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Construction Process and Methods for Soybean Meal Steel Silo
During the rolling process of the silo wall, inspect various parts of the soybean meal steel silo. Follow the inspection items and frequency specified in the construction quality standards.
Construction Process and Methods for Soybean Meal Steel Silo
Foundation Inspection
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Inspection of Embedded Components: Verify the distribution, dimensions, positions, and quantities of the embedded components in the foundation according to the design drawings and process requirements.
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Check Stability and Levelness: Confirm the stability, load-bearing capacity, and levelness of the temporary construction platform.
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Acceptance of Foundation: If the foundation meets the requirements, accept the foundation platform for the construction of the soybean meal steel silo.(What is a soybean meal silo?)
Planning the Installation Line for Silo Base
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Define Installation Line: After accepting the foundation, plan the installation line for the silo base according to the diameter and position specified in the design drawings.
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Site Preparation: Clean the construction site and prepare for the construction work.
Arrival and Inspection of Materials, Equipment, and Components
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Transportation to Site: Transport construction equipment, tooling accessories, prefabricated components, and main and auxiliary materials to the site according to the notice.
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Documentation and Approval: Compile and organize detailed records and certification documents for the construction equipment, tooling, prefabricated components, and materials. Submit these documents to the engineering supervision department for inspection and approval.
Lifting Materials and Equipment onto the Platform
After receiving approval from the project supervision department, lift the construction equipment, tooling accessories, prefabricated components, and materials onto the foundation platform.
Layout and Stacking of Materials and Components
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Equipment Placement: Place the bending machine at one end of the temporary construction platform, facing the exit direction. Position the forming machine at the specified distance behind the bending machine, and place the uncoiling machine at the specified distance behind the forming machine.
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Material Layout: Arrange the steel coil materials in order of thickness, with thinner coils closer to the uncoiling machine.
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Reinforcement Bar Stacking: Stack reinforcement bars with those used first on top and those used later at the bottom. Place smaller-sized materials on top and larger-sized materials at the bottom.
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Silo Roof Material Stacking: Stack the materials and components for the silo roof in the same manner, with those used first on top and those used later at the bottom.
Layout, Support, and Adjustment of Construction Equipment and Column Framework
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Marking and Leveling: Mark the installation line for the silo, determine the position of the column framework, and check the levelness of the foundation platform.
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Equipment Layout and Adjustment: Arrange and support the equipment according to the construction quality standards, and adjust the radial position of the silo.
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Support and Connection: Assemble the load-bearing brackets and connect the framework. Adjust the angle of the bracket arms and the helical angle of the guide wheels.
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Material Placement: Place the materials at the designated locations.
Equipment Commissioning and Construction Preparation
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Power Connection and Testing: Connect the power supply, commission the equipment, and conduct a联动test run.
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Adjust Processing Gaps: Adjust the operating gaps of the forming machine and bending machine components.
Construction of Soybean Meal Steel Silo
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Lifting and Loading: Lift the steel coil specified in the design drawings to the uncoiling machine using a triangular bracket and electric hoist.
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Cutting and Feeding: Cut the head of the steel coil into a conical shape to allow it to enter the forming machine. Begin feeding and rolling.
Wall Closure
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Forming and Bending: After the steel coil is processed into a combined upper and lower ring by the forming machine, check the geometric dimensions of the formed slot according to the construction quality standards. If qualified, the processed steel coil enters the bending machine. The formed steel coil is then rolled into a flat, convex rib with a 45-degree angle to the silo wall, enhancing the hoop load capacity of the silo.
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Closure of Wall Plates: Before closing the silo wall, measure the length of the formed steel coil. When it matches the designed circumference of the silo wall, the upper and lower ring steel coils are combined by fitting the upper slot of the lower coil into the inner side of the lower slot of the upper coil. The combined slots enter the bending machine to complete the closure of the wall plates.
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Quality Check and Adjustment: After the wall plates are closed, use a vernier caliper to check the thickness of the spiral rib. Adjust the bending machine to meet the construction quality standards (i.e., 5d∠D≤6d, where d is the thickness of the steel coil and D is the thickness of the rib). Then, begin the rolling of the silo wall.
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Level Cutting of Wall Top: Use a horizontal cutting machine to trim the top edge of the silo wall.
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Installation of Silo Roof: After rolling two to three rings of steel coils, stop the machine and install the silo roof.
Installation of Lower Expansion Ring
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Inspection and Measurement: Clean and measure the top edge of the silo wall. Report to the supervising engineer for temporary inspection of the steel coil thickness and the diameter of the silo wall (calculated from the circumference using a steel tape measure).
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Welding of Expansion Ring: After confirmation, use J422Φ3.2mm welding rods with a current of 200A to 260A to weld the lower expansion ring to the specified position on the top of the silo wall.
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Adjust Ellipticity: Adjust the ellipticity of the silo wall top to meet the construction quality standards (measured by the difference between the maximum and minimum diameters of the silo wall).
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Marking for Purlin Installation: Define the installation line for the lower end of the purlins.
Installation of Upper Expansion Ring and Purlins
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Marking and Positioning: Define the installation line for the upper end of the purlins on the upper expansion ring. Use a support frame to position the upper expansion ring and adjust its direction so that the purlin installation line aligns with the radius of the silo wall (using a horizontal line and plumb bob for alignment).
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Arch Height Determination: Measure the arch height of the silo roof using a horizontal line and a steel ruler to measure the vertical distance from the lower edge of the upper expansion ring to the line.
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Welding and Inspection: Use J422Φ4.0mm welding rods with a current of 260A to 340A to weld the purlins to the upper and lower expansion rings. Weld the two circumferential tie rods between the purlins to form the roof frame of the silo. Report to the supervising engineer for temporary inspection of the weld quality. After approval, install the roof cover plate (outer skin).
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Safety Measures: Workers operating on the roof frame must wear safety belts. Temporary rings for hanging safety belts should be added to the upper expansion ring to ensure the safety of high-altitude operations.
Installation of Roof Cover Plate
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Welding Methods:
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Lap Welding: Weld one edge of the cover plate to the purlin intermittently. The other edge of the next cover plate is lapped over the previous one, and the lap seam is continuously welded. The weld seam must be free of slag, porosity, cracks, or fissures, and the weld thickness must be greater than the thickness of the welded plate.
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Butt Welding: Place one edge of two cover plates on a purlin with a 4mm gap and weld them to the purlin simultaneously. The weld seam must be free of slag, porosity, cracks, or fissures, and the weld thickness must be greater than the thickness of the welded plate.
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Welding and Inspection: Use J422Φ3.2mm welding rods with a current of 260A to 320A. After completing the weld seam, clean the weld seam and spatter, and report to the supervising engineer for temporary inspection of the cover plate weld quality.
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Safety Measures: Workers installing the roof cover plate must wear anti-slip shoes due to the steep slope of the roof to prevent slipping and accidental injuries. If necessary, they should wear safety belts and attach them to reliable hooks.
Painting of Roof Inner and Outer Surfaces
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Cleaning and Painting: After the roof cover plate welding is completed and inspected, clean the weld slag and spatter, and repaint the rust-proof primer on the weld seam and its surroundings. Apply the specified rust-proof and finish coats according to the regulations.
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Painting Process: Remove the rust-proof primer burned by welding from the components, and repaint the primer and subsequent coats as specified.
Installation of Roof Guardrail Posts
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Welding Guardrail Posts: After the roof cover plate is welded, fully weld the roof posts to the lower expansion ring at the lower end of the purlins. The flat side of the angle steel posts should face inward, and the flange side should face outward.
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Welding Handrails: Weld the rolled handrail pipes to the posts to form a unified structure.
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Installation of Guardrail Flats: Measure and mark the installation line for the guardrail flats, and point-weld them to the posts. The joints of the guardrail flats should be fully welded on both sides.
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Quality Check and Painting: After the guardrail welding is qualified, clean the weld seams and apply the specified coats of paint. The steel structure of the silo roof is now complete.
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Safety Measures: Workers operating at unsafe positions or heights should wear safety belts and attach them to the completed guardrail posts or handrail pipes.
Rolling of Silo Wall and Installation of Reinforcement Bars
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Installation Line and Rolling: After the roof installation is complete, mark the installation line for reinforcement bars according to the design drawings and the required number of installations. Roll the silo wall to a certain height, and install the reinforcement bars (on the inner side of the silo wall) according to the specified type, size, and dimensions in the design drawings.
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Verticality and Welding:
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Use a level to ensure the verticality of the reinforcement bars, which should be in contact with the lower edge of the lower expansion ring. Temporarily weld the bars to the silo wall first, and then fully weld the exposed seams between the reinforcement bars and the lower expansion ring.
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The weld length at the joints of the reinforcement bars with the silo wall should be no less than 50mm, and the weld thickness should not be less than the thickness of the welded plate.
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For connections between two segments of reinforcement bars, use connecting plates as specified in the design drawings. The exposed seams between the connecting plates and the reinforcement bars should be fully welded with equal strength, and the weld thickness should not be less than the thickness of the welded components.
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For butt joints of reinforcement bars, use equal strength welding. To meet the requirements, the bottom seam of the groove should have an increased gap or a bevel to ensure the weld quality meets the standard.
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Welding Parameters:
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For butt joints and connections between reinforcement bars, use J422Φ4.0mm welding rods with a current of 260A to 340A.
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For installation of reinforcement bars, use J422Φ3.2mm welding rods with a current of 200A to 280A.
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Painting of Welded Joints on Silo Wall Surface
Remove the oxide scale from the welded joints on the silo wall surface. Then, apply the specified coats of paint as per the design drawings, ensuring each coat dries before applying the next one.
Splicing of Silo Wall Rolling Plates
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Cutting and Preparation: During the rolling process of the silo wall, when one roll of steel plate is finished and the next roll is to be spliced, use a square or T-square to draw the cutting line and remove the irregular end of the steel plate with a hand-held grinding wheel.
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Control of Plate End: After the previous roll of steel plate is rolled, control the repaired plate end to be about 500mm in front of the entrance of the forming machine.
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Loading and Preparation of Next Roll: Lift the next roll of steel plate onto the uncoiling machine using a triangular bracket and electric hoist, and pull out the end of the plate.
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Splicing and Welding: Use the same method to cut and prepare the end of the next roll of steel plate. Carefully align and tack weld the two prepared plate ends together. Use J422Φ2.5mm welding rods with a current of 200A to 260A, welding from top to bottom. The weld seam should be smooth and regular, free of slag, porosity, or cracks. Additionally, the weld thickness should not exceed the thickness of the welded plate.
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Painting of Splice Seam: Apply the specified coats of paint to the outer surface of the splice seam.
Splicing of Different Specifications of Rolling Plates and Reinforcement Bars
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Inspection and Reporting: During the rolling process of the silo wall, when it is necessary to splice different specifications of steel plates according to the design drawings, report to the supervising engineer for temporary inspection and review. Fill out the hidden project inspection form for the silo, and only proceed with the subsequent construction after confirmation.
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Splicing Method: The splicing method for different specifications of steel plates is the same as in Section 2.1.17.
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Inspection and Reporting for Reinforcement Bars: When splicing different specifications of reinforcement bars, report to the supervising engineer for temporary inspection and review. Fill out the hidden project inspection form for the silo, and only proceed with the subsequent construction after confirmation.
Continue Rolling the Silo Wall to the Specified Height and Cut the Lower Edge of the Silo
Grounding of Soybean Meal Silo
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Verticality and Ellipticity Check: After the silo is grounded, use a theodolite to check the verticality and ellipticity of the silo wall. If the deviation exceeds the standards specified in the construction quality standards, adjust the verticality and ellipticity of the silo wall. This can be done by adjusting the height and angle of the column support arms. After meeting the standards, report to the supervising engineer for inspection and confirmation.
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Welding of Grounding Reinforcement Bars: After the verticality and ellipticity of the silo wall meet the standards, weld the reinforcement bars of the silo wall to the embedded components in the foundation. If the deviation between the embedded components and the grounding reinforcement bars exceeds 75mm from the design requirements, the relevant technical department should provide remedial measures or solutions, and strictly follow the rectification measures or solutions for construction.
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Remedial Measures: If the deviation between the embedded components and the grounding reinforcement bars is between 30mm and 75mm, use additional stiffeners to reinforce the connection between the reinforcement bars and the embedded components.
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Welding Requirements: The connection between the grounding reinforcement bars and the embedded components in the foundation must be fully welded as per the design drawings, and the weld thickness must meet the specified requirements.
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Completion of Construction: After all the grounding reinforcement bars are welded to the embedded components, the construction of the soybean meal steel silo is considered complete.
Installation of Process Holes and Openings in the Silo
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Door Installation: After the silo is grounded, mark the edge of the opening according to the specified position, height, size, and installation requirements in the design drawings. Use oxyacetylene cutting to open the door installation hole, mark the bolt hole positions, drill holes, install rubber pads, seal with silicone sealant, align the inner and outer door flanges, insert bolts, and tighten. Apply the specified coats of paint to complete the process.
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Installation of Roof Hatches, Manholes, and Level Gauges: Strictly follow the specified orientation, size, and distance in the design drawings to mark the edge of the opening. Use oxyacetylene cutting to open the installation hole and fully weld the process openings to the roof cover plate. The weld seam must be free of slag, porosity, cracks, or fissures. Additionally, the weld thickness must not be less than the thickness of the thinner welded component.
Removal of Equipment and Demolition of Scaffolding
Clear the site, remove equipment and scaffolding, and move to the next construction location.
Quality Inspection During Silo Wall Rolling
During the rolling process of the silo wall, inspect various parts of the soybean meal steel silo. Follow the inspection items and frequency specified in the construction quality standards. Record the inspection data in detail in the construction quality inspection report forms for the silo project. Submit them to the project supervision department for review in a timely manner as required.
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