PIC-PLAST SOLARIG Alpine 135 User manual

SOLARIG™TUNNEL KIT
InstallationManualModelAlpine135
Version1.0

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
-ii -
Document Version Control
Version
Date
Changes
Author
1.0
July 2014
Initial version
Anne Lustig-Picus
All rights reserved. Neither this documentation nor any part of it may be reproduced, stored
in a retrieval system, translated into another language, or transmitted in any form or by any
means, electronic, mechanical, photocopying, recording, or otherwise, without the prior
written permission of 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. The information
contained in this document is subject to change without notice. PIC-PLAST Ltd. reserves the
rights to make any such changes without obligation to notify any person of such revision or
changes. PIC-PLAST Ltd. makes no commitment to keep the information contained herein up
to date.
Moshav Merchavia 19105, ISRAEL
Tel: + 972-4-6426141 Fax: [phone]
[email protected]et www.pic-plast.com
© Copyright 2014 PIC-PLAST™ Ltd.

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Contents
SOLARIGTM 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...............................................................................................................................................10
Assembling the Arcs....................................................................................................................................11
First and Last Arcs ..................................................................................................................................11
Middle Arcs ............................................................................................................................................13
Stretching a String Frame............................................................................................................................15
Raising the Arcs ...........................................................................................................................................17
Phase 2: Pouring Concrete ...............................................................................................................................23
Measuring and Marking ..............................................................................................................................23
Pouring Concrete.........................................................................................................................................23
Phase 3: Stabilizing...........................................................................................................................................24
Digging Trenches.........................................................................................................................................24
Reinforcing, Post-Concrete .........................................................................................................................25
Phase 4: Covering with Nets.............................................................................................................................28
Nets for Front and Back...............................................................................................................................28
Nets for Sides ..............................................................................................................................................30
Roof Cover...................................................................................................................................................35
Curtain for Side (VSC)..................................................................................................................................39
Phase 5: Maintenance......................................................................................................................................41

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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SOLARIGTM Tunnel Kit Model Alpine 135
PIC-PLAST thanks you for purchasing the SOLARIGTM TUNNEL KIT. We are certain that the
correct use of our product will yield improved growth results.
This manual includes all relevant details to allow optimal installation of the product. Read
the instructions carefully and make sure to follow all the guiding information in the order
shown, to benefit from the product in the years to come.
Warning
Installing the product not in accordance with the instructions may cause
damage to both the product and crops growing within.
Please contact us directly with any questions by phone: [phone] or via the website:
WWW.PIC-PLAST.COM
This manual covers the alpine version. A tunnel kit suitable for tropical climates is also
available. Dimensions of the basic structure: 15m x 9m (135 square meters). There are no
external cables in the alpine version. You can make the basic structure longer by adding
more internal arcs.
This product is available in two versions:
•Closed roof (SOLARIGTM cover)
•Ventilated roof with a roll-up system (VRR)
There are a number of additions to these versions:
•Ventilated side with curtain (VSC) –sides covered with a 50MESH insect net plus a
roll-up curtain with a SOLARIGTM cover
•Additional lower air-flow protection
•Front metal door (FMD)
The overall installation process is identical for all versions. If you purchased additions to the
basic product, follow the installation instructions, which are detailed in separate manuals.
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
•Tropical-135InstallationManual –For installing the kit in tropical climates
•FMD-Installation Manual –For installing the front metal door
•VSC-Installation Manual –For installing the ventilated side with curtain

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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. The basic kit has five arcs total and covers 135m2.
NOTES: These instructions are based on the 5-arc version, suitable for alpine climates.
Tools and Equipment
For the installation you need these tools:
•2kg hammer
•Marking stakes, 8 units 60cm long
•Spray paint
•Builder twine for marking and measuring 100m
•Measuring tape, 30m long
•Level tool
•Colour marker
•Digging tools
•Knife/scissors
•2 ladders, 4m high
•Rope, to pull the roof covering
•10 x wood planks (2 x 4s), 70 cm long
•Concrete: 350kg of cement, 1 cubic meter of gravel, 1 cubic meter of sand
Parts Inventory
Table 1: Part identifiers
Part ID
Description
Qty.
Graphic
METAL
ARC2410
Arc pipe 70mm x 40mm x
2410mm
30
ARC1600
Arc pipe 70mm x 40mm x
1600mm
5
HOR3784314
Horizontal pipe ø42.7 x
3780mm x 1.4mm
8
HOR2324318
Horizontal pipe ø42.7 x
2320mm x 1.8mm
6
VER2213514
Vertical pipe ø35mm x 2210mm
x 1.4mm
4

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Part ID
Description
Qty.
Graphic
DIA4585318
Diagonal pipe for PSS ø53mm
x 4580mm x 1.8mm
4
PVR2304318
Pole vertical reinforcement
ø42.7mm x 2300mm x 1.8mm
10
PHR563214
Pole horizontal reinforcement
ø32mm x 560mm x 1.4mm
10
PHR403214
Pole horizontal reinforcement
ø32mm x 400mm x 1.4mm
10
PDR1003214
Pole diagonal reinforcement
ø32mm x 1000mm x 1.4mm
10
HORU3706040
C Profile 60mm x 40mm x
3698mm x 1.4mm
8
OVKU7042
U Clamp 70mm x 42mm x
2.5mm
15
OVKU13142
U Clamp 131mm x 42mm x
2.5mm
6
OVKU16047
U Clamp 150mm x 47mm x
2.5mm
20
OVKSL1
Connection plate (pole/arc)
2.5mm
20
OVKL7040
L Bracket 70mm x 40mm x
3mm
32
OVKL4040
L Bracket 40mm x 40mm x
3mm
20
MTTA10040
L Bracket 30mm x 100mm x
3mm
30
HTOM40R
Omega clip ø42.7mm x
2.5mm (closed)
4
OVKW4030
Square washer 40mm x
30mm x 4mm
27
IA1040
Anchor nail for assembly only
8
RW1035
Rubber washer 35mmX10mm
69

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Part ID
Description
Qty.
Graphic
BW1035
Bent washer 35mmx10mm
24
FW1035
Flat washer 35mm x 10mm
95
TKRP3852518
Rolling pipe (dia.
25x1.8mmx3.85m) net length
3.79m (only the male end is
shown)
8
CHZ25N
Curtain handle for roof
ventilation (dia. 25mm)
2
OR08
Open ring wrench for B08
2
SD1/4
Screwdriver for SDS1/4
1
PF09
Perforator
1
SC04
4mm galv. cable
152
CL05
5mm cable locker (used for
PSS wires)
26
CC04
Cable clamp 4mm (includes
fixing process)
55
B0830
Bolt 8mm x 30mm
166
B0840
Bolt 8mm x 40mm
25
B0860
Bolt 8mm x 60mm
258
B0870
Bolt 8mm x 70mm
22
B0890
Bolt 8mm x 90mm
20
B08R60
Eye bolt 8mm x 60mm
4

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Part ID
Description
Qty.
Graphic
B08R90
Eye bolt 8mm x 90mm
80
N08
Nut 8mm
700
W08
Washer 8mm
730
SDS1/4
Self-drill screw SDS 1/4 X 3/4
128
LP3750
Locking profile 3750mm
8
LS200
Locking spring 2000mm
16
HSW25
Galv. wire 2.5mm
230
CSH04
Carabine (locking ring) 4mm
32
MCH30
Metal chain ø3mm for PSS
(cut in units of 2.1m)
13
PC25100
Plastic clip dia. 25mm x
100mm for pipe ø 25
50
BRB4170
Black rubber band ø4mm x
170mm (with ball)
100
PLASTIC
Roof
SOLARIG Top BC MATT cover
(11.04m x 15.8m) rope both
edges (2.08mx3+2.50mx2)
1
VSC Side +
bottom
protection
SOLARIG Classic with net
(16m X 2.6m) + SOLARIG
curtain
2
25mm grey strip
50
Front
50-Mesh insect net, one with
Velcro door and one without
Velcro door
2
Winter Fronts
SOLARIG Classic
(9.5x3m+7.5x3m) x 2 sets
2

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Part ID
Description
Qty.
Graphic
CABLES
Cable-1
Length - 4020mm (end to end
of bolts)
4
Cable-2
Length - 4380mm (end to end
of bolts)
4
Cable-3
Length - 4330mm (end to end
of bolts)
4
Cable-4
Length - 7390mm (end to end
of bolts)
2
Cable-5
Length - 6670mm (end to end
of bolts)
3
Cable-6
Length - 4970mm (end to end
of bolts)
10
Cable-7
Length - 2330mm (end to end
of cable loop) - used for PSS
6

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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.
1. Make sure the planned tunnel area is clear of hazardous objects.
2. Make sure the area planned for the tunnel is level. The maximum permitted incline
is 2% (20cm in height per 10m length).
3. Make sure there is water drainage out of the tunnel.
4. Determine wind direction and place the structure so that the wind will blow at a 45o
angle.
5. Inspect the figures and instructions before starting measurements and make sure
the instructions are clear.
6. Make sure you have the tools required for measurement and labelling, listed in the
Required Tools and Equipment section.
Digging Holes
1. Examine Figure 1. Set out marking stakes at points A, B, C, and D. You will leave
these stakes in place during the entire construction process.
2. Use spray paint to mark the outline of each hole to be dug.
3. Dig 10 holes.

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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.
•All the middle arcs are identical.
First and Last Arcs
You will need the parts shown in the figures. Assemble as shown.

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Figure 2: First and last arcs parts
Figure 3: First and last arc connections

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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.

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Figure 5: Middle arc parts
Figure 6: Middle arc connections

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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. Stretch builder twine between the marking stakes, 15 cm above ground level.
2. Use a marker or coloured chalk to mark the centre of each dug hole on the builder
twine, where the centres of each arc will be.
3. Determine the corners according to the figures below and use the golden triangle
(Figure 8) to create 90obetweenthesidesofthestructure.
4. Establish the basis for further measurements by creating a frame 17m long by 9.04m
wide using builder twine.
Figure 7: Marking distances
Figure 8: Golden triangle

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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Figure 9: Marking distances between arcs
Figure 10: Marking points on the string

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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•Stabilize with two ropes and anchors (Figure 12).
Figure 12: Raising the first arc

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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

SOLARIG™ TUNNEL KIT
Installation Manual for Model Alpine-135
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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. Align in all directions:
oHeights of arcs: align the first hole above ground with the string. Use wood
planks (Figure 16).
oWidth of arcs: check the distance between anchors.
oSides of tunnel: check they form a straight line.