Berliner Seilfabrik TERRANOS GEOBALL 5 User guide

TERRANOS®
Netscapes
MOUNTING INSTRUCTION
Geos
GEO RANTUM
(GEOBALL 5)
ART.NR.: 90.130.025
Contents
1 Personnel and Tools........................................................................... 2
1.1 Personnel.............................................................................. 2
1.2 Tools..................................................................................... 2
2 Introduction......................................................................................... 3
3 Mounting of the GEOBALL 5.............................................................. 4
3.1 Framework Assembling......................................................... 4
3.1.1 Foundation Plan ...................................................... 5
3.1.2 Framework Plan ...................................................... 6
3.2 Net Fastening........................................................................ 8
3.3 Inner Item Mounting.............................................................. 9
3.3.1 Rope Ladders.......................................................... 9
3.3.2 Hammocks, Hand Over Hand Loop Ropes,
Climbing Ropes....................................................... 9
3.3.3 Drawings ................................................................. 10
3.3.4 Assembling Positions .............................................. 12
3.4 Foundation Plates................................................................. 12
3.5 Final Work............................................................................. 12
4 Foundation Work................................................................................ 13
4.1 Diggings................................................................................ 13
4.2 Foundation Tubes................................................................. 13
4.3 Concrete the Foundation....................................................... 13
5 Maintenance....................................................................................... 14
5.1 Visual Check of all Parts....................................................... 14
5.1.1 Framework .............................................................. 14
5.1.2 Net........................................................................... 14
5.2 Check of the Foundation Tubes............................................ 14
Berliner Seilfabrik
GmbH & Co.
Lengeder Straße 4
D - 13407 Berlin
Fon: 030 - 414724 - 0
Technical Hotline: 030 - 414724 - 25 / - 30 Fax: 030 - 414724 - 33

TERRANOS®
Netscapes
1 Personnel and Tools
1.1 Personnel
You need a minimum of 2 skilled labour for the right assembling of the
GEOBALL 5.
1.2 Tools
The following tools are required for the mounting:
1. lifting gears ( e.g. pulley block, rope pulley )
2. step ladder, appr. 4 m long
3. ratchet with ½" square drive
4. elongation with ½" square drive, 70 mm long
5. socket for wrenches with ½" square drive, wrench size 30
6. hexagon socket screw key for wrench size 8
7. high-strength screw retention for inner items
8. drilling machine
9. twist drill ∅21 mm
10. hammer
11. spade
12. bubble level
Tools are available for account.
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 2 of 14

TERRANOS®
Netscapes
2 Introduction
The GEOBALL 5 requires a special mounting sequence which is coarse
described on this page. Be aware that it is necessary to have a complete
playground surface when start the assembling. The description of the
complete mounting course is following.
The coarse mounting sequence for the GEOBALL 5 is:
1. Adjustment of the mounting place at the play area.
2. Mount the complete GEOBALL 5 framework.
! Attention: Tighten all screws at first not with full strength.!
3. Tighten all screws if the assembling of the framework system is
finished.
4. Assemble the triangular and the pentagon nets.
5. Add-on the net-funnel.
6. Mark the assembling position for inner items.
( climbing ropes, hammocks, hand over hand loop ropes, rope ladders )
7. Drill the holes at system balls for inner items.
8. Mount the inner items of the GEOBALL 5.
9. Close the assemble openings of the system balls ( except foundation
balls ) with rubber caps at the end of the mounting.
10. Dig in all foundation plates.
11. Dig the foundation pits under the GEOBALL 5 framework.
12. Fix the foundation tubes at the foundation balls.
13. Close the assemble openings of the foundation balls with rubber caps.
14. Concrete the foundation.
15. Allow the concrete to set.
16. Restore the playground surface.
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 3 of 14

TERRANOS®
Netscapes
3 Mounting of the GEOBALL 5
3.1 Framework Assembling
A. Coarse adjustment of the foundation points at the play area.
! Attention: The GEOBALL 5 will be mounted at the final place. You
dig the foundation pits under the foundation balls after
completing the mounting. !
B. The right position of structural tubes and balls is described in the frame-
work plan, chapter 3.2.2. Usually the balls type G5 as well as the
structural tubes 60 x 2 x 1191 are black coloured and the balls type G6
as well as the structural tubes 60 x 2 x 1223 are crimson coloured. The
markers for the ball types are at the border of the assemble opening.
C. The framework will be assembled level by level.
! Attention: Tighten the screws at first not with full strength.!
D. You have to centre the horizontal structural tubes ( black = horizontal
and crimson = soft inclined ) of the playground level at drill-holes of the
foundation balls. Fix the structural tubes with hexagon head cap screws
M 20 x 80, washers and spring washers from the inner side of the ball.
For each length of the tubes we use other connection types at the balls.
The groove for fixing the crimson
structural tubes 60 x 2 x 1223 is
ring-shaped and is disc-shaped for
fixing the black tubes 60 x 2 x 1191.
You mount the ring completely. The
structural tube at the entrance has
to be removed from the ring when
mounting the framework and will be
used in the higher again.
structural tube
ball connector
∅250 mm
washer
spring washer
hexagon head cap
screw M 20 x 80
E. Adjust the GEOBALL 5 finally after ring mounting at playground level.
( see foundation plan, chapter 3.1.1 )
F. Centre the next structural tubes, showing inclined into height, at the
free drill-holes of the foundation balls and fix the tubes with hexagon
head cap screws M 20 x 80, washers and spring washers from the
inner side of the ball. ( see drawing point D )
G. Next fix the ball at the other end of the structural tube with hexagon
head cap screws M 20 x 80, washers and spring washers. Go ahead
step by step by mounting balls and tubes level by level like described.
( refer to drawing point D )
H. After completing framework mounting you have to tighten the screws
completely. Please adhere to the use of tools recommended in chapter
1.2 in order to avoid higher initial tension.
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 4 of 14

TERRANOS®
Netscapes
3.1.1 Foundation Plan
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 5 of 14

TERRANOS®
Netscapes
3.1.2 FrameworkPlan
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 6 of 14

TERRANOS®
Netscapes
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 7 of 14

TERRANOS®
Netscapes
3.2 Net Fastening
Beginning at horizontal structural tubes in playground level you have to fix
all nets ( triangular net, pentagon net, net-funnel in top of framework ) with
rope clamps or double rope clamps, hexagon socket screws M 10 x 45 and
self-locking nuts. ( refer to drawing )
The top of each triangular net is showing in direction of ball type G6.
The right position of rope clamps at the structural tubes depends on the
rope position. Double rope clamps will be used when two rope ends come
together on a fastening point at structural tubes. You have to use single
rope clamps at the entrance and at playground level, where only one rope
end has to be fixed.
! Attention: If you use the double rope clamps, you have to hang on
both rope ends together into the clamp. The foundation plates of the
net-funnel will be fixed at ground when you have finished mounting
of the complete GEOBALL 5. ( see chapter 3.4 ) !
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 8 of 14

TERRANOS®
Netscapes
3.3 Inner Item Mounting
3.3.1 Rope Ladders
First mark the assembling position of the
three rope ladders. The positions are
shown in chapter 3.3.3 and 3.3.4. Next fix
the rope ladders with single rope clamps,
hexagon socket screws M 10 x 45 and self-
locking nuts at the horizontal structural
tubes 60 x 2 x 1191 at the top pentagon of
the framework system.
! Attention: The foundation plates will be fixed at ground when you
have finished mounting of the GEOBALL 5. ( see chapter 3.4 ) !
3.3.2 Hammocks, Hand Over Hand Loop Ropes, Climbing Ropes
For these inner items are no drill-holes prepared at the delivered ball
connectors. You have to drill the holes at site. The positions are shown in
chapter 3.3.3 and 3.3.4.
! Attention: Conglutinate the connections of the inner items with a
high strength screw retention to avoid unauthorised removing. !
First mark the assembling position of the inner items. You have to hold the
items on the necessary balls and to mark the drill-hole position. Afterwards
drill the holes with help of a drilling machine and a twisted drill ∅21 mm. In
addition burr the holes.
If all holes are drilled and burred you have
to assemble the hammocks, hand over
hand loop ropes and climbing cables.
At first you have to stick the distance rings
over the eye bolts M 20. Following thread
up the eye bolt M 20 through the prepared
drill-hole and fix it with self-locking nuts and
washers from the inner side of the ball.
! Attention: The foundation plates will be fixed at ground when you
have finished mounting of the GEOBALL 5. ( see chapter 3.4 ) !
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 9 of 14

TERRANOS®
Netscapes
3.3.3 Drawings
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 10 of 14

TERRANOS®
Netscapes
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 11 of 14

TERRANOS®
Netscapes
3.3.4 Assembling Positions
All balls for inner item fixing are in the second level of the framework.
The angle for the drill-holes follows the mounting position of the inner
items. For the 5 climbing ropes the drill-holes showing straight down to
ground. Horizontal to the playground level are the drill-holes for the hand
over hand loop ropes. The holes are at the different ball connectors in
front to the opposite drill-hole. For the 2 hammocks you get a mounting
angle of nearly 45° to the horizontal playground level. Like at the hand
over hand loop ropes are the drill-holes at the different ball connectors in
front to the opposite drill-hole.
At the structural tubes in the top pentagon of the framework you mount the
3 rope ladders and the net-funnel with rope clamps.
3.4 Foundation Plates
The usual steps to fix the foundation plates at ground are:
1. Dig a pit with a deep of 400 mm to 600 mm under playground
level for the foundation plate. The pit must fit the measure of the
foundation plate ( appr. 510 mm x 310 mm ).
2. Place the foundation plate into the hole. Tense the climbing rope
in such a way, that the rope can barely move sidewards. If
necessary dig the pit deeper.
3. Restore the surface and compact the ground if necessary.
3.5 Final Work
Tighten all screws. Close the assemble openings of the balls with rubber
caps at the end of the mounting. Use a hammer to fit the rubber caps into
the assemble openings.
! Attention: Don’t close the assemble openings of the foundation
balls, because you have to use the openings for foundation work. !
Finally close the drill-holes for structural tube fixing of the entrance
foundation balls with small rubber caps. Use a hammer to fit the rubber
caps into the assemble openings.
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 12 of 14

TERRANOS®
Netscapes
4 Foundation Work
For support of the foundation work you find at chapter 3.1.1 the foundation
plan. You need a minimum quality for the concrete of B 25. The usual foun-
dation work steps are:
A. Mark the foundation positions.
B. Dig the pits for the different foundations.
C. Mount the foundation tubes.
D. Close the assemble openings.
E. Concrete the foundation with a minimum quality for the concrete
of B 25.
F. Allow the concrete to set.
4.1 Diggings
! Attention: Don’t move the GEOBALL 5 for the foundation work. !
When you have marked the five foundation positions dig the pits. The
specify measures are in the foundation plan in chapter 3.1.1. Dig the pits
directly under the framework system.
The foundations are under the horizontal structural tubes 60 x 2 x 1191 in
playground level of the lateral framework pentagons. Refer for the specify
measures to foundation plan
4.2 Foundation Tubes
The foundation tubes will be mounted
angular. See drawing in the framework
plan chapter 3.1.1. Centre the structural
tubes, showing inclined into ground, at
the free drill-holes of the foundation
balls and fix the foundation tubes with
hexagon head cap screws M 20 x 80,
washers and spring washers from the
inner side of the foundation ball. Finally close the assemble openings of
the balls with rubber caps. Use a hammer to fit the rubber caps into the
assemble openings.
structural tube
ball connector
∅250 mm
washer
spring washer
hexagon head cap
screw M 20 x 80
4.3 Concrete the Foundation
Concrete the foundation with a minimum quality for the concrete of B 25
and allow the concrete to set.
Finally restore the playground surface.
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 13 of 14

TERRANOS®
Netscapes
5 Maintenance
For the GEOBALL 5 we recommend a maintenance twice a year or more
often if you have a high play frequency. You need trained personnel for
the maintenance work.
5.1 Visual Check of all Parts
5.1.1 Framework
•Is there any demolition due to the ball’s outside influences?
Is the rubber cap still at the assemble opening?
•Is there any demolition due to structural tubes from outside influences?
Look for corrosion and lacquer demolition and if necessary remove the
corrosion from the structural tube and paint the tube with inorganic zinc.
Tease the lacquer demolition.
5.1.2 Net
•Control the abrasion of the polyamide yarn cover and control if wire
breakage exists. If necessary change the rope parts, positions or nets.
•Is there any demolition due to fixing points from outside influences?
Look for corrosion, demolition and lacquer demolition.
5.2 Check of the Foundation Tubes
In theorie the use of steel in concrete is noncritical, because due to the
alkaline condition of the concrete the steel is covered by a passive layer.
Only at the edge of the concrete solid the passivation is reduced as the
concrete at the edge is carbonized. This inside the concrete the existence
of corrosion can be ruled out. However, corrosion can happen at the
transition between concrete solid and soil (where moisture can accumulate).
Our foundation pipes are invariably zinc-epoxy-polyester-powdercoated and
thus at undamaged condition no subject to electrochemical corrosion. Upon
maintenance it is necessary to check if the undamaged condition of
foundation parts is given.
! Important: Please don’t use sharp-edged tools. Better use a piece of
wood or a brush.
Remark: All the replacement parts and tools that are necessary for the
maintanance are available from the Technical Hotline upon request.
Please have the product identification number ready that is written on the
product label that can be found on one of the framework balls in the first
level. See first page for contact details.
Mounting Instruction
TERRANOS®
GEOBALL 5
Version Jan. 1997
Page 14 of 14