Trellis System

Trellis System

Field Layout (Example shows 3 tunnels together)

Trellis System

NB TUNNELS RUN THIS WAY

Perimeter Anchors 1.6m Anchors must be drilled in-line with the cable from the top of the 60mm Leg. To achieve this, the anchor must be drilled at approximately 45 degrees. If using a 2.25m trellis height, the anchor point should be 2.25m from the 60mm Leg. If using 2.75m trellis height, the anchor point should be 2.75m from the 60mm leg.

DO NOT:- Drill the Anchors vertically or drill a hole to put the anchors in to (unless you want to concrete them in...)

2.25m with 2.25m legs, 2.75m with 2.75m Legs

Trellis System

At the end of the leg row, the 1.6m Anchors are drilled INSIDE the end of the tunnel, between the first two smaller anchors.

1.1m from Small Anchor 1.6m Anchor (Halfway between the first two anchors)

This leaves a clear headland. The 1.6m Anchor here, also needs to be drilled at 45 degrees.

Tip- Drill all anchors before you start standing legs, this makes it easier to move around the field.
Internal Anchors The smaller Anchor is the same unit for the 40mm and 60mm legs :-

It is designed to be drilled with a normal tunnel leg drilling machine. It is important to remember when drilling the anchors, they must account for the gutter in the tunnel legs.

Trellis System

It is vital to understand the importance of accurately drilled legs for this system to work.
It is important for the leg to slope with the field, but also for this slope to be in a straight line. We recommend a minimum slope of 2%, even on flat fields... To create this the anchors at the base of the field may need to be drilled more deeply than those at the top. But, those at the top should never be drilled less deeply than the standard 75cm drill depth It is important to understand also, that we recommend a maximum distance along the fall, in any one direction of 50m, before an interim down pipe bracket to remove water from the structure. Field conditions are rarely flat, even if they are level. It is best to ignore the small variations in topography, while at the same time working with the larger ones.

See Diagram Overleaf:Use a Builders Brick-Laying line to set the anchors in a straight line (Braided Nylon is best, definitely not a heavy rope as it will curve under its own weight) This works best over a section of 10 legs. At 2.2m spacing, the height difference between Leg 1 and Leg 11 would be 2% of 22m, ie 0.44m or 44cm.

This is most simply checked with a water level :A translucent tube with water inside to get a level-line, and measure from this.

If you are in any doubt, please ask for Technical Support.

Trellis System

Trellis System

Legs On a sloping field, legs of the same length as the trellis height will have been supplied eg, 2.25m legs for 2.25m trellis height. If building on a flat site, longer legs may have been supplied to allow trellis height to be maintained, then, anchors need to be drilled more deeply to create gutter fall, eg, 2.75m legs allow for a MINIMUM trellis height of 2.25m with a 2% slope over 25m in any one direction. 60mm legs are used on the perimeter leg row and the first two legs in every leg row.

40mm Legs on internal lines 60mm Legs on perimeter lines

60mm Legs at First 2 and Last 2 positions

Each leg must be bolted to its anchor and leg top.

NB, Mount all the Leg Tops in the same direction, ie with the mounting bolt on the same side, across the whole field, this will make it easier to run cables later.

Trellis System

End Kits The Trellis System End Kit is always built on 2.2m leg spacing.

The First two legs are 60mm diameter, between these are 2.2m Telescopic Struts, comprising a 35mm (male) and 40mm (female). They are mounted on clamps on the legs, in an X formation.

Trellis System

Ensure the legs are vertical, and using the pre-drilled holes (in the 40mm section) as a guide, drill through the 35mm tube, thus setting the length. Insert the bolt provided and tighten in-place. Between the first two legs, there is also a 1.5m telescopic Strut, again, comprising 35mm (male) and 40mm (female) sections. These are fitted in the same way as the X strut, but mounted HORIZONTALLY b etween legs 1 & 2. Note how the telescopic strut connects to the Termination leg, this allows use of the Down Pipe.

1.5m Telescopic Strut mounted horizontally

2.2m Telescopic Strut mounted in X

Hoop Struts are 2.5m and 2.2m long. 2.2m struts go at the apex of the tunnel, between hoop 1 & hoop 2 then between hoop 2 & hoop 3, The 2.5m struts are fixed in to the hoops as shown on drawing

Trellis System

Installing Leg Row Cables

Installing the leg row cables along the leg rows allows the legs to be held strongly, making it easier to put the hoops on. Run out the cable from one end of the tunnel, from the drum, without it

twisting, then cut to length (this can easily be done with a sharp chisel) :-

The cable runs through the clamps on the leg tops (to left or right, but the same side for the whole leg row)

Trellis System

Tensioning Cables
Secure the cable to the Cable Tensioner, which is itself connected via the DShackle to the 1.6m Anchor

The tensioner has an integral ratchet to help tightening but it is important to use the Trellis Tension Kit to pull the cable REALLY TIGHT:-

With the cables tight, check each leg for vertical and tighten the lower nut, this will leave the upper nut and gutter clamps loose, ready to have the gutter installed later.

Hoops and Top Bracing

With the Legs, Leg Row Cables and End Kits in place, it is possible to start installing the Hoops and top Bracing. Start at one end of the field (if the field slopes, start at the lower end). Ideally, you would install all the hoops then the top rail. It may be that the hoops will not stand straight, in which case, stand a few hoops on the legs and install one piece of Top Bracing. If you start from one end, with a fixed End Kit, the Top Bracing will support the hoops.

Trellis System

Top Bracing The Top Bracing is clamped to every hoop continuously, through the centre of the tunnel at the top of the hoop, using twist droppers to give space for the polythene to be tensioned by the ropes. The twist dropper is attached to the hoop by locating a bolt through the two halves and attached at the other end to the top bracing with a second bolt, both supplied.
2.2m Struts

Twist Dropper

Rail End Clamp

Rail Joiner

When positioning the Twist Droppers, pull a tight string along the top of the tunnel to ensure the rail will be straight. The lengths of top bracing are fixed together with joiners. If a joint in the rail falls immediately under a hoop, simply cut the one rail short so the joiner is just to one side of the hoop. NEVER leave an unconnected Hoop/Rail.

Gutter Installation See 4 Series Gutter Manual Section

Trellis System

Cross Cabling Tip - After the cross cables are installed, it is more difficult to move large machinery within the tunnels, so plan through this first.
Cross cables are installed all the way from one side of the block to the other side, similarly to the Leg-Row cables. At the legs, this cable is passed through the grips on the 10mm bolt :-

Leg Row Cable

Cross Cable

At the Perimeter 60mm posts, the cable passes through the post, but first the Trellis Cable Sleeve must be installed through the Post and the Leg Top :-

Bend down, with hammer

Trellis System

BEFORE tightening the cross cables, it is ESSENTIAL to install the Anchor cables. These run from the top of the 60mm Perimeter leg down to the 1.6m Anchor. Use a single length of 6mm cable and create a loop at each end by using the 6mm Cable Grips (2 per loop). One loop connects the Cable to the Anchor,
Cross Cable 2 Cable Grips at each end

Anchor Cable

When the cable is finished, it should hold the 60mm Perimeter Leg vertical, so it is normal to install the Anchor Cable slightly shorter than needed, to allow it to settle. When tightening the cables, ensure the Perimeter Leg remains vertical. Pull the cable with the Cable Tensioning Kit as before, and complete with the ratchet Tensioner.
NOTE :- It is important to bend the end of the cable sleeve over, this prevents it falling out, and more importantly, prevents the Cross Cable Chaffing on the Sleeve end.

Trellis System

Mid Support System Some heavy crops require additional support along the centre of the tunnel. Although this can be done with timber poles, the system may have been specified with steel. If this is the case, mark-out the positions for the Ground Spike at the same time as marking the anchors (see Field Layout). The spike is not drilled in to the ground, but rests on top, with the Support Plate. For tunnels on level ground, where the legs are drilled more deeply to create gutter slope, some Mid Support Poles may appear too long. Simply, cut the pole to length or dig a small hole to allow the plate in to the ground. The Cross Cable must run in, as close to a straight line, as possible, all across the field.

At the top of the 40mm Mid-Support Pole, is the Cable Assembly Unit (TA00073). This is connects the leg/pole to the Cross and Mid-Support Cables

Trellis System

Item
1 2 3 4 5 6 7

Description
M10 Hex Nut Washer, Dia.44mm M10 x 50 Hex Bolt Washer, Dia.34mm M10 x 100, Eye Bolt Washer, M10 Cable Grips TP00337

Quantity per Unit

4 1 1 2 1 1 4

To terminate the Mid Support Cable, use a 60mm Perimeter Leg and large 1.6m Anchor. The Leg must have the addition of a Cable Assembly Unit, 60mm TA00092. This allows connection of the Mid Support Cable to the Cross Cable and the 60mm Leg, but it also has a plate to protect the Mid-Cable from any sharp edges on the Leg:-

Trellis System

Item
1 2 3 4 5 6 7 8 9

Description
M10 Hex Nut Washer, Dia.64mm TP00339 Cable Grips TP00337 M10 x 50 Hex Bolt Washer, Dia.52mm TP00338 Eye Bolt, M10 x 100 Eye Bolt,M10 x 30, TP00382 Flat Plate, TO00383 Washer, M10 XL Plain

Quantity per Unit

5 1 4 1 2 1 1 1 1

Even if the Mid Support Cable is not installed, use the extra 60mm Perimeter Legs on the penultimate Cross Cable to prevent that cross cable moving sideways under load.

NOTE -Any horizontal trellis wires (running along the tunnel above the trellis system) should be fixed to EVERY Cross Cable, this can be done with small grips/clamps or simply by twisting the support wire around the Cross Cables. This helps spread the load and makes the structure stronger.
Trellis System