Flat Bottom Silo

ROSTFREI STEELS PREFABRICATED

Flat Bottom Silos – Precision, Efficiency, and Versatility

Flat bottom silos are specifically engineered with a flat base, making them the perfect solution for permanent, high-volume, long term storage needs. The design incorporates advanced sweep augers, ensuring efficient material discharge and smooth operations even when handling large quantities of stored material. Rostfrei Grain Storage Silos are customised to perform in every Unique Challenging Condition, with primary focus to maintain grain quality.

State-of-the-Art Manufacturing Facility:

Rostfrei operates a cutting-edge manufacturing facility spanning over 435,600 square feet. Equipped with CNC-based machinery, our facility processes 5,000 tonnes of steel each month, ensuring that your project timelines are easily met with Rostfrei’s full support.

ROSTFREI

Offers three variants of Grain Storage Silos:

Our range of this type of Silos in diameter from 9.14 Mtr with capacity 500 MT to 31.97 Mtr with capacity 15000 MT

Our range of this type of Silos in diameter from 3.65 Mtr with capacity 50 MT to 10.96 Mtr with capacity 750 MT

Our range of this type of Silos in diameter from 3.65 Mtr to 4.57 Mtr with varying capacities as per the requirements of our Clients.

Why Rostfrei Silos

In the manufacturing of Rostfrei silos, we exclusively employ sheet metal with the cutting-edge Galvalume (GI) and Zincalume (ZA).

Our high yield strength stiffeners made in galvanised steel improve the weight of the silo which makes easier assembly and optimises the silo behaviour against the action of external agents

The Wave design of our wall sheets

with a gentle radius means more strength and better silo cleaning, improving materials unloading without any residue remaining so products are not contaminated.

Wall sheets

(Side walls) are processed on the dedicated CNC machine where profiling is being done so the sheets could withstand the load of the grain in the silos and pitch and depth of corrugations are considered to provide the better strength to the silos.

We install 8.8-10.9 grade quality bolts

minimum on all our silos with hot dip galvanisation coating with minimum average coating thickness of 40 to 50 micron, depending upon the galvanisation standard.

Our silos with a cylindrical body and 31-degree slopped conical roof

are designed to store the grains, seeds and palletized products.

Design Standards

Rostfrei’s flat bottom silos are engineered to meet the highest international quality benchmarks, ensuring reliability and performance in every aspect. Our silos are designed in accordance with the following European standards

Flat bottom silos from Rostfrei are not just storage solutions; they represent a strategic investment for businesses aiming for efficiency, durability, and scalability. With the ability to meet global standards and adapt to various industrial needs, Rostfrei silos offer the ultimate solution to long-term storage challenges.

FLAT BOTTOM SILO –

Our range of this type of Silos in diameter from 9.14 Mtr with capacity 500 MT to 31.97 Mtr with capacity 15000 MT

Process and Technology:

The process of creating Rostfrei’s flat bottom silos involves a series of precise steps, ensuring the highest quality and integrity of the final product:

Quality Checks: Throughout the production process, multiple quality checks are conducted to ensure the highest standards:

In-Process Quality Check: Continuous monitoring during production to ensure adherence to specifications.
Internal Quality Check of Materials: Rigorous inspection of incoming materials to ensure they meet our high-quality standards.
Pre-Dispatch Inspection: A final comprehensive inspection before shipment to verify the quality and readiness of the product.

INSTALLATION PROCESS:

100 mm raised platform step

Anchoring PCD

Silo dia starts 50 mm away from raised step this gap is filled via RCC & foundation sealant Coping

1. Dome Cap at center is first mounted after verifying foundation works completion & verification

2. First wall Rings are assembled along with Rafters of roof

Each of the wall sheets are overlapped by 150-200 mm at vertical joints, sealed via Butyle seal tape and joined via 8.8 grade HDG (500 GSM) Hight tensile Nut Bolts with rubber washer & Gl washer from either sides. Each of wall sheet is horizontally overlapped 70 mm and sealed via Silicon Sealant (From inside of Silos) and joined via HT Nut bolt galvanized 550 GSM with Rubber washer & Gl washer from either sides

ROOF RAFTERS TO BE ASSEMBLED WITH
TOPMOST RING OF SILO

ROOF RAFTERS WITH DOME CAP ASSEMBLED WITH
TOPMOST RING (1ST RING OF SILO)

ROOF SHEETS ARE OVERLAPPED WITH EACH OTHER BY 200 MM AND NUT-BOLTING (8.8 GRADE HIGH TENSILE HDG) ALONG WITH RUBBER WASHER AND GI WASHER GOOSE NECK VENTS OVER THE ROOF ARE ASSEMBLED OVER ROOF VIA

GOOSE NECK VENTS OVER THE ROOF ARE ASSEMBLED OVER ROOF VIA NUT-BOLTING WITH RUBBER & GI WASHERS, AND SEALING IS DONE USING ANABOND SEAL TAPE & PU SEALANT (SIKAFLEX TS PLUS MAKE). Ladders, Railings are fixed over roof. PU FOAM SEALANT IS APPLIED AT TOP SECTION AND NEAR DOME CAP. VERTICAL JACKS FIXEDINSTALLED FOR LIFTING SILOS VERTICALLY UP

Pressurized water spray testing is done over at every nut-bolt assembly of sheet overlapping, stiffners fix, roof sheets to test integrity of the structure. Once this test is passed, assembly is lifted up via Vertical jacks to add consecutive Rings of wall sheets

Pressurized water spray testing shows the integrity of the workmanship and once it is done, Structure is lifted up for further addition

Goal post (Support for overhead conveyor structure), Wind Rings (Hollow HDG 350GSM metallic pipe of 50 mm), Stiffeners (HDG 550 GSM) etc. are added along with additional wall sheets by simultaneous lifting by vertical jacks

After adding additional two rings to the structure along with other steel parts like wind rings, stiffeners etc., pressurized water spray test is done again for whole structure

Whole Structure is built like this, and there after ancillary equipment’s if any, are added

J Bolts grouted over Base plate are placed over Anchoring PCD pockets. The pockets are then filled with RCC cement with waterproofing solution, and this civil coping is done all around silos

With over 8,000 successful installations, our project team is equipped to professionally handle and commission any silo project, even in the most challenging environments, all while adhering to strict timelines. The silos are meticulously assembled using high-quality sealants and high-tensile bolts. Hydro-testing is performed after the completion of the roof segment and each subsequent ring to ensure optimal performance and safety. To ensure the longevity and efficiency of the silo, our on-site project team provides comprehensive training to the client’s team. This training is designed to promote cost-effective operation and maintenance, ensuring that the silo performs at its best throughout its lifespan.

Applications:

⦁ Grain Processing Industries: Flour Mill, Rice Mills, Pulses Mills, Oats Processing, Millet Processing
⦁ Solvent Industries- Edible Oil manufacturing facilities for Soya, sesame, mustard, Castor etc.
⦁ Animal Feed Industries – Poultry Feed & Cattle feed
⦁ Grain-Based Distillery
⦁ Starch Industry
⦁ Large Scale Storage Facility Management- Food Corporation of India, NCML, CWC etc.

Key Advantages of Rostfrei’s Flat-Bottom Silos

⦁ Designed to Perfection

Our in-house design team, equipped with the latest design software and tools, creates silos to international standards. This ensures exceptionally durable silos with a design life of over 40 years. Part detailing is done using advanced 3D software for utmost precision.

⦁ Precisely Manufactured

We utilize imported machinery from the US and Europe for turret punching and laser cutting. CNC-based operations guarantee the accuracy of every component, ensuring hassle-free installation and zero maintenance or repairs after installation.

⦁ Quality Preservation

Rostfrei Silos are designed not only to store grains effectively but also to maintain their quality throughout all seasons. We go the extra mile by offering customized steel grades, condition monitoring accessories like temperature monitoring and controlling, and a user-friendly operational interface. Crucial operations are automated to preserve grain quality, regardless of operator error.

⦁ Cost-Effective & Prompt Life-Long Service

With an extensive network of service engineers across the country, we ensure prompt after-sales service within 48 hours of a client’s request anywhere in India. This guarantees long-term, hassle-free operation.

⦁ High-Capacity Storage:

A single unit of Rostfrei’s Flat Bottom Silo can store 15,000 metric tons of grain, offering exceptional capacity for large-scale storage.

⦁ Enhanced Durability:

Rostfrei Steel Silos are constructed from high-grade steel with protective coatings and additional corrosion-resistant measures. Every silo undergoes rigorous design life tests, including Finite Element Analysis (FEA) and load analysis, to ensure it performs optimally at the installation site.

⦁ Customization:

Each Rostfrei Silo is fully customizable, from dimensions and material of construction (MOC) to accessories and design parameters, ensuring that all project’s unique requirements are met.

Key benefits of the Storage of the Grain in the RSPL Silos