Portable Farms Aquaponics System Course Assembly Manual. Section H Part B

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1 13 Portable Farms Aquaponics System Course Assembly Manual Section H Part B From Aquaponics University, a Division of PFAS LLC Colle Davis, ALL RIGHTS RESERVED Utility Patent Application Filed December 24, The leg adjustors are simply sections of 2x4 cut to 10 to 14 inches long and screwed to the bottom end of each leg with three or four screws in a wide pattern. The actual leveling of the Grow Table is done using a bottle jack or similar heavy duty jack to raise the Grow Table enough to unscrew the leg adjustor, move it down to be tight against the floor and refasten it b with the screws. When the jack is released and the leg will take up the strain and stay solid and safe under the Grow Table. LEVELING the Grow Table: Start at the highest point on the floor where the Grow Table is to be located and use this point as the shortest leg length of the set supporting the Grow Table. This may or may not be at one end. [If this HIGH point in NOT at an end, then level the Grow Table to the closest end and proceed to level the entire Grow Table from that end point.] Then moving out from this point make sure the Grow Table is leveled using this initial point as reference. Two helpful guidelines: 1) level as you move along the long side of the Grow Table from this high point and 2) Level across the Grow Table at the same time so both sides stay level with each other. Be prepared to go through the entire process more than once. Also be prepared to re-level the Grow Table later if the surface under it is anything except poured concrete. This may be necessary after the gravel is installed, hence the reference to a heavy duty jack (we use a 12 ton bottle jack). Any flooring that is not concrete will settle over time. Gravel, patio blocks, cobble stones and ever concrete blocks or pavers will settle over time and become uneven. A final visual reality check in done by looking down along the side of the Grow Table to see how beautifully level and straight it is after all of your hard work. Hint: If the person building your Grow Table is unfamiliar with the use of a 4 foot level, have another person check their work. If your Grow Table is more than 4 wide use a very straight 2x4 across the Grow Table and set the 4 level on top of that to insure consistency in the reference point. This leveling of the Grow Table is absolutely critical to the successful operation of your Portable Farms Aquaponics Systems installation. The Photos above show the wide variety of legs that can be fashioned and that work well for most situations. Photo 41 show how these set of legs under the Grow Table that were under

2 14 build (hence the mistake ) and shows how the legs were placed too far apart for the type of construction and a cripple or extra leg and cross member had to be placed under the middle of the Grow Table to keep it from sagging and having the water pool and stagnate in the center. Pond Liner: Begin installing the Pond Liner at the head end of the Grow Table. For clarity, we are designating this end of the Grow Table as the one at the opposite end from the Fish Tank. Please note, this does not necessarily mean the end next to the Clarifier which may be over the Fish Tank and/or at the opposite end from the head of the Grow Table. The Head of the Grow Table is the opposite end from where the ATV is to be located and the foot or end of the Grow Table is where the water flows out through the ATV and back into the Fish Tank. SECOND NOTE: Do not staple the foot end of the liner until you have completed the ATV installation. Install the Pond Liner carefully so there are no wrinkles or ridges in it over its entire surface. There will be folds in the corners and these will be made as flat as possible. Make sure there is an overlap on the sides and ends to allow the pond liner to be fastened down using the 1x2 strips screwed or nailed down through the liner into the side pieces. See Photos 43 and 44 below. Photo 45: Placing Pond liner in Grow Table Photo 46: Notice fold required to square corner Carefully work out all of the wrinkles in the pond liner as you finish installing it in the Grow Table. Fasten the liner in place initially with staples and finally by installing the top pieces of trim where the Pond Liner overlap the sides. These trim pieces can be fasten it down with screws or small finish nails. To greatly facilitate keeping the creases and folds out of the Pond Liner we suggest you use three 2x 4 or 2x 6 s almost as long as the end and side to temporarily hold the Pond Liner firmly against the walls of the Grow Table as you fasten it to the top of the rails. (Photo 47)

3 15 Start at the end away from the Fish Tank and securing the long side of the Grow Table FIRST with staples (with the end material generally in place with enough extra over lapping on all sides to insure a good fit). Then the head (short) end is secured with staples (we have an air powered staple gun, but a heavy duty hand stapler is plenty adequate). Fasten the long side AFTER PULLING THE POND LINER TIGHT ON BOTH SIDES WITH THE 2x s to insure no wrinkles or ridges. Photo 47: 2x4 and 2x6 holding liner tight Photo 48: Liner in place and secured before gravel installed There is an extra upright on the edge of the Grow Table in these Photos (see white arrows), it is to support the roof and trellis holding the shade cloth and the plastic sheeting to keep the rain and sun off the plants. This addition can be done after the Grow Table is finished, but before the top 1x2 trim pieces are in place. Photo 49: Pond Liner secured to long side w/staples Photo 50: Fold back Pond Liner to achieve flat corner

4 16 Photo 51: Another view showing hard crease in corner Photo 52: First Corner before stapling The subsequent corners take a little more work but essentially it is the same process. Fold the liner into itself with the fold on the wood side, liner forced against the bottom, against each side, into the corner and secured to the top of the rail. Photo 53: Fold before being tucked BEHIND Liner Photo 54: Liner squared, tucked and stapled Photo 55: Finished pond liner installation Photo 56: Finished installation w/pond liner just visible at edges

5 17 After installing the pond liner correctly in the Grow Table and leaving the foot end unfastened, use the following picture sequence to install the ATV. Carefully fold back the pond liner from the corner (Photo 57 below) where you are going to install the 3 inch Insert. Fold back 12 to 18 inches of the pond liner and tape it to the bottom and sides of the Grow Table so that no sawdust can get under the liner. See Photo 57 and 58. Photo 57 Fold back of liner for Insert Photo 58 Taped liner to keep sawdust out The only opening in the Grow Table is where the 3 Insert holding the ATV is placed in the bottom to return water to the Fish Tank or as we will refer to it as the bottom/foot end of the tray. The insert is normally placed approximately 6 inches in from the end and 6 inches from the side of the Grow Table so it can easily be kept clear of plant roots. See Photo 57 and 58. The ATV can be placed anywhere in this area and can even be offset from the Fish Tank and have a length of ½ PVC pipe running to the Fish Tank Photo 59: Showing the most common location for the Fish Tank and in this instance the ATV is directly behind the arrow and the water can easily return to the Fish Tank.

6 18 In the Photo 59 above the head of the Grow Table is the furthest away from you and the bottom end is directly over the Fish Tank. The ATV return pipe is a short straight piece of PVC dumping the water directly back into the Fish Tank. The placement of the Fish Tank is not restricted to the ends and as long as there is sufficient drop of two inches to the maximum water level in the Fish Tank for the return line from the ATV to let the water flow easily, it can be placed almost anywhere. Under the mid- section also allows for a longer GROW TABLE is most installations. Photo 60: 3 Plastic Insert w/fitting Photo 61: Placement locations for Plastic Insert Drill a 3 inch (76mm) (Photo 61) hole through the plywood bottom with a 3 hole saw (Photo 62) approximately 6 inches from the side and 6 inches from the end of the Grow Table. Be very sure you are not trying to drill the hole through any of the underpinning lumber. Photo 63. Photo 62 3 (76mm) Hole saw Photo 63: Finished hole for 3 inch Plastic Insert

7 19 Then carefully clean all of the sawdust out of the Grow Table. (A shop vacuum cleaner works very well for this task.) Gently lay the pond liner back in place and carefully mark the exact opening where the 3 inch hole in the bottom plywood has been drilled. [Pressing the edge of the hole with your thumb gives the dented appearance you see below in Photo 64] Using a sharp instrument, a sharp set of shears work well or a box cutter, carefully cut out the 3 inch hole in the pond liner. Make sure the two holes (the one in the bottom of the Grow Table and the one in the pond liner) line up correctly. Please take your time doing this step. If you screw this up, you have to start over with the pond liner either repaired or a new one. Not a pretty picture either way. Be patient, go slowly, and measure several times before you cut. Photo 64 Marking for the hole in liner Photo 65 Cutting hole in liner After cleaning the area where the insert will be installed in the plywood, pull the pond liner back out of the way again and place a liberal coating of silicon seal on the inside edge of the 3 inch hole in the plywood. Then place a bead of silicon seal around the top of the hole so when the pond liner material is laid on it there will be sufficient material to seal the two materials together. Now, carefully lay the pond liner back in place with the two holes lined up. Next place a bead of silicon seal around the underside of the lip on the outside of the Plastic Insert. Photo 67. Photo 66: Finished hole in liner Photo 67: Silicone seal inside and on top of opening

8 20 Notice in Photo 65 above that the top rails are already in place. There were two crews working and they simply installed the pond liner over the hole and put on the trim pieces. The guy cutting the hole is our construction engineer and project lead. He has nearly 40 years of construction experience so cutting the hole was quick and easy for him. Photo 68 Silicone on the ridge of the Insert Photo 69 Insert driver in place Now carefully place the 3 Plastic Insert onto the hole. Do not try to force it at this point, it tends not slide into the hole easily. Occasionally it is because the inserts are not all exactly the same size. If the insert that you have slides in easily, smile and then press it very firmly into place and let it dry for at least 8 hours (Photo 69). There are several methods for driving the Plastic Insert into place. The one we use is to place a short piece of 2x4 flat on the top of the level Insert and hit in squarely with a hammer to drive it into the 3 inch hole. [The inserts are now shipped with the threaded fitting already installed in them so be very careful when you lay the 2x4 across the insert to strike it, you may have to drill a relief hole for the fitting.] The hole is exactly the same diameter as the Plastic Insert and forcing the Insert into the hole with the silicon seal creates a very secure and long lasting water tight seal. Photo 70 Plastic Insert In place Photo 71: Insert with threaded male fitting

9 21 When the Insert is in place, spread out the Silicon Seal to make a smooth transition from the bottom of the pond liner to the top lip of the Insert and allow eight hours to cure. [Side note here: Once the gravel is in place, you NEVER have to clean it or remove it. The ONLY time you may have to remove it is if you poke a hole in the liner somehow, so be careful.] Photo 72: ATV in place over Insert (pre shield) Please Note: The ATV (Photo 72) is not for sale as a separate item. It is only available as part of a PFAS Kit. If you are going to use a deeper GROW TABLE please let us know so we can adjust the height. The new ATV assembly uses a white insert, come assembled and you will have to be careful when inserting it into the 3 hole. You can easily disassemble the ATV from the mounting assembly insert. Shield installation: This step and additional technology are new components of the Grow Table. The plastic coffee can shield is just that, a plastic coffee can of the 2 pound size. Brand is not important, being plastic and the right size is important. First step is to drill 10 to 14 holes of ½ to ¾ size near the bottom of the can as shown in the Photos below. More holes are better. If you are not really handy drilling large holes, drill 12 to 18 slightly smaller holes. The hole in the center of the bottom of the can is 3 inches in diameter and done with a 3 inch hole saw, running slowly and carefully. The hole can also be cut out with a sharp knife or scissors. Interestingly most coffee cans have this size indent in the bottom.

10 22 Notice the ridges in the bottom of most plastic cans, they are there for strength. They also allow water to flow under the can, but are not large enough amount of water for the ATV to work properly. [Tiny cheat, once installed you can lift the shield slightly and it will settle back down on the small gravel and create a much large flow are at the bottom.] More holes are better. The insert holding the ATV in place is where the large hole in the bottom of the Shield will rest. Having enough holes in the Shield insures the water will flow in through the Shield fast enough to allow the ATV to function properly. The Shield also keeps the bottom of the ATV much cleaner than being buried in the gravel. Note: The Photos shown here are of a retrofit of an installation. If you are doing a retrofit, carefully clear the gravel away from the ATV, remove the ATV, clean it thoroughly including the weep hole and reinstall it AFTER the Shield is in place. The ATV works so well that it rarely has to be accessed, BUT we have found that over time the weep hole can become clogged and prevent the Grow Table from completely draining on each cycle. The new Shield allows the water to flow much faster next to the ATV and no gunk or debris accumulates now. Lifting the top off of the coffee can Shield to check it occasionally is a now maintenance item. The occasional errant root can also be clipped off easily should one reach the Shield. Photo 73: Coffee can Shield Photo 74: 3 inch hole in bottom, first side holes There are two different Shields pictured here. The one in Photo 74 was installed in a Portable Farms Junior Aquaponics System. The one is Photo 75 was used in a retro fit on an existing Portable Farms installation.

11 23 Photo 75: Second row of ¾ holes Photo 76: Shield installed (note this is a retrofit) Photo 77: Shield with ATV in place on insert Photo 78: Completed Shield in Grow Table Photo 79: ATV after 4 months in cleaned gravel Photo 80: Note gunk and fine sand on bottom The addition of the Shield to house the ATV will help insure the proper functioning of your Portable Farms for many years. NEW PROCESS:

12 24 Photo 80 Extension in place IMPORTANT: Shield around ATV allows you to chase out ants and other bugs Using the coffee can Shield to surround the ATV allows for the flooding of the Grow Table occasionally to remove any bugs who are in the gravel in the Grow Table. This procedure MAY become necessary if you have ants, aphids, earwigs and other undesirables in the gravel in the Grow Table. Using this routine on an annual or more often basis is an excellent way to insure you are not hosting unknown creatures in the Grow Table(s). 1. Remove the shield top 2. Carefully remove the ATV 3. Attach a threaded female fitting to a short length (6 to 8 ) of ½ PVC 4. Attach the threaded female fitting end to the threaded male fitting in the ATV mount 5. Turn on the CAD Pump and fill the Grow Table to the point of just overflowing 6. Turn off the CAD Pump timer or unplug the air pump 7. With the Fish Friendly Insect Control ready, begin to spray the bugs as they emerge 8. Allow the Grow Table stand full of water for 4 to 8 hours 9. Return several time to check for more bugs and spray if needed 10. Remove the short length of PVC and the threaded female fitting and reinstall the ATV (the ATV will trip and drain the water back into the Fish Tank as usual) 11. Turn the timer back on for the CAD Pump or plug in the air pump again 12. Replace the Shield cover 13. Clean off the surfaces of the Grow Table edges 14. Clean up any water that may have leaked onto the floor. GRAVEL The gravel used in the Grow Table is ¾ inch crushed double-washed gravel that you have carefully washed and screened using a ½ inch hardware cloth screen to remove the small gravel and sand. Washing and screening can be done in the same process and this task is the heaviest, messiest part of the construction. [River gravel can also be used and is nearly always cleaner to

13 25 begin with, but does need to be cleaned.] Do not rush this step. Clean gravel of ¾ inch size gravel is very important for the successful operation of the PFAS. There are some very creative methods of cleaning the gravel. Photo 81. A very quick way to wash the gravel is with a cement mixer. Load the mixer with gravel, run a hose it to wash the gravel and dump it out through a screen like in Photo 81. Photo 81 - ½ Hardware cloth - Gravel screen Photo 82 ¾ screened and washed gravel When placing the washed and screened gravel into the Grow Table, make sure to keep the finished gravel level. Fill the Grow Table with gravel up to the top of the pond liner in the Grow Table, not to the top of the trim pieces see Photo 82. When the water is running through the gravel it will not be visible, even when the tray starts to drain from its maximum water level. The ATV is specifically designed for the correct water level and when installed correctly and having the gravel level with the top of the pond liner on the sides will result in the system cycling to exact specifications. If you see water above the gravel, place more gravel over the spot so you cannot see the water. Water exposed to the light will create an algae problem. Make sure the water is never visible. The ATV used in the PFAS is calibrated to work with the specifications covered in this manual and needs only to be installed (screwed down securely on the ½ inch threaded male fitting coming up through the Plastic Insert) and which is connected to the Return Line to work properly. Be careful when installing the ATV onto the ½ inch threaded male fitting that you do not over tighten it and force the male fitting to turn in the Insert. This may break the seal and cause the fitting to leak. PFAS LLC does NOT SELL the ATV as a separate item. The drain line from the ATV into the Fish Tank MUST NOT TOUCH THE WATER or it will not work correctly. Placing a 45 degree elbow on the bottom end also helps to swirl the water in the Fish Tank.

14 26 There you have it, your very own Grow Table assembly procedure taken from the incredibly efficient and effective Portable Farms Aquaponics System. The rest is up to you. If you are relatively handy with tools, can follow directions well and have some space on your patio, backyard, rooftop, or driveway, you can have a Grow Table up and running is a few hours. Let me know how Grow Tables work out. Please send us some pictures and we ll compare notes. For commercial installations PFAS LLC does all of the Module installations. The greenhouses have to be installed and functional, the utilities will be in place and the materials to build the Modules will be on-site before we send in our crew. Contact us for more information on Commercial Installations. Let me know how Grow Tables work out. Send me some pictures and we ll compare notes. PLEASE NOTE: As a reminder, after satisfactory completion of the Coursework from Aquaponics University, you will then be eligible for six s and two phone calls of technical support for your installation within a year of date of purchase. After you have taken advantage of your six s and two phone calls or after a year has passed from the date of purchase, calls to us with questions are billed at $95 per call no matter how long the call runs and s with questions are $35 per .