10 Factors to consider when planning

your Grain Storage Steel Bin Project

Mauro Tognocchi 11/02/2016 Tech Paper # 2

1. Seismic, Wind and Snow Conditions.

You are making a
At the initial stage of a project the requirements for design of the
large investment in
bins and other grain equipment for seismic conditions, wind steel bins (silos) in
conditions and weather conditions must be specified. the interest of
Seismic. Structurally speaking, grain bins are highly loaded making a reasonable
structures and with the grains content piled up very high income.
vertically. Because of this, a seismic event can cause an
important combination of forces on the silo. Other related A number of
structures at a grain facility (conveyor support towers, grain considerations in
dryers, catwalks, etc) can also affected by the seismic event.
this Technical Paper
Wind. The use of local wind velocity data allows the most by TWP
International can
The facility owner or the project engineer should
help you ask the
specify to contractors and equipment suppliers
what building code, national or state standard
right questions,
the facility is required to comply to. choose the right
people for your silo
accurate calculation of wind pressures on bins. project and ensure

Snow. Local information on the mass of snow loads should be

that the installation
used to prevent the silo from being vulnerable to structural serves its function
failure and possible collapse. Generally speaking, the building properly, protecting
code identifies the ground snow load, which silo designers use
lives, property and
as the starting point to estimate the uniform design snow load
on the roof. the environment
with a structurally
Seismic, wind and snow forces on the silos are determined by
applying provisions from structure design codes. These design
sound, functional
codes give engineers specific values to design for a given and cost-effective
location and provide a method to generate design forces to silo design.
calculate such structures. In absence of such data, and only as a
preliminary approach, some idea of the worst conditions to be expected can be obtained by talking to
long-time residents of the area.

On top of this, the facility owner or the project engineer should specify to contractors and equipment
suppliers what building code, national or state standard the facility is required to comply with.

It is also important to consider that during a seismic event or a strong wind, some structures attached
to steel bins (towers, catwalks and other equipment) can apply forces in a direction that they normally
do not. Attention on those forces should be part of the installation design process, especially when such
structures or equipment are supplied by a vendor different from the steel bin vendor. Sometimes, such
forces can end in a catastrophic silo failure if not considered.

A close work between the steel bin manufacturer engineering staff and the project engineer shall
happen to ensure all these factors are properly considered.

2. Weather Conditions and Grain Quality

Preserving grain quality in warm climates is more difficult than in colder zones, even when the
deterioration is ruled by the same mechanisms regardless of the climate.

Grain quality preservation in tropical areas must consider several conditions: imported grain or local
grain coming directly from the farm, type of grain, moisture content, altitude, handling, etc. As a quick
guide, you can consider the main following factors:

Grain handling can affect the natural protective coat of seeds, making it easy to be attacked by insects.
Additionally, breakage and fine material caused by handling, will segregate causing a potential loss. A
tender handling of grains is a good practice to limit the damage.

Insects can cause grain contamination and loss, and are especially likely to create issues in tropical

Preserving grain quality in warm climates is more difficult than in colder zones,
even when the deterioration is ruled by the same mechanisms.

climates. Installation must consider the possibility of having an adequate sanitation and the possibility
of successful and safe fumigation.

Molds can cause kernel damage, odor, caking, and heating in stored grain. Controlling molds is related
to controlling the moisture and temperature within the grain mass stored in the bin. Agricultural
engineering handbooks provide an analysis of temperature and moisture content for best preservation
of each grain type. This topic is closely related to aeration of grains.

Again, the steel bin manufacturer must ensure the client all these factors are properly considered in
their design.
3. Aeration
The objective of maintenance aeration management is to keep grain temperature stable and as close as
possible to outside air temperature to avoid moisture migration and to keep grain temperature low to
minimize deterioration. That must be done economically to a temperature safe for storage, also
considering the storage time requirements.

The amount of air required to keep the temperature of the grain may not reduce the moisture content
very much. Although aeration is not a grain drying system and should not be considered as such, some
drying can occur when the weather is very dry and the fans are run for a very long time.

Aeration systems always work in combination with a grain temperature monitoring.

Only if the interior grain temperature increases over time and only if the warmest grain in the bin is
warmer than the daily average ambient temperature will aeration be beneficial.

The amount of air required to keep the temperature of the grain may not
reduce the moisture content very much. Aeration should not be considered a
grain drying system, even some drying can occur when the weather is very dry
and the fans are run for a very long time. Exceptionally, a cooling-drying system
using high air rates (m3 air/hour/m3 grain) and particular techniques can be
designed.

The design engineer needs to know whether the aeration system will be used for holding high moisture
grain for a certain period, cooling-drying grain, long or short term storage just maintaining conditions,
or long term storage during the spring or summer.

The aeration flow is defined as the volume of air delivered in the time unit, then it can be expressed as
m3 / h, m3 / min, etc. It is characterized by two parameters: flow rate (Q) and pressure (P). The concept
of specific flow (Qs), which refers to the amount of air that receives a cubic meter of grain in the unit of
time, is a suitable parameter for determining the requirements of use in different types of aeration.

Answering the question on how much aeration rate is needed in a certain grain
storage project, needs deeper analysis on conditions. Some references on the
aeration flows ordinarily used, can be seen in the following table:

Aeration Objective Specific flow [m / hr / m]

Cool and stabilize grain temperature 2.5 to 10.0
Keep cold wet grain 15.0 to 30.0
Dry and cool in dry-aeration 35.0 to 100.0
Natural air drying 120.0 to 360.0
4. Bins Foundation
One of the most common causes of failures in silos is related to the foundation. A geotechnical
engineering firm should be engaged to do a soil investigation and report for the site of the silos. This
report will provide information that is not only important for the foundation design but for the storage
silo design.

It is still quite common for small bins to be constructed on foundations designed without determining
the strength of the soil. In many cases there is just a slab poured in place. Sometimes it does not present
a problem just because the bins are small.

For bigger silos, it becomes vital that soil investigations are taken and foundations designed based on
the findings because larger bins mean increased floor loads.

Depending on its report, the bin supplier may provide you with a foundation design or
recommendations for design by the geotechnical or civil consultant.

One of the goals of the soil investigation is to determine what settlement is expected. Both uniform or
differential settlement must be anticipated. Uniform settlement will not pose a problem in general if
moderate, but differential settlement can be a major problem causing the silo to tilt and collapse. Some
settlement will always occur with silos. Because of this, any lighter structure attached to the silo must
be connected with some type of sliding connection to prevent damage to both silo and structure.

Remember that the silo foundation is one of the most critical components of your project. It is very
important that it is properly designed and levelled, with enough reinforcing steel correctly placed and
that the correct strength of concrete is used.

The silo foundation is one of the most critical components of your project. It is
very important that it is properly designed and levelled, with enough reinforcing
steel correctly placed and that the correct strength of concrete is used.

5. Effective dust control

This topic is more related to handling equipment, but included because of its significance: dust
explosions are an always present risk faced by grain storages.

NFPA 654 (The National Fire Protection Association Standard for the Prevention of Fire and Dust
Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids
Latest Edition) is probably the current Best Engineering Practice designed to protect grain storage
facilities from combustible dust explosions. The standard identifies measures to be taken to avoid dust
explosions by designing facilities and work practices that prevent the production and dispersion of
dust as well as controlling ignition sources and provides mitigation recommendations for explosions.

Various explosion protection methods are permitted by this Standard. Often combinations of protection
measures present the best engineering and financial solution. The most commonly used protection
methods are explosion relief venting and explosion suppression, always combined with a modern Silo
design consisting of locating bucket elevators and other vulnerable equipment outdoors to minimize
the explosion propagation. Other important measure to be considered is always do what you can to
minimize dust. A long list of dust collectors combined with design that minimizes turbulence in
sensitive places like elevator boot are also available.

It is important to mention that making your facility safer does not necessarily mean making it
significantly more expensive. A great deal of experience has been gathered and documented
worldwide over the last 50 years on this topic. Make sure your design considers this.

Making your facility safer does not necessarily mean making it significantly more
expensive.

6. Maintainable design
Facilities with difficult access still need regular maintenance to avoid costly problems. Dirt sitting on a
bin roof can produce deflection and considerable damage. Make sure bin roof is safely accessible.

When putting tunnels under the bin for the use of conveyors, make sure the tunnels are wide enough
for maintenance access to the reclaim conveyor. If the tunnel base is under ground level, make sure a
good drainage system with sump is installed.

Free-standing bucket elevators of almost any height are available nowadays and used in combination
with steel bins. As free-standing elevators are in general not contained in steel structures, there is no
easy access of maintenance personnel to all levels. It is necessary to include a standard steel ladder
attachment to the casing, including a steel safety guard and a generous steel platform at head level.
Support of loading equipment via properly engineered towers and catwalks should be chosen
whenever possible.

Elevators are generally placed in pits, although this should be avoided when possible. If pits must be
used, ample space should be provided to allow for maintenance.

Inspection Doors are needed throughout the installation. When handling fine and dusty material, they
must be dust-tight to limit dust propagation, as previously said.

7. Galvanized structures and Life Cycle Design

The steel used to construct steel bins is covered with a thin coating of zinc or in some limited cases,
aluminum-zinc coating on both sides. The zinc will protect the steel against corrosion. The thicker the
coating, the longer the protection will last, in direct relation with your bin life. Silos manufacturers
specify different zinc coatings: Z-375, Z-450, Z-600. The number means the grams of zinc per square
meter that the steel has applied on both sides. As a practical rule, always prefer the higher figure for
your silo.

Silos manufacturers specify different zinc coatings: Z-375, Z-450, Z-600. The
number means the grams of zinc per square meter that the steel has applied on
both sides.
8. Bin loading and unloading
Steel bins are thin-shelled structures that can fail if subject to non-uniform stresses. Off-center loading
or unloading can create non-uniform pressures on the bin walls that can result in bin damage or even
catastrophic failure. Additionally, conveyor systems must not be used over nominal capacity because it
may increase dynamic loads on the bin. Increased dynamic loads on bin sidewalls could cause
distortion and structural failure.

9. Silos erection company

The owner and/or his consultant engineer will be most comfortable dealing with a contractor who has
completed many similar projects. An experienced contractor follows proper erection procedures, is
familiar with sound techniques, makes proper connections and knows best how the silo and ancillary
constructions or equipment must function. The complexities of erecting, temporarily bracing and
finishing a large structure are best handled by a person with experience. An important percentage of
silo failures occur during construction.

Before hiring the erection contractor, make sure he is serious about safety. Ask questions regarding
safety committee and dedicated safety supervisor. Erection crews should be tested for illegal
substances before accessing to erection site. They must have a competent person in fall protection at
each project site and a fall protection plan that defines safety setup prior to beginning a project.
Erection crews should receive appropriate and documented training.
10. Some other questions you must ask
The following can also be common causes of failures in bins and accidents. Be aware of them during
design and operation stages.

Is the new silo attached to (or very close to) another existing silo or
building? How can be affected?

Does the design provide adequate and effective ventilation in tunnels?

Were fire separations and prevention considered in this project?

What future use requirements should be incorporated to present design?

What are the safety and environmental consequences of a bin structural

failure? Were they considered in design?

Are augers and conveyors properly designed and attached?

Is there a device to prevent simultaneous loading and unloading of the

bin?

Is there a procedure in place to check that sidewall sheets and/or

stiffeners are correctly installed?

Are roof vents designed to avoid blockages that can cause excessive
pressures on roof?

Is there a device to prevent bin overfilling?

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