................................................... 70
Chapter 10 Accessories ......................................................................................................................................71
2 Ring Door Installation and Accessories .......................................................................................... 71
2 Ring Door Assembly ....................................................................................................................... 72
Optional Bin Step Assembly (WD-042) ............................................................................................. 74
Base Angle ........................................................................................................................................ 75
Base Stiffener Shim ........................................................................................................................... 75
Chapter 11 Warranty ............................................................................................................................................77

PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 5
1. 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. 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
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.

6 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
2. Decals
Roof Damage Warning and Disclaimer
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!
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. Running fans during high humidity/cold weather conditions can
cause air exhaust or intake ports to freeze.

2. Decals
PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 7
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: [phone]
Rotating flighting will
kill or dismember.
Flowing material will
trap and suffocate.
Crusted material will
collapse and suffocate.
Keep clear of all augers.
DO NOT ENTER this bin!
Failure to heed these
warnings will result in
serious injury or death.
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.
DC-GBC-1A

2. Decals
8PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
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: [phone]
Failure to heed these warnings
could result in serious injury, death,
structural damage or collapse of tank.
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:
DC-GBC-2A
WARNING
DON’T DO

PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 9
3. Foundation Requirements
Foundation Requirements for Top Dry Bins (4.00" Top Dry
Bin Corrugation)
Requirements
The following foundation recommendations are a revision to earlier manuals distributed by the GSI Group.
NOTE: There are changes in foundation dimensions from past publications. These dimensions are critical
to the proper installation and function of each foundation.
Selecting the Proper Site
The selected site should be level, firm and free from underlying debris. The bin can be installed
satisfactorily on slopes, but as the slope increases, additional labor and materials are required for the
foundation. The concrete foundation surface must be level. If some fill is required, it should be watered
and tamped thoroughly to prevent uneven settling from the weight of the bin. Naturally, the site must allow
convenient access for easy loading and unloading, plus provide additional space for future units. Also
consider the positioning of handling equipment, availability of electricity and the placement of fans,
heaters, and gas tanks.
Scribe the Diameter
Having determined the center of the site, drive a small 2 x 4 in the ground to mark the center point of the
foundation. The top of the stake should be the same height as the finished foundation will be. Using one
large spike, nail a straight 2 x 4 (approximately 2' longer than the radius of the bin) to the top of the center
spike. The swiveling 2 x 4 will act as a compass, enabling you to scribe the correct diameter of the
foundation and later locate the anchor and stiffener bolt locations. (NOTE: Making the 2 x 4 2' longer than
the radius allow the 2 x 4 to also be used as a leveling device and for pulling concrete.) (See Figure 3A.)
Figure 3A

3. Foundation Requirements
10 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Foundation Requirements for Top Dry Bins (4.00" Top Dry
Bin Corrugation) (Continued)
Prepare the Foundation Forms
Having scribed the diameter of the foundation, proceed by digging the foundation’s footing. This consists
of a large circular trench dug inside the foundation line, (Refer to foundation details for necessary
information). Once the footing has been dug, you are ready to build the forms. It is important that the forms
be rigid enough to hold its shape against the poured concrete. Also, the foundation must be flat. Sloped
floors cannot be used in drying bins. A carpenter’s level placed on top of the compass 2 x 4 will enable
you to set the top of the forms to match the top of the center stake. Check the form work with a transit
to ensure a uniform elevation for the entire foundation. The foundation should be level within 1/8" on
non-stiffened tanks and 1/4" on stiffened tanks at bin wall perimeter. Stiffened tanks must be shimmed
level. (See Figure 3B.)
Figure 3B
All foundation specifications shall be construed as recommendations only. Because of the many variable
conditions in actual installation, the GSI Group, assumes no liability for results arising from the use of such
recommendations.
Alternate Foundation Forms
There are two (2) styles of foundation forms commonly used. The first is the circular form shown in
Figure 3B. The second style of foundation can be made of 2" x 8" boards set into a square with the
corners blocked off to form an octagon. This eight sided form will approximate a circle and can also be
constructed easily.

3. Foundation Requirements
PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 11
Foundation Requirements for Top Dry Bins (4.00" Top Dry
Bin Corrugation) (Continued)
Second Style of Foundation
Figure 3C
Place the Reinforcement
Once the forms and trench have been prepared, begin the placement of reinforcement rods at various
levels in the foundation’s footing. See the appropriate charts and drawings for the bin to determine
requirements and positions of the reinforcement. The reinforcement rods offer their greatest strength
whenlappedproperlyandconnectedbywiringorwelding.Next,placeaminimum of 2" of compactedsand
ontheinside section of thefoundationto provideagood base for theconcreteand protect againstrodents.
The sand should then be covered with four (4) mil polyethylene plastic which will act as a moisture barrier.
Two (2) layers of 6 x 6 wire mesh should then be added to the entire area of the foundation to complete
the preparation of the bins foundation. (See Figure 3C.)

3. Foundation Requirements
12 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Inline Centrifugal Fan Pad
Placement of the Fan Pad: GSI Transitions/Fans only.
If a fan is to be installed, refer to Figure 3D to determine the concrete pad size.
1. The top of this pad should be level with the top of the bin’s foundation.
2. Recommended pad thickness is 4" minimum.
3. Front of pad should be perpendicular to bin wall.
4. Pad for heater not required.
IMPORTANT: Fan pad and fan must be leveled and smooth for proper operation. Vibration problems can
result from improper fan leveling.
Figure 3D

3. Foundation Requirements
PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 13
Duct and Drying Fan Pad Optional
Placement of the Duct Fan Pad: GSI Top Dry Duct System only.
Refer to Figure 3E to determine the duct pad size.
1. The top of this pad should be level with the top of the bin’s foundation.
2. Recommended pad thickness is 4" minimum.
3. Front of pad should be perpendicular to bin wall.
Figure 3E

3. Foundation Requirements
14 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Anchor Bolt Placement
Having poured and leveled the concrete, use the center stake and straight 2 x 4 again to find the bolt circle
radius for the outside hold-down brackets. Select a starting point and stretch a pre-measured chord along
the imaginary circle formed by the bolt circle radius. Take into consideration the placement of these bolts
so as not to interfere with the positions of bin doors and transitions. (Refer to below chart for necessary
radius and chord lengths.) Take the time and work carefully since accuracy is important.
NOTE: Top edge of slab where the bin wall sets must be held to within 1/8" of level.
Figure 3F
Bin Diameter “B” Bolt Circle Radius # of Anchors “E” Chord Distance
24' 12' - 2-7/8" 16 4' - 9-5/16"
30' 15' - 2-11/16" 20 4' - 9-1/8"
36' 18' - 2-1/2" 24 4' - 9-1/16"

3. Foundation Requirements
PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 15
Frost Free Pad (Top Dry Bins)
NOTES:
1. Foundation site should be well drained and free of vegetation or debris.
2. Foundation design is based on a minimum soil bearing capacity of 3000 PSI. If soil bearing capacity
is in doubt, contact a local soil testing engineer.
3. Concrete shall have a minimum compressive strength of 3000 PSI at 28 days.
4. Requirements for reinforcement do not include overlap.
5. Lap all circumferential bars 35 bar diameters and stagger all laps in plan 3'-0".
6. All material used for backfill inside the ring wall should be clean, well graded, crushed stone of
sand-gravel mixture. Backfill should be placed at 6" lifts and well compacted.
7. The optional #4 rebar grid can be substituted for the wire mesh in most cases. Place the #4 bars in
the pad in an 18" x 18" grid.
Figure 3G
* Contact GSI Engineering for heights greater than 6".

3. Foundation Requirements
16 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Frost Free Foundation (Top Dry Bins)
Diameter of Bin: 24'
Corrugation: 4.00"
Diameter of Bin: 30'
Corrugation: 4.00"
Diameter of Bin: 36'
Corrugation: 4.00"
Ring # B N Outside
Radius Sq. Ft. Mesh 6 x 6 - 6/6 Optional #4 18" x 18" Grid (Ft.) Length #6 Bar (Ft.) Total Cu. Yds. Concrete
61'-1" 212'-9" 900 600 200 13
7, 8 1'-9" 212'-9" 900 600 200 15
9, 10 2'-6" 313'-2" 900 600 400 18
Ring # B N Outside
Radius Sq. Ft. Mesh 6 x 6 - 6/6 Optional #4 18" x 18" Grid (Ft.) Length #6 Bar (Ft.) Total Cu. Yds. Concrete
61'-2" 215'-9" 1400 900 200 19
7, 8 1'-10" 215'-10" 1400 900 200 21
9, 10 2'-8" 316'-1" 1400 900 500 25
11 3'-8" 416'-5" 1400 900 700 29
Ring # B N Outside
Radius Sq. Ft. Mesh 6 x 6 - 6/6 Optional #4 18" x 18" Grid (Ft.) Length #6 Bar (Ft.) Total Cu. Yds. Concrete
61'-3" 218'-9" 2000 1300 300 26
7, 8 2'-0" 218'-11" 2000 1300 400 30
9, 10 2'-10" 319'-0" 2000 1300 600 33
11, 12 3'-11" 419'-6" 2000 1300 900 39

PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 17
4. Hardware
Hardware/Bolting Requirements
IMPORTANT: Do not tighten bolts to exceed the torque specifications listed below.
Important Hardware Usage
20 Gauge through 15 gauge sidewall sheets, use 5/16" x 3/4" bolts and nuts (S-275).
14 Gauge and 13 gauge sidewall sheets, use 5/16" x 3/4" bolts and nuts (S-275).
Use 5/16" x 1-1/4" (S-277) for attaching floor flashing to the sidewall.
Figure 4A
Grade 2
Grade 2 bolts are designated with a plain head.
Grade 5
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.
Grade 8
Grade 8 bolts are designated by six (6) slash marks on the head.
Grade 8.2
Grade 8.2 bolts are designated by six (6) slash marks on the head in a sunrise pattern.
All 3/8" diameter bolts are to be grade 8 or 8.2.
Bolt Size Torque (Ft. Lbs.)
Minimum Maximum
5/16"-18 15 20
3/8"-16 35 42
7/16"-14 65 72
1/2"-13 95 105
CAUTION
Under no condition shall any other bolts be substituted for those supplied by GSI.

4. Hardware
18 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Refer to Top Dry Tank Bolting Requirements for Complete Bolt Usage
0.3125" x 0.750" Pre-assembled with a steel backed neoprene washer.
This bolt is used to connect horizontal and vertical seams for 13 gauge and thinner sidewall sheets
to each other and to bolt the stiffeners to the sidewall sheets. It is also used in attaching roof panels
to the top sidewall sheet and attaching roof panels and flashing to the center collar.
0.3125" x 1.250" Pre-assembled with a steel backed neoprene washer.
This bolt is primarily used to connect roof panels together where they overlap. It is also used at the
bottom of the flat bottomed bins to attach the base angle to the sidewall sheet. A small number of
these are provided for joints and splice plates (FC-42076) for the stiffeners to sidewall connection.

4. Hardware
PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36' 19
Refer to Top Dry Tank Bolting Requirements for Complete Bolt
Usage (Continued)
NOTE: Theonlywashersshippedloose with the bins arethesteelflat washers. The 5/16" steelflatwasher
(S-845) is used where the base angle attaches to the sheet and some are used at the main eave
clips. The 3/8" steel flat washers (S-248) are used at the stiffener splices and some are used in the
roof rafter splices.
0.375" x 1.000" Hex flanged head without a plastic sealing washer.
This bolt is used to splice the stiffeners together on the flanges. A steel flat washer is used on the
nut side of the connection. They are also used on “C” channel splices and mounting “C” channel
to wall bracket.
0.375" x 1.500" Hex flanged head without a plastic sealing washer.
This bolt is used to attach the wall bracket to the sidewall and stiffener. A steel flat washer is used
on the nut side of the connection.

4. Hardware
20 PNEG-1276 Top Dry Autoflow Construction Manual 24', 30' and 36'
Location of Accessories
Below is a typical Top Dry bin layout showing suggested locations of Top Dry accessories. When locating
the manway be sure the outside ladder will not interfere with other accessories below. Roof vents should
be spaced evenly around the roof. (Quantity will vary with individual systems.) (See Figure 4B.)
NOTE: The Top Dry system should be provided with a dependable equipment ground.
Figure 4B