Everything must be in place - before you even think about putting anything inside the bin, the bin itself must be completely finished. Absolutely everything must be securely in place. First, the bin itself must be properly anchored to its foundation, with all bolts where they should be and properly tightened.

Guards and shields exist for a reason, and it’s not to annoy you. It’s to save your life. So put them where they should be. Stick safety decals in the right places too, making sure they’re legible. If people can’t read them, there’s absolutely no point.

You don’t know when you’re going to need to access any part of the structure, so all ladders, handrails, platforms, stair and steps need to be securely in place right from the start. And again: With all bolts where they should be and properly tightened.

Function and access are vitalIt is also vital to be sure everything is working properly and

prepared for any eventuality that might occur when filling the bin for the first time. The unloading equipment and unload gates must function correctly and they must be closed.

The working areas surrounding the bin need to be clean and clear of clutter.

Electrical performance must be checked and lockouts installed (if needed) on equipment. Any temperature cables must be fastened to the floor according to the manufacturer’s recommendations to prevent displacement during filling.

And it may sound obvious, but make certain that everyone is out of the bin before filling it.

Plan for the worstWhatever you do, know exactly who or where to call for

immediate help in case of an emergency or injury. And make sure they’ll be available and able to reach you quickly.

Be patient On larger bins, filling in several stages may be required by the

manufacturer to prevent uneven settlement. Many manufacturers require, or at least suggest, stage loading to prevent excessive uneven differential settlement during the initial fill. Behlen Mfg. Co. recommends that for the first stage the grain bin be filled to 1/3 of eave height. It will then take 10 days for the desired

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Key factors in bin usageby Kirk Nelson, Director of Marketing and Sales, Behlen Mfg. Co.

In the second of a four part series, Milling and Grain take a closer look at the essential elements of bin maintenance. The way you carry out the initial filling of a bin can have long-term effects over the rest of its life. And any accidents during the process could severely shorten yours. Preparation and initial execution are thus critical.

54 | Milling and Grain

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consolidation to occur. For the second stage it is recommended that the grain bin be filled to 2/3 of eave height. It would then take another 10 days for consolidation. Only then can the final 1/3 be filled. So be patient and take it slowly.

Subsequent fillingWhen it comes to subsequent filling of the bin (ie, filling after

the first operational use), the checklist is almost as long. The initial installation preparations have now been replaced by a still fairly extensive list of tasks required for maintenance.

The bin must be cleaned between fillings. All kinds of problems can result if it is not. The unloading equipment needs to be checked to ensure it is functioning correctly, and all intermediate gates must be closed. If there is a power sweep auger, it should be placed over the intermediate sumps. And don’t forget those temperature cables (if you’re using them): It is essential to attach them to the floor as specified by the manufacturer’s recommendations.

As before, make certain that everyone is out of the bin before filling it. Common sense? Sure. But it’s amazing how often even highly intelligent people will forget to check some of the most basic things. Which is, of course, precisely why we need checklists.

Shut the sidewall door(s) properly, making sure the inner door panels are closed, sealed and latched. Then fill the bin only through the centre, and don’t allow the grain to be pushed horizontally to one side of the bin.

Overfilled bins can, and do, fail. So make sure you know the maximum capacity of yours, and don’t try sneaking in “just a bit more”. Use spout/chute lengths to prevent overfilling.

Continue to fill the bin to the desired level, and not beyond the roof eave-level.

Unloading the bin To maintain uniform loads on the sidewalls, grain must be

unloaded from the centre of the bin. The centre sump must be opened first. Intermediate sump(s) must not be used until all grain is completely emptied through the centre sump. Failure to heed this practice could damage the structure of the bin.

Never, ever simultaneously fill and discharge the bin. Simultaneous filling and unloading results in grain behaving

more like a fluid than granular material. Increased fluidic behaviour of grain can cause increased sidewall loads. Service life of the bin can be drastically reduced and risk of structural failure, economic loss and personnel injury will increase by simultaneously loading and unloading.

Do not empty the bin through a sidewall door or cut a hole in the bin sidewall. This will cause uneven load distribution and excessive down pressure that may, again, result in bin failure.

It is vital to ensure that there are adequate vents installed on the bin to prevent a vacuum from forming in the upper portion of the bin during unloading. The pressures on the roof caused by such a vacuum could damage or cause structural failure to the grain bin roof.

Never vacuum out of the sidewall door unless all grain has been emptied, by gravity, through the centre sump first, followed by intermediate sump(s).

Sweeping the binWhen inside the grain bin, performing cleaning or maintenance,

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perform lock out and tag out procedures to disengage power to all unloading equipment power and to prevent reenergising. Never enter a bin when unloading equipment is operating, as you may become entangled in the sweep or the unloading auger! Failure to heed this warning may result in serious personal injury or death!

Checklist for sweeping the bin: • Be certain that no bridged grain or vertical crusting is evident. • Start to sweep the bin after all grain has flowed by gravity

through centre and intermediate sumps. • If you have a multiple-pass sweep auger, lock out the inner

sweep system before adding the outer sweep section.• Have another person present. • If the sweep auger fails to operate, call the sweep auger

manufacturer. • Return the sweep to original position over intermediate sump

gates.

VentilationGrain bin roofs are not designed to withstand excessive air

pressure differentials. General ventilation recommendations are 1 ft2 (0.093 m2) of vent area for every 1000 cfm (28.3 m3/min). Consult the bin manufacturer for the maximum recommended

pressure differential in the roof area. Be alert to the possibility of frost build-up on air passage screens, to a point of complete blockage. This may occur when high relative humidity, high grain temperatures, or high grain moisture levels are combined with freezing or near-freezing temperatures. Running fan(s) during these conditions can create frost build-up and airflow blockage causing the roof to dome. Precautionary measures must be taken to prevent this condition.

Do not pile grain against the roof. Grain piled too high will block the roof vents. Blockage of the roof vents will restrict the effective vent area and can virtually eliminate it. The area above the surface of the grain must allow for free movement of air to the vents. Be aware of the possibility that the screens of the roof vent may collect moisture and freeze shut. This can happen when high relative humidity, high grain temperatures, or high grain moisture levels are combined with freezing or near-freezing temperatures. Do not run the fan(s) during these conditions. It could create frost build-up and airflow blockage, causing the roof to dome.

If negative air roof fans are used in the roof vents, they must

operate simultaneously with the positive air fans at the base of the bin. They need to be wired so that negative air fans start a few seconds after the positive air fan. This is done so the air has enough time to be pushed through the grain to replace the air that leaves through the roof. Failure to do this could result in roof failure.

Bins with side draw systemsSide discharge is only permitted in bins specifically

manufactured for a side-draw flume system. This system must be installed to the manufacturer’s specifications. No corrugated steel bin should be unloaded through the sidewall without the installation of a side-draw system and the permission of the manufacturer. A side-draw should never be added to existing bins without first consulting the manufacturer.

Side-draw systems have interior baffles to channel grain from the top storage to the discharge chute. This is because grain flows off the top of the grain surface when withdrawn from below.

The use of a flume system should be reviewed with a geotechnical or foundation engineer. Geotechnical investigations or past experience may indicate significant foundation level soil variations or a site propensity toward differential settlement, under which conditions side-draw usage may be prohibited or severely restricted. Installation of a flume system may also require installation of additional wind rings and larger-diametre anchor bolts. Installation of multiple systems requires the approval of the bin manufacturer.

Furthermore, a side-draw system should not be the only discharge system available. Such systems are not intended to be used as continuous fill/empty systems. A standard centre discharge and conveyor must be installed.

Refilling after side-draw system use Grain cannot be completely emptied using a side-draw. Before

the bin can be refilled after being even partially unloaded with a side-draw system, the grain needs to be leveled or completely emptied through the centre sump. It is important that the sidewall pressure is equal before refilling. Behlen Mfg. Co. recommends unloading the grain through the centre sump until the grain reaches equal wall heights so that an inverted cone is formed in the remaining grain. Formation of such an inverted cone will help evenly distribute the lateral forces on the bin sidewalls. Once this inverted cone is achieved and the sidewall pressures are equal, it is safe to refill the bin through the centre peak ring.

It is important to note that the design of baffles can be used only with a side-draw system. Intermediate sumps located near the side-draw flumes cannot be used as the primary outlet. Unloading must be done correctly through the side-draw, centre sump, and then the intermediate sumps. Never use the intermediate sumps until all grain has flowed by gravity through the centre sump. Unloading through the intermediate sump initially will cause uneven load distribution that may cause bin failure.

Before a grain bin can be refilled, the bin should be completely emptied. Total clean-out of the bin prevents the build-up of compacted grain, which cannot be emptied by gravity flow. Also, be certain no grain is matted to the sidewall. If matting occurs, remove the mouldy grain with a wire brush and repaint.

Behlen Mfg. Co. is a leading international manufacturer of grain storage systems. These structures are used worldwide in a multitude of locations storing a wide variety of grain. Behlen bins range in size from a few thousand bushels to over 1, 500,00 bushels. The Behlen grain storage buildings can be custom designed for many applications.

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“Everything must be in place - before you even think about putting anything inside the bin, the bin itself must be completely finished”

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129-013 Milling&Grain 8.27x11.7 4C.indd 1 2015-04-15 4:52 PM

Ag Growth International Inc. (“AGI”) (TSX: AFN) is pleased to announce that the previously disclosed arrangement to acquire the Westeel division of

Vicwest Inc. (TSX: VIC) was completed on May 20, 2015. Headquartered in Winnipeg, Manitoba, Westeel is Canada’s leading provider of grain storage solutions offering a wide range of on-farm and commercial products for the agricultural industry.

“The strategic acquisition of Canada’s leading brand in grain storage further establishes AGI as a global leader in grain handling and storage solutions,” said Gary Anderson, AGI’s Chief Executive Officer.

“AGI and Westeel share a deep commitment to product quality and customer service and combined we create a Canadian-based global agricultural leader with a long history of serving the needs of our customers. Westeel’s complementary product offering expands our growth platform within North America and around the world and we look forward with enthusiasm to bringing this outstanding company into the AGI family.”

“AGI places the highest value on the contributions of its employees and we look forward to meeting and welcoming all of the people at Westeel,” said Tim Close, President of AGI. “We are very excited to get to work on growing Westeel along with AGI and realising upon the enormous potential of the combination of these great companies.”

Financial highlightsThe aggregate purchase price for Westeel was

US $221.5 million. The purchase price includes net cash on closing of approximately US $13 million and a redundant manufacturing plant with an estimated market value of US $4 million.

The acquisition was financed through the issuance of 1,112,050 subscription receipts at US $46.55 per receipt for gross proceeds of

US $51.75 million, the issuance of US $51.75 million of extendible convertible unsecured subordinated debentures, and long-term debt. With the completion of the Westeel acquisition, the subscription receipts have been exchanged for 1,112,050 common shares and the maturity date of the debentures has been extended to December 31, 2019.

Pro forma 2014 revenue of the combined companies is over $600 million. The combination of Westeel with AGI results in a more geographically balanced revenue profile with a pro forma 2014 geographic breakdown as follows:• Canada 44 percent (AGI standalone 26 percent).• US 39 percent (AGI standalone 55 percent).• International 17 percent (AGI standalone 19 percent).

Westeel generated adjusted EBITDA of approximately US $20 million in 2014. The estimated adjusted EBITDA reflects earnings of the Westeel business (before any costs associated with Vicwest’s corporate support functions that were not transferred to AGI as part of the Westeel acquisition) less incremental corporate support costs AGI estimates will be required post-closing. For the year ended December 31, 2014, AGI generated adjusted EBITDA of US $78 million, resulting in pro forma adjusted EBITDA for the period of US $98 million.

Management believes the acquisition of Westeel provides significant SG&A, sales and manufacturing synergies with estimated near-term synergies of US $5 million per annum.

AGI announces completion of Westeel acquisition

58 | Milling and Grain

Storage News

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Westeel is pleased to announce its strategic alliance with the FWS Group of Companies whereby it will provide Westeel Centurion bins and Westeel Catwalk systems for four different CWB (formerly the Canadian Wheat Board) locations. FWS was contracted by CWB to construct four new grain terminals in the provinces of Manitoba and Saskatchewan in Canada.The first of the four projects for CWB completed by FWS is in Bloom, Manitoba where two Westeel Centurion grain bins measuring 24 metres (78 feet) in diameter and 28 metres (91 feet) in height have been constructed with a 48-metre long (157 feet) Westeel Catwalk. The two bins include Westeel’s patented commercial roof and a total capacity of 609,140 bushels. The Catwalk system boasts a dual walkway, bar grating floor, and a conveyor path measuring 0.70 metres (27 1⁄2 inches) in width.“We have a long-standing relationship with Westeel and appreciate the precise manufacturing and quality engineering that goes into their products,” said Rori Bouchard, Senior Project Manager with the FWS Group of Companies.“FWS and CWB are industry leaders in agriculture and it’s a great opportunity for Westeel to partner with them and showcase the high quality manufacturing and construction capabilities we have here in the Canadian prairies” said Denis Tétrault, Business Manager, North America with Westeel.The other three sites are in Colonsay, Saskatchewan; Pasqua, Saskatchewan; and St Adolphe, Manitoba.

Westeel Bins completed by FWS in the first of four CWB sitesStorage project

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FWS was contracted by CWB to construct four new grain terminals in the provinces of Manitoba and Saskatchewan in Canada.

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