APA READYRACK User manual

Updated: March 2023
INSTALLATION MANUAL
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PAGE 2 - INSTALLATION MANUAL
READY RACK
TABLE OF CONTENTS
PAGE
2 TABLE OF CONTENTS
3 PARTS LIST
4 SITE PREPARATION, UTILITIES, SURVEYING
5 REVIEW & INSTALLATION PREPARATION, UNEVEN GROUND, MEASURING
6 FOUNDATION INSTALLATION (HELICAL)
7 FOUNDATION INSTALLATION (SCREW), ALTERNATE FOUNDATION INSTALLATION,
POST INSTALLATION (SCREW ONLY)
8 POST INSTALLATION (SCREW ONLY - CONTINUED)
E/W STRUT PURLIN-TO-N/S CHORD
10 E/W STRUT PURLIN SPLICE, CROSS BRACE TUBE INSTALLATION
11 CABLE BRACE-TO-FRONT (SOUTH) POST
12 PANEL INSTALLATION
13 CABLE BRACE-TO-REAR (NORTH) POST
14 PRO TIPS
9 TUBE CLAMP STAGING, N/S CHORD-TO-POST, FINE HEIGHT ADJUSTMENT,
15 O&M REQUIREMENTS

STRUCTURAL MEMBERS
[1] FOUNDATION (HELICAL)
[2] FOUNDATION (SCREW)
[3] FRONT (SOUTH) POST
[4] REAR (NORTH) POST
[5] CROSS BRACE TUBE
[6] N/S CHORD
[7] E/W STRUT PURLIN
HARDWARE
[8] END CLAMP ASSEMBLY
[9] MID CLAMP ASSEMBLY
[10] 3/8-16 SERRATED FLANGE NUT
[11] 3/8-16 CHANNEL NUT
[12] 3/8-16X1.00” SERRATED FLANGE BOLT
[13] 3/8-16X2.75” SERRATED FLANGE BOLT
[14] M16-2.0X25 HEX SET BOLT (SCREW ONLY)
[15] TUBE CLAMP BOLT
[16] STRUT SPLICE
[17] CABLE BRACING
[18] TUBE CLAMP
PARTS LIST
PAGE 3 - INSTALLATION MANUAL
READY RACK
E/W STRUT PURLIN-TO-N/S CHORD
1
2
3
4
5
6
7
8 9
10 11 12 13 14 15
16 17 18

PAGE 4 - INSTALLATION MANUAL
READY RACK
SITE PREPARATION
Site preparation should be conducted prior to construc-
tion. This will typically involve grubbing, rock and debris
removal, and any other preparation that will facilitate
swift and unhindered installation.
UTILITIES
All utilities should be marked before any construction
begins.
SURVEYING
To ensure that the solar array is installed according to
customer plans, the site should be surveyed accord-
ing to the scope of work. This includes the North and
South foundation locations for the Ready Rack system.
For projects with signicant topography, survey points
should be checked with a tape measure.
CONSTRUCTION 101
All structures, regardless of how complex, are built one
step at a time. Each new step builds on the previous. In
order for the nal structure to be complete, it is best
to ensure that each step is done correctly. It is far easi-
er, faster, and cheaper to take your time to ensure each
step is done correctly before moving on. There is no rem-
edy for an error other than a correction. Time and eort
will be put forth eventually to redo steps, reconstruct,
and make adjustments, but far less eort is required to
correct mistakes as they appear. If errors are xed im-
mediately, each subsequent step will begin correct and
projects will run more eciently.
It is recommended to completely install a test row from
beginning-to-end of the row, and from beginning-to-end
of all steps (from layout, to panel installation, and ad-
justments). This will help you understand not only how
to install the product, but understand how tolerances
stack up, how mistakes in one step cause errors in oth-
er steps, and how to make the adjustments required to
keep everything in tolerance and looking good.
NOTE
Foundation locations should be surveyed by a profes-
sional surveyor, who can stake out row locations to the
highest precision.

REVIEW & INSTALLATION PREPARATION
After site preparation has been completed and the site
surveying is done, the foundations are ready to be in-
stalled. It is the responsibility of the site lead to review
and understand the site foundation layout, surround-
ings, installation procedures, and to manage the instal-
lation to completion. Each project has dierent require-
ments (embedment depths, spans, etc.) that need to be
met according to site testing and data gathered prior to
the start of the project. The site lead must verify that
the foundations on site match the order and project re-
quirements.
Dimensions in the East-West direction will change de-
pending on row length, row location, and location with-
in the row. Closely follow the construction plans and if
there are any questions or discrepancies, bring them up
to the site lead or project manager before installing any
foundations.
UNEVEN GROUND
For sites with ungraded or rolling topography, it is im-
portant to ensure that the foundations are set to the
correct depths. In cases where post locations can not be
marked on the ground (uneven terrain), it is advised to
check the survey points with a steel tape measure.
MEASURING
All measurements in the East-West direction must be
made with a steel tape measure, and made from the
start of the row, not foundation-to-foundation. For ex-
ample, if the plans were to call for the rst 4 spans to
be 100” each, the tape should be staked to the ground,
and the ground should be marked at 0”, 100”, 200”, 300”,
400”.
Measuring from foundation-to-foundation allows tol-
erances to stack up. In this case, a 2” tolerance would
have stacked up to be 8” o by only the fth foundation,
and will cause major installation issues further down the
road. If necessary, tape measures should be marked pri-
or to use or prints should be marked up to indicate addi-
tive measurements (ie. 0”, 8’4”, 16’8”, 25’0”, 33’4”).
For Ready Rack systems, the North and South points
must remain in line with each other (one should not
“chase” the other). Ensure the points are square every
few sets by measuring diagonals. If marks are found to
be out of square, make adjustments to correct.
EQUAL
Measuring diagonals
100"
200"
300"
400"
PAGE 5 - INSTALLATION MANUAL
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PRO TIP
1

PAGE 6 - INSTALLATION MANUAL
READY RACK
FOUNDATION INSTALLATION (HELICAL)
1. Attach the helicals to front (South) posts.
[1] HELICAL FOUNDATION
[3/4] FRONT (SOUTH)/REAR (NORTH) POST
[10] 3/8-16 SERRATED FLANGE NUT
[13] 3/8-16X2.75” SERRATED FLANGE BOLT
2. Drive the foundation with a single point, starting at
one end of the site. Ensure the foundation is held plumb
and in the proper location using a level.
3. Drive the foundation to the correct depth as indicated
by the construction documents. Also ensure the upper
bolt holes are rotated to align in the East-West direction.
4. Repeat further down the South side of the row with
another foundation to create the next transition point
for a string line, once again measuring and ensuring
plumbness. When topography is present, additional
transition posts must be installed at transition points so
that the string line can ow through hills and valleys at a
moderate rate. Although the racking will follow terrain,
it has limitations. Therefore, ensuring smooth ow will
greatly aid the installation process.
5. Run a string line between all foundations at the same
height. For consistency, string line should run along the
same side of the foundation for the entirety of the site.
For example, always wrap counterclockwise, then install
new foundations on the South side of the string. This
will help prevent zigzagging.
6. Ensure the heights of all posts are correct and ow
with the terrain in the method indicated in the construc-
tion documents.
7. Once the South side posts are installed, install the
North side posts by adjusting the height to the designed
tilt angle per foundation set (check the build plans for
the correct tilt angle). Use a steel guide and angle nder
to determine the tilt. Repeat the string method for the
North side posts.
NORTH
EAST
1”
1”
1” ±1”
Rotate so holes
align east/west
±2° Plumb
1”
PRO TIP
2
1
3/4
10
13
PRO TIP
3
Racking should conform to
the terrain

PAGE 7 - INSTALLATION MANUAL
READY RACK
NOTE
Check all survey points before pilot drilling.
FOUNDATION INSTALLATION (SCREW)
1. Preinstall the set bolts to ensure the integrity of the
welded nut.
2. Drive the foundation with a single point, starting at
one end of the site. The string line method is best for
ensuring a straight line and a perfect plane of the array.
Foundations are typically installed 6” above grade.
3. Ensure the foundation is held plumb and in the proper
location using a level.
4. Drive the foundation to the correct depth as indicated
by the construction documents.
5. Install all remaining foundations, using a string line
as a guide for placement and height if necessary. Use a
tape measure as described in the preparation process.
ALTERNATE FOUNDATION INSTALLATION
For sites with medium-to-heavy rock or bedrock, holes
may need to be piloted and backlled prior to founda-
tion install. When required, perform the following steps
prior to the steps above.
1. With an auger or rock drill, drill a pilot hole to correct
depth and diameter.
2. Fill the hole with stone as indicated by APA. The
amount of stone varies based on the site’s soil type.
POST INSTALLATION (SCREW ONLY)
1. Insert the front (South) post at the rst point on the
South set of foundations.
2. Measuring from the ground to the top of the post,
ensure the post is at the correct height according to the
construction documents. Also ensure the upper bolt
holes are rotated to align in the East-West direction.
Temporarily secure the post in place with a quick clamp
or similar tool.
3. Repeat further down the front (South) side of the row
with another foundation to create the next attachment
point for the string line, once again measuring and ensur-
ing plumbness. When topography is present, additional
transition posts must be installed at transition points so
that the string line can ow through hills and valleys at a
moderate rate. Although the racking will follow terrain,
it has limitations. Therefore, ensuring smooth ow will
greatly aid the installation process.
PRO TIP
4
NORTH
EAST
1”
1”
1” ±1”
Rotate so holes
align east/west
±2° Plumb
1”
PRO TIP
5
PRO TIP
6

PAGE 8 - INSTALLATION MANUAL
READY RACK
PRO TIP
7
POST INSTALLATION (SCREW ONLY - CONTINUED)
4. Continue to the end of the row as required to set a
string line.
5. Run a string line between all foundations at the same
height. For consistency, string line should run along the
same side of the foundation for the entirety of the site.
For example, always wrap counterclockwise, then install
new posts on the South side of the string. This will help
prevent zigzagging.
6. Ensure the heights of all posts are correct and ow
with the terrain in the method indicated in the construc-
tion documents.
7. Secure the transition posts at the foundations with
three (3) bolts and remove the temporary clamps.
[2] SCREW FOUNDATION
[3/4] FRONT (SOUTH)/REAR (NORTH) POST
[14] M16X2.0 25MM HEX BOLT (GROUND SCREW
SET BOLT)
8. Once heights are veried correct and rotation is
correct, bolts can be tightened. Every post should be
checked to ensure the bolts are fully seated.
9. Once the front (South) side posts are installed, set the
rear (North) side posts by adjusting the height to the
designed tilt angle per foundation set (check the build
plans for the correct tilt angle). Use a steel guide and an-
gle nder to determine the tilt. Repeat the string meth-
od for the rear (North) side posts.
Top view of post and fully tightened bolts
14
2
3/4

PAGE 9 - INSTALLATION MANUAL
READY RACK
TUBE CLAMP STAGING
1. Slide the tube clamps over both the rear (North) and
front (South) posts prior to attaching the N/S chord
or stretch the clamp apart, t it around the post, and
squeeze it back to its original shape. Refer to the con-
struction documents for the bracing requirements and
locations.
[18] TUBE CLAMP
[3/4] FRONT (SOUTH)/REAR (NORTH) POST
N/S CHORD-TO-POST
1. Attach the N/S chord to the West side of the posts.
Refer to the construction documents for the correct
hole locations.
[6] N/S CHORD
[3/4] FRONT (SOUTH)/REAR (NORTH) POST
[13] 3/8-16X2.75” SERRATED FLANGE BOLT
[10] 3/8-16 SERRATED FLANGE NUT
FINE HEIGHT ADJUSTMENT
1. Sighting down a row, looking from East or West, look
for inconsistencies in the heights of the racking. Adjust
the height by removing the N/S chord hardware and ad-
justing the height using the adjustment holes before re-
attaching the hardware.
E/W STRUT PURLIN-TO-N/S CHORD
1. Bolt the E/W strut purlin to the N/S chord using the
correct hole location per the construction documents.
[7] E/W STRUT PURLIN
[12] 3/8-16X1.00” SERRATED FLANGE BOLT
[11] 3/8-16 CHANNEL NUT
18
3/4
6
10
3/4
13
7
12
11
Use slots to adjust N/S chord
upwards or downwards

PAGE 10 - INSTALLATION MANUAL
READY RACK
E/W STRUT PURLIN SPLICE
1. Connect two E/W strut purlins by using the splice to
make a continuous rail. Stagger the location of the splic-
es between foundations to reduce sagging.
[16] STRUT SPLICE
[10] 3/8-16 SERRATED FLANGE NUT
[12] 3/8-16X1.00” SERRATED FLANGE BOLT
2. Ensure the bottom or southern most E/W strut purlin
is straight by adjusting it in the slot or by moving the
N/S chord. Once visually straight, fasten down. Use
spacers (scrap wood, scrap metal, etc.) to set the re-
maining E/W strut purlins to keep even spacing per the
construction documents.
CROSS BRACE TUBE INSTALLATION
1. Install the cross brace tube at the lower location on
the rear (North) post and at the upper location on the
front (South) post. Check the construction documents
for the appropriate placement and tolerences.
[5] CROSS BRACE TUBE
[15] TUBE CLAMP BOLT
12
10 16
Use temporary
spacers between E/W
strut purlins to main-
tain even spacing
during install
15
5
PRO TIP
8

PAGE 11 - INSTALLATION MANUAL
READY RACK
CABLE BRACE-TO-FRONT (SOUTH) POST
Depending on the array and project parameters, a set
of posts may get multiple sets of cable braces to limit
movement and reduce fatigue. Refer to the construc-
tion documentation for locations and frequency of ca-
ble bracing.
1. If clamps were not installed prior to installing the N/S
chord (highly recommended), spread the clamp apart,
slide around the post, and re-compress it. Install clamps
on the front (South) and rear (North) posts as required.
2. Once clamps are installed, string a cable between the
two clamps. Note that there may be multiple lengths of
cables on one job; refer to construction documentation
to use the correct one.
3. Secure cable with bolts, loosely. Ensure that the bolts
are pointing to the interior of the rack.
4. Install all cables on the front (south) posts as indicat-
ed in the construction documents. Cables should be taut
and have no noticeable slack or sag.
[3] FRONT (SOUTH) POST
[15] TUBE CLAMP BOLT
[17] CABLE BRACING
[18] TUBE CLAMP
Note: In areas involving terrain, custom bracing may
be needed. This is achieved by cutting a piece to the
correct length o of a spool. It will then be crimped by
a swagging tool.
NOTE
Cable braces are not used to induce static tension, like
trusses of a bridge, but instead only to keep the posts
from spreading or shifting.
17 3
18
15

PAGE 12 - INSTALLATION MANUAL
READY RACK
PANEL INSTALLATION
1. Beginning at one end, start setting the panels by
squaring the rst panel to the bottom E/W strut purlin.
Refer to the construction documentation to determine
the correct orientation of the panel.
2. Place the top panel after squaring the bottom pan-
el. Make sure the spacing between the top and bottom
panel is correct. Note: Use a xture to create the proper
gap, such as a piece of wood and spare clamp from the
site.
3. Place transition panels periodically throughout the
row, squaring them to the rack as you go. Once these
transition panels have been placed, run a string across
them to create your leading edge for the row. This is
done to provide the best aesthetics while keeping the
panel placement within specication.
4. Stage panels throughout the row in preparation to be
set to the string line.
5. When starting panels, mid clamps can be placed in any
area of the E/W strut purlin, except for splice locations.
6. Tighten the clamps square to the panels and ensure
the grounding teeth are coming into contact with the
panel frame.
7. Repeat steps down the row, moving transition panels
as you reach them if necessary.
Properly seated
mid clamp assembly
Properly seated
end clamp assembly
PRO TIP
10
PRO TIP
9

PAGE 13 - INSTALLATION MANUAL
READY RACK
CABLE BRACE-TO-REAR (NORTH) POST
Depending on the array and project parameters, a set
of posts may get multiple sets of cable braces to limit
movement and reduce fatigue. Refer to the construc-
tion documentation for locations and frequency of ca-
ble bracing.
1. Install the bracing on the rear (North) posts following
the process used for front (South) posts.
Note: In areas involving terrain, custom bracing may
be needed. This is achieved by cutting a piece to the
correct length o of a spool. It will then be crimped by
a swagging tool.
NOTE
Cable braces are not used to induce static tension, like
trusses of a bridge, but instead only to keep the posts
from spreading or shifting.

PAGE 14 - INSTALLATION MANUAL
READY RACK
[6] When dealing with extreme topography, addition-
al transitions will have to be added to make the rack-
ing ow with the terrain.
[7] Use grip clamps when setting post transitions.
This is the best technique to use so that no improp-
er dimpling is done to the posts if adjustments are
needed. Once desired ow is reached, tighten the set
bolts.
[8] Use a grip clamp to squeeze and close the clamp
shut while installing the tube clamp bolt. Connect the
cross brace tube to the tube clamp with a squeeze
vise. This process takes less eort as the clamps are
very rigid.
[9] When staging panel clamps, tighten the bottom
nut until the spring is slightly compressed. This will
help the panel installer free up one hand. If the spring
is not compressed prior to staging, the clamp will spin
and another installer will have to hold the panel.
[10] To square the panel, measure the distance from
the edge of the panel to the at part of the E/W strut
purlin on both sides, ensuring equal distance.
PRO TIPS are pieces of advice from installation ex-
perts. They are intended to provide practical solu-
tions to real-world problems that you may encounter.
Before implementing any of the below tips, make
sure to request approval from APA’s Engineering
team, as not all solutions are allowed on every site.
[1] Use a steel tape rather than a berglass tape to
measure distances over the length of the row. Fiber-
glass can stretch over time and aect layout and in-
stallation lengths.
[2] With extreme topography, every foundation must
be marked and the string line must be attached to
every foundation in order to ensure that the racking
will ow at every high and low point.
[3] While it is very dicult to make every post per-
fectly plumb and at the correct height, care should be
taken to keep them within the tolerances specied in
the plans in order to ensure that the system ts and
functions as intended.
[4] Install the beginning, middle and end foundations
about half of the way to depth (typically until threads
are not showing). Then attach a string line to these in-
stalled foundations, creating a straight line for the in-
stallation process. This will give the installer a guide
and ensure that the foundations are plumb.
[5] If holes are pre-drilled, they must be lled with
aggregate immediately, ensuring debris or water
doesn’t fall into the holes. If this happens, a void can
be created causing the foundations to possibly sink
in the future.
PRO TIPS

PAGE 15 - INSTALLATION MANUAL
READY RACK
OPERATION & MAINTENANCE
Regular inspections and proper maintenance are essential to maintain the design life and warranty of the Ready Rack
solar racking system. Solar racking is exposed to many elements from initial construction to seasonal changes and
can even be susceptible to severe weather conditions. The following Operation and Maintenance procedures should
be followed and performed on an annual basis to ensure the warranty for the racking system remains active. The
procedures below highlight the critical points to be examined and maintained for a properly functioning solar racking
system.
BOLTED CONNECTIONS
Bolted connections need to be visually inspected annually to ensure the components are properly joined together. At
the beginning, middle, and end of each row, there are torque marked nuts/bolts per the APA QA/QC process. These
marked locations should be visually inspected to conrm no movement of the bolted connections has occurred. If
loose hardware is found, re-tighten to the specications noted in the plan set for the racking system.
SOLAR PANEL CLAMPS
Clamps need to be visually inspected annually to ensure modules are properly secured. If loose clamps are found,
retighten to the specications noted in the plan set for the racking system.
GALVANIZE COATING
The galvanized coating ensures that the steel components are protected from corrosion and that the solar racking
system will last for the entire project life. The solar racking system should be inspected annually for any areas of cor-
rosion or rust. If areas are found, they should be repaired in a timely manner by cleaning the area and then generously
applying cold galvanizing compound.
The cut, slit and sheared edges of the racking system are exposed steel that are expected to show corrosion or rust.
This is normal and should be expected, but does not aect the structural integrity of the system.
Copper should be isolated and cannot touch the galvanized coating, as it will expedite corrosion.
CROSS BRACING CABLE WIRE
If applicable to your project, the bracing needs to be visually inspected on an annual basis to ensure that it has not
become loose. Cables are required to be taut for motion limiting, but do not need to be tensioned.
SYSTEM DAMAGE
The solar racking system should be visually inspected for other types of damage. Examples include damage from
mowing equipment, maintenance equipment, falling trees or branches, storm damage, system lean, soil erosion, etc.
Any components that are damaged or deformed should be replaced as they may be weaker or corrode faster than
intended. Some components may be able to be repaired onsite if replacement is not practical. For assistance with
replacement parts or instructions on repairing a component, contact APA.
GENERAL OPERATION
It is important to maintain the solar racking system to ensure the design lifespan.
Keep all vegetation managed and o of the racking system and solar modules.
Check that module cleaner solution, weed killer, or other chemicals used on or around the solar racking system are not
corrosive to galvanized or stainless steels.
Check electrical wiring to ensure it is managed properly and protected.
Take note and log when inspections were performed and if any corrective actions were taken or need to be taken in
the future.