APA READYRACK User manual

Updated: February 2023
INSTALLATION MANUAL
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PAGE 2 - INSTALLATION MANUAL
GEOBALLAST
TABLE OF CONTENTS
PAGE
2 TABLE OF CONTENTS
3 PARTS LIST
4 SITE PREPARATION, UTILITIES, SURVEYING
5 REVIEW & INSTALLATION PREPARATION, UNEVEN GROUND, MEASURING
6 BASKET ASSEMBLY
7 BALLAST STAGING & FILL WITH AGGREGATE, POST INSTALLATION
8 POST INSTALLATION (CONTINUED)
9 TUBE CLAMP STAGING, CROSS BRACE TUBE INSTALLATION
N/S CHORD-TO-POST, FINE HEIGHT ADJUSTMENT, E/W STRUT PURLIN-TO-N/S CHORD,10
E/W STRUT PURLIN SPLICE
12 PANEL INSTALLATION
13 CABLE BRACE-TO-POST
14 PRO TIPS
14 O&M REQUIREMENTS

STRUCTURAL MEMBERS
[1] WIRE BASKET ASSEMBLY
FOLDED WIRE BASKET
SHORT SPIRAL RING [21]
LONG SPIRAL RING [22]
[2] ELBOW TUBE
[3] ELBOW CLAMP PLATE
[4] BASE TUBE
[5] FRONT (SOUTH) POST
[6] REAR (NORTH) POST
[7] CROSS BRACE TUBE
[8] N/S CHORD
[9] E/W STRUT PURLIN
HARDWARE
[10] END CLAMP ASSEMBLY
[11] MID CLAMP ASSEMBLY
[12] 3/8-16 SERRATED FLANGE NUT
[13] 3/8-16 CHANNEL NUT
[14] 3/8 FENDER WASHER
[15] 3/8-16X1.00” SERRATED FLANGE BOLT
[16] 3/8-16X1.25” SERRATED FLANGE BOLT
[17] 3/8-16X2.75” SERRATED FLANGE BOLT
[18] 3/8-16X3.00" SERRATED FLANGE BOLT
[19] M16-2.0X25 HEX SET BOLT
[20] TUBE CLAMP BOLT
[21] SHORT SPIRAL RING
[22] LONG SPIRAL RING
[23] STRUT SPLICE
[24] CABLE BRACING
[25] TUBE CLAMP
[26] BASKET STABILIZER
PARTS LIST
PAGE 3 - INSTALLATION MANUAL
GEOBALLAST
N/S CHORD-TO-POST, FINE HEIGHT ADJUSTMENT, E/W STRUT PURLIN-TO-N/S CHORD,
1
2
3
4
5
6
7
8
22
9
10 11
12 13
21
14 15 16 17 18 19 20
23 24 25
26

PAGE 4 - INSTALLATION MANUAL
GEOBALLAST
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. For Geoballast sys-
tems, this means the preperation of level stone pads.
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 elbow tube locations for the Geoballast 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.
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 in the cor-
rect location. 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 Geoballast 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
GEOBALLAST
PRO TIP
1

BASKET ASSEMBLY
1. Unfold the semi-assembled wire basket assembly.
[1] WIRE BASKET ASSEMBLY
[2] ELBOW TUBE
[4] BASE TUBE
[12] 3/8-16 SERRATED FLANGE NUT
[16] 3/8-16X1.25” SERRATED FLANGE BOLT
[18] 3/8-16X3.00” SERRATED FLANGE BOLT
[21] SHORT SPIRAL RING
[22] LONG SPIRAL RING
[26] BASKET STABILIZER
2. Bolt the base tube to the elbow tubes.
3. Place the wire basket assembly on its side and posi-
tion the elbow and base tube assembly into the bottom
of the wire basket assembly so that it is positioned with-
in the cutouts of the mid and end panels of the basket.
4. Fold the bottom panel of the basket back into place
and insert the short spirals. Then proceed by inserting
the long spirals.
5. Stand the assembly up and check elbow tube for
plumbness.
6. Secure the elbow tubes to the basket assembly using
the elbow clamp plate by placing it inside the basket and
pinching the wire mesh of the basket between the two
surfaces.
7. Install stabilizer to ensure basket integrity.
PAGE 6 - INSTALLATION MANUAL
GEOBALLAST
4
1
2
18
12
22 21
26
21 12
16

BALLAST STAGING & FILL WITH AGGREGATE
1. An equipment operator should carry the basket and
tube assembly to each foundation location.
2. Positing the basket and tube assembly so that the
North and South survey points align with the center of
the elbow tube. Stage all ballast assemblies in the row.
3. Once the location has been conrmed, ll the ballast
assemblies with aggregate as specied in the construc-
tion documents.
POST INSTALLATION
1. Insert the front (south) post at the rst point on the
south set of elbow tubes.
2. Measuring from the ground to the top of the post,
ensure the post is at the correct height according to the
construction plans. Also ensure the upper bolt holes are
rotated to align in the East-West direction. Temporari-
ly 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.
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 plans.
PAGE 7 - INSTALLATION MANUAL
GEOBALLAST
PRO TIP
2
PRO TIP
3

PAGE 8 - INSTALLATION MANUAL
GEOBALLAST
POST INSTALLATION (CONTINUED)
7. Secure the transition posts at the foundations with
three (3) bolts and remove the temporary clamps.
[5/6] FRONT (SOUTH)/REAR (NORTH) POST
[2] ELBOW TUBE
[19] M16X2.0 25MM HEX 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) 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). Set a steel guide on top
of the front (south) and rear (north) posts and use an 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
19
2
5/6
Image of completed assembly.
1. Filled with stone and upper posts
installed.
PRO TIP
5
PRO TIP
4

PAGE 9 - INSTALLATION MANUAL
GEOBALLAST
TUBE CLAMP STAGING
1. Slide the tube clamp over the rear (north) post 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 construction prints for the bracing
requirements and locations.
[25] TUBE CLAMP
[5/6] FRONT (SOUTH)/REAR (NORTH) POST
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.
[7] CROSS BRACE TUBE
[20] TUBE CLAMP BOLT
25
5/6
20
7

PAGE 10 - INSTALLATION MANUAL
GEOBALLAST
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.
[8] N/S CHORD
[5/6] FRONT (SOUTH)/REAR (NORTH) POST
[17] 3/8-16X2.75” SERRATED FLANGE BOLT
[12] 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.
[9] E/W STRUT PURLIN
[15] 3/8-16X1.00” SERRATED FLANGE BOLT
[13] 3/8-16 CHANNEL NUT
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.
[23] STRUT SPLICE
[12] 3/8-16 SERRATED FLANGE NUT
[15] 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.
8
12
5/6
17
9
15
13
15
12 23
Use slots to adjust N/S chord
upwards or downwards
Use temporary
spacers between E/W
strut purlins to main-
tain even spacing
during install

PAGE 11 - INSTALLATION MANUAL
GEOBALLAST
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
7
PRO TIP
6

PAGE 12 - INSTALLATION MANUAL
GEOBALLAST
24 5/6
CABLE BRACE-TO-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 North and South posts as required.
2. Once clamps are installed, string a cable between the
two clamps. Note: There may be multiple lengths of ca-
bles 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 as indicated in the construction doc-
uments. Cables should be taut and have no noticeable
slack or sag.
[5/6] FRONT (SOUTH)/REAR (NORTH) POST
[20] TUBE CLAMP BOLT
[24] CABLE BRACING
[25] 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.
25
20

PRO TIPS
PRO TIPS are pieces of advice from installation experts. They are
intended to provide practical solutions to real-world problems
that you may encounter. But before implementing any of the be-
low 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 dis-
tances over the length of the row. Fiberglass can stretch over time
and aect layout and installation lengths.
[2] When dealing with extreme topography, additional transitions
will have to be added to make the racking ow with the terrain.
[3] With extreme topography, every foundation must be marked
and the string line must be attached to every post, in order to en-
sure that the racking will ow at every high and low point.
[4] While it is very dicult to make every post perfectly 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.
[5] Use grip clamps when setting post transitions . This is the best
technique to use so that no improper dimpling is done to the posts
if adjustments are needed. Once desired ow is reached, then
tighten the set bolts.
[6] When staging panel clamps, tighten the bolt 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.
[7] 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.
PAGE 13 - INSTALLATION MANUAL
GEOBALLAST

PAGE 14 - INSTALLATION MANUAL
GEOBALLAST
OPERATION & MAINTENANCE
Regular inspections and proper maintenance are essential to maintain the design life and warranty of the Geoballast
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
Annually, bolted connections need to be visually inspected 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. Annually, the solar racking system should be inspected 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.