Original operating instructions. Transit silo. Model. Transit silo

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1 Original operating instructions Transit silo Model Transit silo Ambros Schmelzer & Sohn GmbH & Co KG Dr.-Zimmer-Str. 28, Waldershof Telefon Fax

2 Table of Contents 1 Foreword General Preliminary technical remarks Structural requirements Preparatory work Overview of construction phases Major structural components Components for supporting construction Components for funnel Components for walls Components for roof construction Components for ladder Assembly Preparation Safety information Structure Phase I: supporting structure Phase II: Funnel for transit silo Phase III: walls for transit silo Phase IV: Roof construction for transit silo Phase V: ladder Commissioning, operation and maintenance Commissioning Operation Maintenance...53 Transit silo Page 2 of 53

3 Read and observe the operating manual and safety information before beginning assembly! Explanation of symbols: Important note Wear safety shoes! Wear head protection! Wear hand protection! Transit silo Page 3 of 53

4 1 Foreword 1.1 General The following points are to be taken into account when assembling and operating the installation. The local building regulations must be observed. Before beginning assembly, it should be verified whether or not a planning application is necessary for the construction of the installation. The applicable accident prevention and safety regulations are to be observed during assembly and operation of the silo. In particular, the necessary working and protection scaffolds are to be used. Sufficient carrying capacity of the substrate must be ensured. Otherwise, appropriate precautions must be taken to ensure adequate stability of the silo installation under load. It is important to ensure that the installation is set up flat and straight. The applicable fire protection regulations are to be observed. The construction and operation are to be performed in accordance with these instructions. The assembly and operating instructions must be carefully read in order to ensure proper construction and operation of the installation. The individual parts are to be verified using the enclosed parts list in order to ensure a complete and proper construction and to avoid future reclamations. Screw and plug connections must be made completely and friction-locked using the fixation devices made available. The general safety regulations for handling bulk materials are to be observed in all cases. The requirements of the accompanying static structural analysis with regards to the general construction measures necessary for assembly must be complied with. On-site changes and modifications of the system are not permitted. Transit silo Page 4 of 53

5 1.2 Preliminary technical remarks This manual describes the construction or assembly and operation of the installation. It is supported by drawings and illustrations. A position plan with provided position numbers and a foundation plan is created for each silo installation. These are provided along with the created parts list. This clarifies the type and number of parts to be used. The installation of the individual building components is explained in the pictures of the assembly details. A static structural analysis for the silo installation is also enclosed with the construction documents. It also contains technical information about the execution of the required general construction measures (for example foundations). All plugs and anchors for the fixation of parts are to be used in accordance with manufacturer specifications. All required on-site welding works are to be performed by appropriate qualified personnel. 1.3 Structural requirements The silo cell is designed for installation on a flat substrate. Since loading of the ground must be possible for the operation of the installation, an adequate reinforced concrete construction is necessary; this means that the loading capacity of the concrete, the thickness of the concrete plate and the reinforcement must correspond to the requirements of the static structural analysis. The installation is designed for the following use: - Location: Inside and outside of buildings. Without additional live loads and impact loads - Filling: Dry cereal, corn or similar bulk material (for example colza) Non-bridging (max. humidity 15%) - Bulk density: 750 kg / m³ - Friction angle: 30 Dynamic loads are to be avoided. Loads due to additional equipment (for example conveyors) are to be separately verified. Transit silo Page 5 of 53

6 1.4 Preparatory work According to the static structural analysis, foundations are to be created on-sitein the course of the general preparatory building works, in accordance with the position plan. The surfaces of the foundations must be exactly horizontal and flatin order to ensure proper installation of the building components. The dimensional tolerances according to DIN 18201, DIN and DIN are to be observed in all cases 1.5 Overview of construction phases Construction phase IV: Roof construction for transit silo Construction phase III: Walls for transit silo Construction phase II: Funnel for transit silo Construction phase V: Construction phase I: Supporting construction Ladder Transit silo Page 6 of 53

7 2 Major structural components 2.1 Components for supporting construction Item 1.1: Silo pillar left Item 1.2: Silo pillar right Item 1.3: Transit framework Transit silo Page 7 of 53

8 Item 1.4: longitudinal transit framework with entry Item 1.5: longitudinal transit framework Item 1.6: joint angle Items : threaded rod screw Item 1.8: M16 threaded rod Transit silo Page 8 of 53

9 2.2 Components for funnel Item 2.1: Lower left funnel plate Item 2.2: Lower right funnel plate Item 2.3: Upper left funnel plate Item 2.4: Upper right funnel plate Item 2.5: Tension plate for high funnel Transit silo Page 9 of 53

10 Item 2.6: Tension plate for low funnel Item 2.7: Funnel corner reinforcement Item 2.8: Perpendicular funnel reinforcement Item 2.9: Lap joint stiffening Item 2.10: Funnel surface stiffening Transit silo Page 10 of 53

11 Item 2.11: Funnel tension bar Item 2.12: Funnel tension bar Item 2.13: Funnel tension bar Item 2.14: Funnel tension bar Item 2.15: Funnel tension bar Item 2.16: Funnel tension bar Item 2.17: Funnel tension bar Item 2.18: Funnel tension bar Transit silo Page 11 of 53

12 Item 2.19: Discharge flange Item 2.20: Suspension for push-rod Item 2.21: Push-rod for shifter Item 2.22: Transition Ø /200 Item 3: flat shifter Ø200 Transit silo Page 12 of 53

13 2.3 Components for walls Item 4.1: Middle wall support Item 4.2: Middle wall support with entry Item 4.3: Wall support ridge Item 4.4: Corner wall support Transit silo Page 13 of 53

14 Item 4.5: Diagonal tension bar Item 4.6.1: Type A foot board left Item 4.6.2: Type A foot board right Item 4.6.3: Wall plate type B Item 4.6.4: End panel type C Item 4.7: End panel type A entry Item 4.8: Wall plate type entry Transit silo Page 14 of 53

15 Item 4.10: Exchangeable profile 2.4 Components for roof construction Item 5.7: T50 trapezoidal sheet Transit silo Page 15 of 53

16 Item 5.1: Ridge bolt for trapezoidal sheet with foot plate Gable top Item 5.6: Cover plate Item 5.2: Ridge capping Item 5.3: Eaves square profile Item 5.4: Pediment left Item 5.5: Pediment right Transit silo Page 16 of 53

17 2.5 Components for ladder Item 6.2: Mounting bracket for ladder Item 6.1: Ladder with safety cage Item 6.3: Mounting bracket for ladder Item 6.5: Mounting bracket for ladder Item 6.4: Mounting bracket for ladder Transit silo Page 17 of 53

18 3 Assembly 3.1 Preparation The silo cell is supplied on pallets among other things. Please take care not to damage building components during unloading. After receiving the shipment, proceed as follows: First verify the received shipment for completeness. The enclosed parts list and building components list in this manual may assist you for this. Inspect the received goods for possible transport damage. Make sure that the components are well protected from humidity during their storage. In case of transport damages to the parts, you may reach us by phone under +49 (0) , or by at: Keep your order number, delivery slip number and delivery address handy. Please also provide these during written communication. 3.2 Safety information Wearing of foot protection is recommended. For your safety, please wear head protection. Wearing of hand protection is recommended. The applicable accident prevention measures are to be observed. 3.3 Structure Unpack the parts and sort them according to the position plan and the parts list. The individual components are to be set up part per part according to the project related position plan. An exactly vertical construction is to be ensured. To do this, measure the diagonal distance from silo pillar to silo pillar Phase I: supporting structure Transit silo Page 18 of 53

19 Transit Obtain the building component designation from the appended parts list. Point 2 - Main building components may be helpful for this. Observe the transit direction of the transit silo from the beginning of construction on. Transit silo Page 19 of 53

20 Mark the future positions of the silo pillars on the foundation. Measure the diagonals to verify that the transit silo is exactly vertical later on. Both measured values must be identical for this. Figure 1 Place the left silo pillar (Item 1.1) and right silo pillar (Item 1.2) flat next to one another on the ground. Now place the longitudinal framework (Item 1.4) at its position as shown in figure 1. Figure 2 Bolt in the right silo pillar (Item 1.2) to the longitudinal framework (Item 1.4) using the provided bolts. Figure 3 Transit silo Page 20 of 53

21 Now bolt the longitudinal framework to the framework angle bracket (Item 1.6) and to the right silo pillar on the face side (Item 1.2). Figure 4 Once this is done, insert the threaded rods (Item 1.8) and attach them to the GEWI anchor plates (Item 1.9), the GEWI anchor nut (Item 1.10) and the GEWI counternut (Item 1.11). Figure 5 Transit silo Page 21 of 53

22 Repeat the process, only replace the longitudinal framework (Item 1.4) with the longitudinal framework with entry (Item 1.5). Now place both components in a vertical position. Attach both frame parts to the foundation. Warning: Use the necessary working and protection scaffolds for this. Figure 6 Now insert both transit frames (Item 1.3) in the construction. Figure 7 Transit silo Page 22 of 53

23 Bolt the transit frame (Item 1.3) to the right silo pillar (Item 1.2) using the provided bolts. Figure 8 Furthermore, the transit framework (Item 1.3) must be connected to the framework angle bracket (Item 1.6) and with the right silo pillar on the face side using screw connections. Figure 9 Transit silo Page 23 of 53

24 3.3.2 Phase II: Funnel for transit silo Obtain the building component designation from the appended parts list. Point 2 - Main building components may be helpful for this. The funnel is completely assembled on the ground and only lifted into the standing support structure as a last step. Transit silo Page 24 of 53

25 Start by assembling the funnel by respectively screwing the lower left funnel plate (Item 2.1) with the lower right funnel plate (Item 2.2) as shown in figure 11. Furthermore, the lower funnel plates must be screwed together via the corner. A corner reinforcement for the funnel (Item 2.7) is to be affixed on both sides. Figure 10 Screw the tension plate for the upper funnel (Item 2.5) or the tension plate for the lower funnel (Item 2.6) to the lower left funnel plate (Item 2.1) and the lower right funnel plate (Item 2.2) with two vertical funnel plate reinforcements (Item 2.8). Figure 11 Transit silo Page 25 of 53

26 The next step is to screw the upper left funnel plate (Item 2.3) and the upper right funnel plate (Item 2.4) overlapping with the respective lower funnel plate. Funnel corner reinforcements (Item 2.7) must also be attached on both sides over the corners. Furthermore, the plates are to be connected as shown in figure 13. Figure 12 Screw the upper tension plate (Item 2.5) or the lower tension plate (Item 2.6) with the upper left funnel plate (Item 2.3) and the upper right funnel plate (Item 2.4), a vertical funnel reinforcement (Item 2.8) is to be attached on both sides. Figure 13 Transit silo Page 26 of 53

27 In order to reinforce the funnel, attach the overlap stiffening (Item 2.9) and the funnel surface stiffening (Item 2.10) on all four sides in an overlapping fashion. Figure 14 Furthermore, the funnel tension rods (Item Item 2.18) contribute to the stability of the part. The connection is made as shown in figure 16. Please observe that the tension rods (Items 2.11, 2.13, 2.15 and 2.17) are to be attached to the upper tension plates (Item 2.5) and the tension rods (Items 2.12, 2.14, 2.16 and 2.18) are to be attached to the lower tension plates (Item 2.6). Figure 15 Transit silo Page 27 of 53

28 The tension rod (here: Item 2.11) is to be simply screwed to the respective tension plate (here: Item 2.5) using the provided screw material. Figure 16 Finally, the outlet flange (Item 2.19), the transition Ø /200 (Item 2.22) and the flat slider Ø200 (Item 3) are to be attached to the funnel. To do this, plug the outlet flange from the inside though the funnel opening, the connection is then made as shown in figure 18. Figure 19 shows how the transition is to be attached to the outlet flange. And figure 20 shows the connection between the transition and the flat slider. Figure 17 Transit silo Page 28 of 53

29 The respective lower funnel plate (here: Item 2.1) is screwed to the outlet flange (Item 2.19). Figure 18 The outlet flange (Item 2.19) is connected to the transition (Item 2.22) by screws on each corner. Figure 19 The transition (Item 2.19) is connected to the flat slider (Item 3) using the provided tension ring. To do this, lay the tension ring over both rims and close the tension ring. Figure 20 Transit silo Page 29 of 53

30 Construction phase II : Funnel for transit silo Construction phase I : Supporting structure As a final step, the funnel is lifted into the supporting construction from above. This should be performed using a crane, a telehoist load lugger or other appropriate equipment. Figure 22 shows the type of connection. Figure 21 Place the assembled funnel with its upper funnel plates (Items 2.3 and 2.4) on the framework of the carrying construction (Item 1.3, 1.4 or 1.5) and verify that the drill holes in the funnel plates overlap with those in the framework. Figure 22 Transit silo Page 30 of 53

31 3.3.3 Phase III: walls for transit silo Obtain the building component designation from the appended parts list. Point 2 - Main building components may be helpful for this. The walls are completely attached to the base, and the last step is to screw the walls to the supporting structure. Transit silo Page 31 of 53

32 Start by setting up the middle wall support (Item 4.1) with a corner wall support (Item 4.4) and a ridge wall support (Item 4.3) as shown in figure 23. Now assemble them as shown in figure 24, respectively one type A left foot plate (Item 4.6.1) with on type A right foot plate (Item 4.6.2). Figure 23 Using the provided screws, attach the type A left foot plate (Item 4.6.1) and the type A right foot plate (Item 4.6.2) to the tension plates of the corner wall supports (Item 4.4) Figure 24 Transit silo Page 32 of 53

33 Now arrange the remaining three corner wall supports (Item 4.4), the second ridge wall support (Item 4.3) and the middle wall support with entry (Item 4.2) as shown in figure 25 and screw these to the respective foot plate (Item 4.6.1, Item and 4.7) as shown in figure 24. Figure 25 Now insert the next row of type B wall plates (Item 4.6.3) and the entry type wall plate (Item 4.8) over the entry. Figures 27 and 28 show the type of fixation. Figure 26 Transit silo Page 33 of 53

34 Screw the type B wall plates (Item 4.6) with the corner wall supports (Item 4.4) or the ridge wall supports (Item 4.3), the middle wall support (Item 4.1) or the middle wall support with entry (Item 4.2). Figure 27 Furthermore, the type A left foot plates (Item 4.6.1) or the type A right foot plates (Item 4.6.2) are to be screwed to the type B wall plates (Item 4.6.3). Figure 28 Transit silo Page 34 of 53

35 Attach the remaining type B wall plates (Item 4.6.3) as shown in figures 27 and 28 until they reach the position shown in figure 29. Figure 29 Then screw the type C closing plates (Item 4.6.4) all around the circumference. This is also done according to a similar principle to that shown in figure 27 and figure 28. Figure 30 Transit silo Page 35 of 53

36 An alternation (Item 4.10) is mounted for stiffening of the walls over the entry. The exact assembly is described in figure 32. Figure 31 The alternation (Item 4.20) is screwed to the middle wall support with entry (Item 4.2) and the adjacent entry type wall plate (Item 4.8) using the supplied drilling screws. Figure 32 Transit silo Page 36 of 53

37 Now the diagonal tension rods (Item 4.5) are fixed respectively to the middle wall support (Item 4.1), the middle wall support with entry (Item 4.2) and the ridge wall support (Item 4.3). The exact assembly is illustrated in figure 34. Figure 33 Screw the diagonal tension rods (Item 4.5) with the respective wall support, here: middle wall support (Item 4.1), using the provided screws. Figure 34 Transit silo Page 37 of 53

38 Construction phase II : Funnel for transit silo Construction phase III : Transit walls silo Construction phase I : Supporting structure Finally, the assembled walls are lifted onto the carrying construction. For this, use a crane, a telehoist load lugger or other appropriate equipment. For further work, a working and protection scaffold is necessary. Figure 36 shows how the supporting structure, the funnel and the walls are screwed together. Please note: Height differences between the walls and the supporting structure that occur due to the funnel plates must be compensated using the provided compensation plates. Figure 35 Align the walls with the supporting structure so that the holes in the left type A foot plates (Item 4.6.1) and the right type A foot plates (Item 4.6.3) are on the same axis as those of the upper funnel plates (Items 2.3 or 2.4) and those of the framework (Item 1.3, Item 1.4 and 1.5). Figure 36 Transit silo Page 38 of 53

39 3.3.4 Phase IV: Roof construction for transit silo Obtain the building component designation from the appended parts list. Point 2 - Main building components may be helpful for this. As shown in the following figures, the roof construction is not assembled separately on the ground but directly assembled on the existing construction. Transit silo Page 39 of 53

40 First, the ridge crossbar for the trapezoid plate (Item 4.3) is mounted on both ridge wall supports (Item 4.3) with the foot plates as shown in figure 38. Figure 37 To do this, screw the foot plates of the ridge crossbar for the trapezoid plate (Item 5.1) to the plates of the ridge wall supports (Item 4.3). Figure 38 Transit silo Page 40 of 53

41 Once this is done, attach the eaves angle profile (Item 5.3) to the middle wall support (Item 4.1), the middle wall support with entry (Item 4.2) and the respective corner wall support(item 4.4) using drilling screws. The fixations is clarified by figures 40 and 41. Figure 39 Screw the eaves angle profile (Item 5.3) to the middle wall support (Item 4.1) or here, to the middle wall support with entry (Item 4.2) using drilling screws. Figure 40 Transit silo Page 41 of 53

42 Additionally, screw the eaves angle profile (Item 5.3) to the respective corner wall supports (Item 4.4). Figure 41 Expand the construction by attaching the trapezoid plates T50 (Item 5.7) to the construction. The way this should be done is clarified in figures 43 and 44. Figure 42 Transit silo Page 42 of 53

43 Screw the T50 trapezoid plates (Item 5.7) to the ridge crossbar for trapezoid plate with foot plates (Item 5.1). Figure 43 For further stability, screw the T50 trapezoid plates (Item 5.7) to the eaves angle profile (Item 5.3) using drilling screws. Figure 44 Transit silo Page 43 of 53

44 Expand the construction by attaching the trapezoid plates T50 (Item 5.7) to the construction. Figures 46 and 47 detail the way this should be done. However, before doing this, the pediments (Item 5.4 and Item 5.5) are to be attached to the type C closing plates (Item 4.6.4), the ridge wall supports (Item 4.3) and the T50 trapezoid plates using drilling screws. Figure 45 Attach the ridge cover (Item 5.2) to the trapezoid plates (Item 5.7) using drilling screws. Figure 46 Transit silo Page 44 of 53

45 The gable peak closing plates (Item 5.6) are also to be attached to the pediments (Item 5.4 or Item 5.5) using drilling screws. Figure 47 Transit silo Page 45 of 53

46 3.3.5 Phase V: ladder Obtain the building component designation from the appended parts list. Point 2 - Main building components may be helpful for this. As shown in the following figures, the ladder is not separately assembled on the ground, but directly assembled onto the existing construction. Transit silo Page 46 of 53

47 First, weld a ladder holding bracket (Item 6.2) to the lower cross-beam of the longitudinal framework with entry (Item 1.5). Figure 48 Pay attention to the alignment and position of the ladder holding bracket (Item 6.2). Weld it to the longitudinal framework with entry. Figure 49 Transit silo Page 47 of 53

48 Drive the ladder with safety cage (Item 6.1) into the previously welded ladder holding bracket (Item 6.2). For your own safety, secure the ladder against tipping. Now drive the ladder (Item 6.1) into the second ladder holding bracket (Item 6.3). Align them. Once this is done, attach the ladder holding bracket to the longitudinal framework with entry (Item 1.5). And close the connection completely. Figure 50 Here you can see the position of the ladder holding bracket (Item 6.3). The ladder (Item 6.1) is supported against both holding brackets (Item 6.2 and Item 6.3) with a ladder step. To secure it against slipping, screws are inserted into the allotted holes. Figure 51 Transit silo Page 48 of 53

49 Now, two further ladder holding brackets (Item 6.4) are welded onto the upper cross-beam of the longitudinal framework with entry (Item 1.5). Figure 52 Figure 53 Transit silo Page 49 of 53

50 Both ladder holding brackets (Item 6.2) are welded to the upper cross-beam of the longitudinal framework with entry (Item 1.5) as can be seen in figure 56. Here too, additional screws are used to in the provided holes to further secure the assembly. The last assembly step consists of welding a final ladder holding bracket (Item 6.5) to the middle wall support with entry (Item 4.2). Figure 54 Position the mounting bracket for the ladder (Item 6.5) as shown in figure 55. Align the mounting bracket and weld it with the middle wall support with entry (Item 4.2). The ladder (Item 6.1) is also secured against sliding using additional screws at the level of this mounting bracket. Transit silo Page 50 of 53

51 Figure 55 Transit silo Page 51 of 53

52 Figure 56 The last step is to check all screw connections as well as the threaded rods. If all steps of these assembly instructions were followed, the assembly is complete. Transit silo Page 52 of 53

53 4 Commissioning, operation and maintenance 4.1 Commissioning Before commissioning, verify the proper attachment of connection elements and tighten them if necessary. Also check that the flat slider and the entry are both closed. If this is the case, the transit silo can be filled with bulk material. 4.2 Operation The maximum headroom of the transit silo must be taken into account. 4.3 Maintenance Regularly inspect the complete installation for deformations and signs of wear. Grain dust can combine with the condensation water that forms during grain drying to form a thick layer of dirt on the walls of the transit silo. This layer can be a breeding ground for mould, acarians and corn weevils. Therefore regularly check whether cleaning of the inside of the transit silo is necessary. For your own safety, wear breathing protection during the cleaning process. Transit silo Page 53 of 53

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