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Summary of Contents for PIC-PLAST SOLARIG Alpine 135
- Page 1 SOLARIG™ TUNNEL KIT Installation Manual Model Alpine 135 Version 1.0...
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Page 2: Installation Manual For Model Alpine
PIC-PLAST Ltd. While every precaution has been taken in the preparation of this document, PIC-PLAST Ltd. assumes no responsibility for errors or omissions; neither is any liability assumed for damages resulting from the use of the information contained herein. -
Page 3: Table Of Contents
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Contents SOLARIG Tunnel Kit Model Alpine 135 ...................... 4 Related Publications ............................4 Equipment ................................5 Tools and Equipment............................. 5 Parts Inventory .............................. 5 Phase 1: Raising the Arcs ..........................10 Preparing the Site ............................10 Digging Holes ............................... -
Page 4: Solarig Tm Tunnel Kit Model Alpine 135
Related Publications ➔ For more information about PIC-PLAST, refer to the following documentation: • Alpine-135BoxContents – Lists the contents of each box in the kit. The list is supplied with the boxes •... -
Page 5: Equipment
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Equipment This section lists the required tools and equipment, and shows pictures of the parts. The contents of the boxes are detailed in a separate document. Because the tunnel kit is modular, you can add more internal arcs, thereby making the tunnel longer. - Page 6 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Part ID Description Qty. Graphic DIA4585318 Diagonal pipe for PSS ø53mm x 4580mm x 1.8mm PVR2304318 Pole vertical reinforcement ø42.7mm x 2300mm x 1.8mm PHR563214 Pole horizontal reinforcement ø32mm x 560mm x 1.4mm PHR403214 Pole horizontal reinforcement ø32mm x 400mm x 1.4mm...
- Page 7 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Part ID Description Qty. Graphic BW1035 Bent washer 35mmx10mm FW1035 Flat washer 35mm x 10mm TKRP3852518 Rolling pipe (dia. 25x1.8mmx3.85m) net length 3.79m (only the male end is shown) CHZ25N Curtain handle for roof ventilation (dia.
- Page 8 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Part ID Description Qty. Graphic B08R90 Eye bolt 8mm x 90mm Nut 8mm Washer 8mm SDS1/4 Self-drill screw SDS 1/4 X 3/4 LP3750 Locking profile 3750mm LS200 Locking spring 2000mm HSW25 Galv. wire 2.5mm CSH04 Carabine (locking ring) 4mm MCH30...
- Page 9 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Part ID Description Qty. Graphic CABLES Length - 4020mm (end to end Cable-1 of bolts) Length - 4380mm (end to end Cable-2 of bolts) Length - 4330mm (end to end Cable-3 of bolts) Length - 7390mm (end to end Cable-4 of bolts)
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Page 10: Phase 1: Raising The Arcs
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Phase 1: Raising the Arcs This phase consists of site preparation, digging holes, constructing the arcs on the ground, and raising them into position. Preparing the Site The dimensions of the tunnel are 15m X 9.04m. The Alpine-135 model kit requires a cleared space of roughly 19m by 12m. -
Page 11: Assembling The Arcs
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 1: Digging holes Assembling the Arcs Assemble each of the five arcs separately, on the ground, roughly in place: • The first (arc 1) and last (arc 5) arcs are identical. •... - Page 12 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 2: First and last arcs parts Figure 3: First and last arc connections - 12 -...
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Page 13: Middle Arcs
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 4: First and last arcs: reinforcements Middle Arcs For all arcs except the first and the last, you will need the parts shown in the figures. Assemble all the middle arcs as shown. - 13 -... - Page 14 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 5: Middle arc parts Figure 6: Middle arc connections - 14 -...
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Page 15: Stretching A String Frame
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Stretching a String Frame NOTES: • Keep the marking stakes in place until the end of the pouring concrete stage, to keep the base marking. • Pull the builder twine taut (tightly), ensuring that it does not touch any obstacle. Steps: 1. - Page 16 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 9: Marking distances between arcs Figure 10: Marking points on the string - 16 -...
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Page 17: Raising The Arcs
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Raising the Arcs 1. Raise the first and second arcs as shown in the following figures: • See the depth of the arcs in the holes (Figure 11). Figure 11: Placement of the arc in the hole - 17 -... - Page 18 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 • Stabilize with two ropes and anchors (Figure 12). Figure 12: Raising the first arc - 18 -...
- Page 19 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 13: Position of anchors for first arc • Add C-profiles at 1/3 height and HOR3784314 pipes at the peak. • Add pipes between arcs 1 to 2 and arcs 5 to 4, at 2/3 height on both sides. Figure 14: Connecting first arc to second arc - 19 -...
- Page 20 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 15: Stabilizing first and second arcs 2. Continue adding arcs, one at a time, stabilizing as shown above. Release ropes from the previous internal arcs before adding a new arc. (Leave the ropes attached to the first arc in place.) 3.
- Page 21 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 16: Securing the arcs. Note the wood planks 4. Between all arcs, add: o C-profiles HORU3706040 at 1/3 height on both sides of the structure. o Pipe HOR3784314 at peak. 5. Only between arcs 1 to 2 (and arcs 4 to 5): add pipe HOR3784314 at 2/3 height on both sides of the structure.
- Page 22 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 17: Angled PSS pipes (DIA4565318R) from arc 1 to arc 2 7. Add angled pipes from the horizontal pipe on the first arc to 1/3 height on the second arc. Use metal clip HTOM40R and L-bracket OVKL4040-R1. Repeat for the last arc.
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Page 23: Phase 2: Pouring Concrete
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Phase 2: Pouring Concrete In this phase you mark the area again and pour concrete into the holes. Measuring and Marking 1. Re-measure the distances between the marking stakes and correct if necessary. 2. -
Page 24: Phase 3: Stabilizing
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Phase 3: Stabilizing In this phase you add a trench around the tunnel and reinforce the arcs. Digging Trenches Let the concrete dry for approximately 24 hours. While you are waiting, you can dig trenches around the poles (Figure 18). -
Page 25: Reinforcing, Post-Concrete
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 19: Trench measurements Reinforcing, Post-Concrete After concrete is dry (or nearly dry), perform the following steps, as shown in the figures: 1. Reinforce the arcs with cable #1 (Figure 20). This is only between arcs 1 and 2, and between the last two arcs (4 and 5). - Page 26 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 20: The cable (#1) connecting between end arcs Figure 21 shows how to connect cables #2 and #3. They are only used only for the ends (between arcs 1 and 2, and between the last two arcs 4 and 5). Figure 21: Cables #2 and #3 - 26 -...
- Page 27 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 2. Add L brackets MTTA10040 to middle arcs (all arcs except for the first and last) at the peak. 3. Add cables (#4) between middle arcs at 2/3 height on both sides of the structure (Figure 22).
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Page 28: Phase 4: Covering With Nets
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Phase 4: Covering with Nets Before adding nets, remove all supporting ropes. You will need the ropes when you add the roof net. Nets for Front and Back The instructions are identical for the front and back nets. 1. - Page 29 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Folding down the length of the front net. Attaching the middle eyelet. Attaching eyelets with rubber bands. Stretching the net. Working on both sides simultaneously. Continuing down to the ground. - 29 -...
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Page 30: Nets For Sides
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Stretching at ground level. Burying the excess under dirt. Adding more dirt. 3. Cover net lying on the ground with dirt, except for the area around where the FMD will be. 4. If you have the FMD kit, follow those instructions now. Nets for Sides Equipment: •... - Page 31 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Instructions: 1. Lay out one side net along the length of the structure: o Centre the net so there is an equal quantity of excess fabric at each end of the structure. There should be roughly 50cm spare at each end. o Ensure the 10cm SOLARIG strip is at the top.
- Page 32 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Ensuring excess on both ends. Attaching with self-drill screws. Attaching at the ends. Stretching while maintaining height. Close-up. Working along the length. - 32 -...
- Page 33 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Stretching tightly. Burying the excess with half the dirt. Securing completely with dirt. Stretching the net. 7. Continue the excess net from the sides around to the front eyelets so that the net overlaps the corner of the tunnel, and attach them on the front (and back).
- Page 34 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Figure 26: Side net connection to front net Pulling excess to the front. Utilizing the person on the inside. - 34 -...
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Page 35: Roof Cover
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Cutting off the excess. Burying the corner excess. Flattening the edge of the locking profile. Roof Cover Equipment: • A minimum of six people. • Ladder • Pulling ropes • Warnings Tightly secure the SOLARIG roof cover for optimal strength and so it will last longer. - Page 36 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Instructions: 1. Spread out the cover on one side of the tunnel. Fold the cover in accordion style and lay it along the tunnel structure. If the roof includes a curtain, take into consideration its orientation.
- Page 37 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Pulling the cover over the roof structure. Laying the cover alongside the structure. Spreading the roof cover. Holding the corners. Checking equal distribution of the cover. Threading string through sleeve. - 37 -...
- Page 38 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Tightening the rope. Tightening at other end. 6. Use the locking springs to stretch and anchor the sides to the locking profile. Anchor one side of the roof cover with screws while stretching and ensuring a uniform surplus length through the entire length.
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Page 39: Curtain For Side (Vsc)
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Curtain for Side (VSC) Instructions: 1. Thread the sleeve with a rolling pipe, inserting the female end first. 2. Add more pipes, securing them one to the other with bolts and washers. 3. - Page 40 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Adding clips to lock the pipes to the sleeve. Connecting the ropes between the eyelets above and below the curtain. Attach a handle to the last pipe. - 40 -...
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Page 41: Phase 5: Maintenance
SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 Phase 5: Maintenance You should perform preventive maintenance on the Alpine-135 structure once a month: • SOLARIG plastic covers and nets: Verify that the plastic sheets are stretched out and not flapping. Check for holes and cuts in the nets and plastic sheets. Sew cuts or holes closed with a needle and thread. - Page 42 SOLARIG™ TUNNEL KIT Installation Manual for Model Alpine-135 - 42 -...