GRAIN STORAGE SYSTEMS

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2 GRAIN STORAGE SYSTEMS FOPRO Grain Systems is a market leader in the design and manufacture of grain storage silo and handling systems. FOPRO has earned an excellent reputation worldwide with superior system design, project creation capabilities, engineering, high-quality materials and workmanship. FOPRO produce grain silo facilities by using modern and highest level of technology machines for long-term grain storage needs. FOPRO, as your solution partner, produces superior quality products with excellent design and safety standards in order to guarantee customer s satisfaction. FOPRO excellent quality of production and assembly are guaranteed by ISO 9001:2008 certification. FOPRO main working principles are: Quality management Customer satisfaction Excellent production After sales service Non-stop development Compliance with the highest international standards. Organizational capacity and management of turnkey projects. Flexibility. Short implementation times. Financial capacity. Highly industrialized production process, according to the most stringent quality control procedures. Contact FOPRO about your handling and storage needs for commodities such as corn, wheat, barley, soybeans, pulses, rice, sunflower, palm kernels, and other free flowing products like wood pellets, animal feed, and some minerals. Whether your storage requirement is large or small, FOPRO will provide the design and manufacturing support you need.

3 FLAT BOTTOM STEEL SILO: FLAT BOTTOM STEEL SILO: FOPRO steel silos are designed according to the specifications and standards given below : - Dynamic analysis of the silo structural system is done according to the seismic and soil conditions of the area which the silos will be installed - Snow load is calculated according to conditions of the area which the silos will be installed. - Wind load is calculated according to the height of the silo especially for the empty case of silo. - Static and dynamical analysis of the silo is done for the case of 25 C temperature change - Static and dynamical analysis of the silo is done according to the vertical and horizontal load of grain - After the designing with CAD-CAM programs, the silos are manufactured with CNC controlled machines, quality control is done by the quality control department. Standard Silo Design Parameters : - Euro Code 3 (EN :2007) Part 4.1 & DIN ANSI/ASAE EP433 / 2001 & ANSI/ASAE EP545 / 2000 Seismic Design : UBC 4 Seismic standard (Aº=0.35) Wind Velocity : 145 Km/hr Wind Load : 120 Kg/m2 Design roof load for dead load plus snow load : 150 Kg/m2 Grain Products to be Stored: Wheat bulk density ; 800 Kg/m³ Corn bulk density ; 720 Kg/m³ Rice bulk density ; 640 Kg/m³ The FOPRO galvanized steel silos are produced by advanced technology and designed to respond all types of grain storage. The advantages of Flat Bottom Steel silos: Lower investment costs. Lower erection costs. Shorter implementation time. Entirely modular silo equipment provides to disassemble and move the facility to another site and/or to enlarge the facility. FOPRO flat bottom type grain storage steel silos in different sizes are available, from 3.66 meters up to meters (diameter), according to the storage capacity required by the Customer (from 25 m3 to m3 of wheat or other kind of cereals). FOPRO outer steel stiffened flat bottom silos and accessories are used worldwide.

4 SILO SIDEWALL STEEL PLATES: High quality and extremely strong materials are used during the production process of the silos. Galvanized structural steel plates used in the production of the silos are able to withstand strength 450 MPa (4590 Kg/cm²). All 3.0mm - 1.2mm thickness silo side-wall plates have EN 10326/10143 standard and S350GD + Z450 quality structural steel has the following features; Yield strength Tensile strength Elongation in 50 mm ; 350 MPa minimum ; 450 MPa minimum ; 12% minimum: All sidewall sheets have 943 mm vertical coverage and 2871 mm horizontal coverage. Narrow corrugated form is given to the silo side wall plates for the pressure to be the most resistant. Corrugation profile has mm pitch and mm depth. On taller silos, FOPRO uses two sidewall panels laminated (double layer) together for greater strength. The corrugated sidewall sheets are engineered for fast erection.. Zinc coating amount on the steel, is increased to guarantee the protection against inner friction and all outer natural effect. Amount of zinc coating on the manufactured sidewall sheets, are determined according to the loading/unloading frequency and some natural events such as humidity, wind and sandstorm of the place where silo is to be built. Special galvanize plating is used for superior corrosion resistance, the standard galvanized plating of the sheets are (G-90) 275 gr/m2, (G-115) 350 gr/m2 and (G-140) 450 gr/m2 zinc coating according to the customer's request. Durable bolts ensure a long life for FOPRO products. Galvanized coated, Grade 8.8 and 10.9 fasteners used both on sidewall and stiffener columns. Special paste is used in all silo body sheets and upper cone connection points in order to obtain full airtight and full waterproof. Thanks to bonded washer and strip caulking, efficiency on sealing is obtained. Double bolts (triple or four on large diameter silos) are used for all sidewall sheets. STIFFENER & SPLICES: Silo strength is further maximized through the use of FOPRO s strong upright stiffener columns which carry the vertical load of the bin to the foundation. Splices strengthens the structure of the silo which are manufactured from high strength 450 MPa steel and as large as stiffener s cross-sectional area Stiffener & Splice thicknesses are manufactured from 2 mm to 8 mm according to the silo strength design. Stiffeners are hot dip galvanized and mounted externally to silo sidewall steel plates. Stiffener base plate is factory welded to bottom stiffeners providing durable bin/silo anchorage in order to resist lateral and uplift loads. Also it resists to earthquake loads.

5 SILO ROOF SYSTEM: The FOPRO silo roof is one of the strongest silo roofs available. FOPRO s roof structure specially designed and manufactured by using high strength steel with 275 gr/m² zinc coating. It provides an excellent sealing by fully overlapped, strong structure. FOPRO s roofs are framed by sturdy beams. FOPRO standard roof models are custom designed roofs and they are manufactured according to bear the specific loads such as different snow and wind loads, temperature cables and handling equipment. The inclination of the roof is 30 degrees which provides optimum filling of the silo. To reinforce the strength and durability of the roof of grain silos with wide diameters special sturdy cross section structural roof is used. Steel Silo roof panels are designed over 4 (four) panels to provide high strength according to every side wall steel sheets and supported with high tonnage ridging. The ridging are special manufactured with FOPRO s computer aided design (CAD) to present more safety and resistance production. 8.8 quality high strength galvanized bolts are used in all roof sheet connection places in order to obtain highest degree of durability of all FOPRO silos There is one inspection- control cover on the roof of the silo. SILO SIDEWALL & ROOF WIND RINGS FOPRO wind rings are assembled on the silo body to provide stable structure to the silo during filling and discharge. During the discharge process, silo resists the pressure and stress of the sidewalls by the help of these wind rings. This allows to use the silo with confidence for many years. FOPRO wind rings can also be used in the roof to strength the construction as used in the silo body sheets. FOPRO wind rings are assembled on the silos according to the diameter of the silo, seismic zone and side discharge gates.

6 SILO ENTRANCE AND LADDER SYSTEM: FOPRO outside ladders and roof ladders provide a safety on roof access. Spacing between sidewall ladder and sidewall, embossing on the ladder rungs are specially designed for safety and not to slide. Resting platforms are located at certain levels according to related standards. Inside ladders are also available for maintenance and the controls inside silo. FOPRO also offers circular stair and specially designed roof ladders with hand-rails and stairs optionally which are more comfortable and safe equipments. Meanwhile, inside ladders are also available. FOPRO ladder and platforms are produced completely modular from galvanized sheets. The holes; drilled to the strip sheet metals by CNC Punching Machine gives easiness to bolt assemble. Both external and internal ladders can be assembled to the existing holes by using connection fittings. The standard silo external ladder safety cage system enables people to reach the roof safely. An eave platform can be installed below the manhole for your convenience when entering the bin or inspecting the roof. Access to the roof and the rest platform to observe from manhole are FOPRO s standard silo accessories. STEEL SILO ACCESS SIDEWALL DOOR: Silo access door is offered two pieces in each silo. First is utilized to access from roof when silo is loaded, other is located on second bottom ring for entering silo when silo is empty. Thanks to the inner cover of lower access-door; opening of the door is prevented when silo is loaded and safe usage is provided. The sidewall door, which manufactured by FOPRO, is assembled to silo s bottom second ring has Ø 64 cm diameter to make easy access into silo and also has door support panel. The door is closed from double side with locking bars.

7 ROOF VENTS & ROOF EXHAUST FANs: The roof vents are assembled to over the steel silo roof. The roof vents are designed to exclude outside the heated air from inside of the silo and also prevent from any foreign materials to come into the silo. The roof vents provides to exclude the air freely outside of the silo while the fans are working.

8 AERATION SYSTEM: The grain in the silo must be aerated for long time storage. In this system the silo is aerated by high pressure centrifugal fans. The air passes through the grain and leaves the silo from the ventilation outlets at the roof of the silo. During the foundation laying the air ventilation channels must be left on the surface of the concrete foundation. The sizes of the ventilation channels are calculated according to the capacity of the silo. The diameter of the perforated galvanized during is covered upon the air channels in order to provide efficient grain ventilation inside of the silo. High volume axial and centrifugal fans are made of galvanized steel and designed to deliver high capacity air own at maximum performance. The FOPRO active ventilation system efficiently decreases damage percentage of the grain, decreases relative degree of humidity, reduces risk of grain spoiling, decreases the reproduction rate of insects, etc. In addition, the mobile corrugated ventilation fans which are used in the horizontal silos can be produced. And, by the ventilation outlet at the roof, natural air circulation exists. This natural air circulation is supported by aeration fans and the grain is stored for a while. DOUBLE H-PATTERN All Double H-pattern Commercial flush floor aeration systems consist of plain and perforated corrugated decking, 4 (100 mm) wide hat-beams, 12 (305 mm) high support legs, ledger angles, perforated strips, corrugated filler strips and fasteners. The plain and perforated corrugated decking are either 18 Gauge (1.17 mm) or 14 Gauge (1.83 mm) thick galvanized steel. FLUSH FLOOR AERATION FOPRO Flush Floor systems are easy to install. No preforming is required simply set our formed steel concrete forms in place and pour the floor! Our system includes 14% open perforated planks with round perforation holes to minimize clogging.

9 FOPRO CENTRIFUGAL FANS FOPRO has over 100 models of fans, ranging from 50 and 60 Hz, with low and high speed centrifugal and axial configurations. FOPRO centrifugal fan housings are precision fabricated from heavy gauge galvanized steel which is rust resistant, provides an attractive finish and has a long life. Fan housings are bolted together, using as few pieces as possible to increase the strength and reduce the number of seams that can cause air leakage or wear problems. FOPRO AXIAL FANS: FOPRO axial fans deliver high capacity airflow at maximum performance. Fans feature all-galvanized steel bodies, heavy-duty cast aluminum blades and energy-efficient electric motors. Available in a variety of fan diameters and horsepower ratings.

10 TEMPERATURE CONTROL SYSTEM: The heat control system must be used in the silos during the grain storage because this system allows detecting hotspots, to detect insect activity, to avoid grain reloading for monitoring grain condition. The FOPRO heat control system consists of thermo-cables, thermo-sensors located inside of the thermocables which read the temperature of the grain inside the silo and portable or stationary temperature monitoring system. There are special steel ropes inside of the heat control cables which are designed to prevent extension of the cables. This heat control system can be connected to the PC and the temperature of all grain stored inside of the silos can be controlled from PC. Temperature Monitoring System By using thermocouple, temperature can be monitored at any level of the silo. There are mobile and central display units. This system also can be connected to any automation system. Level Monitoring System: By using some sensors, the level of the grain in the silo can be monitored. This system can be connected to PLC automated system.

11 FOPRO Sweep Auger: Sweep auger handles the grain from side to center of the silo. There are two types of sweep auger. - Mobile and - immobile. The mobile sweep auger is gear reducer driven and equipped with an electric device against cable twist. Unloading Auger: The unloading auger is used to handle the grain from inside to outside of the silo. It s easy to take the unloading auger outside of the grain full silo. It is placed in the auger channel of the silo foundation. These augers are equipped with one center and two intermediate sumps for easy unloading by the help of the sweep auger. The FOPRO silo unloading screw augers are available in different diameters according to the carrying capacity of the auger. All FOPRO screw augers are U shaped and auger upper cover connection places are fastened with bolted system. Bottom sweep auger is used in silos with at bottom to unload the rests of the grain inside the silo; the auger collects the material inside of the silo rotating into 360 and directs the material towards discharge openings located on the unloading auger. These equipments are used for inclined and horizontal handling of grain according to the capacity needed. Sweep screw augers which are used to unload the grain inside constant wheel speed. Sweep auger system with constant auger rotation and regulated wheel speed. The grain unloading process can be operated in 2 different ways: 1 - The screw auger unloading system which capacity is up to 100 tons/hr. is recommended to be used in silos with concrete foundation 2 - The chain conveyor unloading system which capacity can be more than 100 tons/hr. is recommended to be used in silos with concrete foundation and tunnel unloading system.

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