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:
Flat Bottom 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
Hopper Bottom Silos:
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
Truck Loading Silos:
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.
Why Rostfrei Silos
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:
- CNC Drilling for Nut & Bolt Holes: The preparation of nut and bolt holes is done using advanced CNC machinery to ensure precision.
- CNC Bending Process: Components are bent using high-precision CNC machines for accuracy and consistency.
- Profiling and Curving of Wall Panels: Wall panels are profiled and curved using CNC corrugation machines, ensuring uniformity and strength.
- Hot-Dip Galvanizing: Fabricated parts undergo hot-dip galvanizing with a coating of over 500 GSM to enhance durability and corrosion resistance.
Quality Checks
Throughout the production process, multiple quality checks are conducted to ensure the highest standards:
Proper Packaging
Materials are carefully packed for transport, using pallets, crates, wooden boxes, and stands to ensure safe and secure delivery.
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
Roof & Wall Ring Assembly
- Dome Cap at center is first mounted after verifying foundation works completion & verification.
- First wall Rings are assembled along with Rafters of roof.
Wall Sheet Overlapping & Sealing
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) High Tensile Nut Bolts with rubber washer & GI washer from either side.
Each wall sheet is horizontally overlapped 70 mm and sealed via Silicon Sealant (from inside of Silos) and joined via HT Nut Bolts galvanized 550 GSM with Rubber washer & GI washer from either side.
Roof Rafter Installation
ROOF RAFTERS TO BE ASSEMBLED WITH TOPMOST RING OF SILO
ROOF RAFTERS WITH DOME CAP ASSEMBLED WITH TOPMOST RING (1ST RING OF SILO)
Roof Sheet & Vent Assembly
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 NUT-BOLT CONNECTIONS TO ENSURE PROPER VENTILATION AND STRUCTURAL INTEGRITY.
Goose Neck Vent & Roof Accessories Installation
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 FIXED/INSTALLED FOR LIFTING SILOS VERTICALLY UP.
Water Spray Testing & Ring Installation
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.
Water Spray Testing & Structure Lifting
Pressurized water spray testing shows the integrity of the workmanship and once it is done, Structure is lifted up for further addition.
Expert Project Execution
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 (FCI), 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
Grain storage silos play a crucial role in ensuring food security and maintaining the quality of harvested grains. By storing grains in a controlled environment, silos protect crops from weather, pests, and other contaminants, minimizing losses and enhancing food availability throughout the year.
1. Efficient Space Utilization
Silos are designed to store large quantities of grain in a relatively small footprint, making them ideal for maximizing storage efficiency.
2. Controlled Environment
With proper ventilation and temperature control, silos help preserve grain quality by reducing the risk of spoilage.
3. Cost-Effective
Wall panels are profiled and curved using CNC corrugation machines, ensuring uniformity and strength.
4. Automation
Fabricated parts undergo hot-dip galvanizing with a coating of over 500 GSM to enhance durability and corrosion resistance.
5. Sustainability
Throughout the production process, multiple quality checks are conducted to ensure the highest standards.