2 HYDRANTULA BATCH ASSEMBLY: THE BASICS 1. LOCATION OF ASSEMBLY PLANT 1.1 When choosing a location for your assembly plant, prioritize locations near large bodies of water, or in close proximity to them if they allow for launching and transportation of oversized cargo up to the shore line. 1.2 If the assembly plant cannot be located near water, prioritize locations near multilane highways with easy access for large lowbed semi-trailers (up to 20 m). 1.3 Locations near HDPE pipe manufacturing facilities are also highly preferable.

3 1.4 The minimum temperature for polyethylene assembly is +10℃. Use a warm shop when operating in colder climates, or perform assembly seasonally. 2. ASSEMBLY SLAB (CANOPY). 2.1 Assembly should be done on a perfectly flat, horizontal concrete slab (berth) with the following dimensions: * Slab width: 200-250% of the structure’s max. required width. * Slab length: may be less under 200% of the structure’s length (but no less than 150%) provided there is a sufficiently flat area always available near the concrete slab that is approximately level with it and has at least 100% of the structure’s max. length (for installing long bars during assembly). When assembling in a cold climate, the length of the warm shop must be 220% of the structure’s maximum length. However, 50% of its area may have ceilings 3-4 m in height and without telpher coverage. 2.2 When assembling in a windy, rainy, or hot climate, assemble the structure under a canopy or in a cold shop rather than out in the open. Canopy height must be 250$ of the structure’s maximum width and height (depending on which is higher). The canopy must be equipped with an electric telpher on a fixed rail at the center of the canopy. The telpher (hoist) must have a bearing load 180-230% of the structure’s max. weight. (Recommended bearing load: 8-10 t). It is also recommended to have a second hoist on a movable beam with a bearing load of 3-5 t. 2.3 Based on the above, the optimal canopy size for most applications is 24x12 m with a height of 10-12 m to the upper telpher level.

4 When assembling in an open area, ensure regular access to a mobile crane or a crane truck. 2.4 The slab must have mounting rings with at least 4 t of bearing load and 180-250 cm orthogonal increment embedded flush into it. These rings are used for mounting hoists and locking HYDRANTULA fittings during assembly. The berth should have at least four 220V 20-25A double sockets and possibly three-pin sockets (if 380V tools are used). They should also be equipped with floodlights for work during nighttime. 2.5 The site or the canopy must have structural concrete columns at least 80 cm high with several rings (at 20 cm increments) suitable for mounting hoists horizontally. All mounts must have a bearing load of at least 5-6 t. The columns must be installed at 2-3 m increments from one long and one short edge of the slab or canopy and must not obstruct access for lowbed semi-trailers and cranes or hinder transportation of the assembled structure. It is recommended to install supports on the outer side of the columns to organize storage of bars and pipes with long stock length. 2.6 The slab may be marked out in squares with 1 m increments for convenience’s sake. 3. GENERAL PROCESS STEPS: OFFICE: 3.1 Measure the bottom. 3.2 Design the individual structure as a 3D object in STEP or GLB format, or choose a standard structure from the catalog. 3.3 Prepare estimates (BIM), 3D mock-ups and color samples for the customer, purchasers, and shop personnel.

5 3.4 Draw up blueprints and measure out pipes and fittings for shop personnel. Personnel: 1 person WAREHOUSE: 3.5 Provide the shop with pipes, rebar, and fittings from contractors or from your own warehouse. 3.6 Label the fittings and pipes with a white marker. Personnel: 1 person. SHOP: 3.7 Assemble reinforcement cages from rings and rebar. Personnel: 2 people. It is recommended to use composite or stainless-steel rebar cages tied with wire.

6 For form pipes placed in freshwater above the waterline, (epoxied or galvanized) steel rebar may be used. Standard steel rebar or welded rebar stacks will shorten the structure’s service life. 3.8 Prepare fittings (drill pipelines) and weld the edges of structural columns. Also weld expendable concrete wire. Personnel: 2 people 3.9 Assemble the structure planes onto bars and weld the edges. Personnel: 2 people To be performed on the main or smaller berth. The smaller berth should be used if the main berth is under heavy load. The smaller berth must be 200% of the structure’s max width and 150% of the structure’s max height. Also ensure that the berth has a solid, clean and flat surface area for “storing” the planes

7 3.10 Install the 3D structure onto the bars and butter them with an extruder. To be performed on the main berth. Personnel: 3 people. 3.11 Transport or tow the structure to the customer. Personnel: 1-2 people. 3.12 Shop capacity is approximately 1 structure per 3-4 days with fully paralleled production (personnel: 11-12 people) Production time of an individual structure is 9-12 days from delivery of all the materials to the shop and approval of the 3D mock-up. 3.13 With a minimum-sized team of 4 people, shop capacity is 1 structure per 20 days, production time is 20 days. 4. DELIVERY OPTIONS FROM HYDRANTULA: 4.1 HYDRANTULA offers delivery of fittings, colored columns and colored cross bracings, as well as composite rings on demand (BIM) by shipping companies in returnable 90x90x160cm or 100x100x150cm big bags in quantities corresponding to the big bag’s volume. 4.2 L bars are shipped as oversized cargo (stock length). 4.3 We do not ship bars (or any pipes longer than 220cm) or composite rebar in stock length or in rolls.

8 5. REQUIRED SHOP TOOLS AND EQUIPMENT: 5.1 Pipe butt fusion welder for ∅315 or larger 5.2 Portable butt fusion welder for ∅160 5.3 Hand pipe cutter for ∅90-∅315 or larger 5.4 Hi_Jack rack jack 1.2m or larger 5.5 Jigsaw 5.6 Hand polyethylene extruder. 5.7 Angle grinder 5.8 Mixing drill 5.9 Drill 5.10 Welder* (for stainless rebar only) 5.11 Manual hoist 5.12 Slings in various sizes 6. OPTIONS FOR STRUCTURE DELIVERY TO CUSTOMERS: 6.1 By lowbed semi-truck on public road. 6.2 By barge (Barge drop) 6.3 Towed in semi-submerged state. 6.4 By truck in semi-manufactured state (as planes) with further assembly onshore near the installation site 7. METHODS OF ASSEMBLY: 7.1 100% shop assembly 7.2 Assembly of 3D sections within cargo dimension limits for truck delivery with further assembly onshore near the installation site 7.3 Assembly of planes with further assembly onshore near the installation site.

9 CONCRETE MIX FOR HYDRANTULA STRUCTURES The exact mix depends on the type of water (fresh water, sea water), climate zone (whether the body of water freezes or not), rheological requirements for fresh concrete, as well as availability of raw materials (pozzolana, aluminate cement) THE MOST UNIVERSAL MIX: Sulfate-resistant cement M500 - 495 kg/m3 5/10 crushed stone - 1,100 kg/m3 Sand - 640 kg/m³ Microsilica - 18 kg/m³ Superplastificator - as per manual Hydrophobic agent - as per manual Adhering silicon agent - optional Water - as per rheological data Fibra basalt - 600g/m³ or Inox metal - 15-20 kg/m³ (optional)

10 1. WATER AREA SURVEY 1.1 First, it is necessary to survey the boundaries of the water area, in which marine construction is allowed. These boundaries are generally defined by the boundaries of a seafront lot or in a waterbody lease agreement. 1.2 Then determine minimum distances from the water area’s boundaries for various types of hydrotechnical structures to establish a construction footprint. 1.3 Measure the depth and bottom slope within the selected part of the water area. 1.4 Also collect data on the bottom soil to find its approximate bearing capacity and erodibility. Also determine the size of large “random” rocks that may hinder installation. 1.5 Study the possibility of ice drift in case the body of water freezes in winter.. 2. Determine the type of the hydrotechnical structure you wish to build and its additional functions and recreational capabilities. 2.1 Find a local contractor, handyman, or a construction team for DIY work. 2.2 Find a HYDRANTULA dealer. 2.3 Consult with the dealer and choose the fitting models you wish to build. 3. Order the models from the HYDRANTULA dealer directly or via a contractor and decide on rebar and plastic pipe shipments.

11 HYDRANTULA MATERIALS The non-removable HYDRANTULA formwork is made from HDPE and MDPE - two types of food grade polyethylene. Although plastic may not sound like a very green material at first, in this case it is the safest and most environmentally friendly option. 1. Unlike wood, HYDRANTULA does not need toxic treatment for a longer service life in water. Untreated wood will rot away in freshwater in 10-15 years. And in seawater, it will be destroyed by shipworms in 5-8 years. Only rare and expensive types of tropical wood (teak, ipe) are relatively resistant. As a result, wood is increasingly treated with agents containing heavy metals, organic toxins or hazardous petroleum residues. 2. HYDRANTULA does not emit ions of heavy metals (Zn, Mn, Cu, Cr) into water, unlike galvanized steel or marine grade aluminum alloys. These ions make water undrinkable and reduce the biological productivity of many organisms. 3. HYDRANTULA structures are not a major source of microplastics. Over 88% of all microplastics in the ocean comes from plastic wraps and synthetic fibers (propylene rope, discarded fishing nets, synthetic fabrics and nonwoven materials, such as wet wipes). Another 10% comes from plastic bottles and disposable tableware. In general, about 99% of all microplastics in the ocean is generated by domestic waste, composite materials, and fishing nets. Massive plastic structures degrade a hundred times slower and do not pollute water as much with microplastics.

12 X-DAY So, your structure is assembled and is near the installation site. It may stand on the beach or in water. If it has been transported on a lowbed truck or a flatbed with a loader crane, or fully assembled on the beach, all you will need to do is submerge it into water: 1. Lower it into water with a crane right into its final place. To do so, you will need a powerful crane with a long boom at the shore line (in other words, the crane must drive onto the beach or the embankment). This will require a prepared “last mile” of the rode. Alternatively, place the structure in water near the required installation site in such a way so that it floats and does not topple over. The structure’s total internal volume is generally 4-5 times larger than its weight, so it will barely submerge (less than 25% of it will be underwater) and will not be stable enough if it is fully sealed. Pouring concrete into a fully sealed and floating form will be very difficult; the structure will very likely topple over. As such, forms are generally made with many holes so that they could better submerge. HYDRANTULA structures have near-zero buoyancy when filled (they are slightly lighter or slightly heavier than water). As a result, the natural immersion level of such structure is definitely higher than its design installation depth. Because of the higher immersion level, they will be impossible to tow to the installation site. Submerged structures require several pontoon to keep the immersion level moderate (knowingly less than their installation depth). 3. HYDRANTULA has a special F200 fitting for precise mounting of blue plastic barrels with

13 217 L of volume to the structure’s beams as removable pontoons. Several of such barrels placed properly at the required height will ensure sufficient immersion and stability of the entire structure. 217L barrels have bung holes with special valves that allow to slowly “bleed” the air out of them and ensure gradual “immersion” of the structure to the bottom. Barrels without any air will have minimum buoyancy and can be easily removed from the F200 fitting hoop and dragged onto the beach. 4. In calm water areas, the assembled form with 217L barrels installed above the structure’s midpoint (height wise) can be towed by a motorboat or a jet ski to a sufficient distance, which helps avoid coordinating transportation of oversized cargo on public roads. 5. In case of installation on the sea, the structure can be transported on top of a barge (incl. with heavy construction equipment), or towed in semi-submerged state as described in above in item 4. 6. The structure can be unloaded from the barge with a built-in crane or an excavator with a sufficiently far bucket outreach. Alternatively, you can use a mobile crane on the shore or drop the structure by tying it to the shore and sending the barge astern. 7. Warning! Dropping the barge can be dangerous and may lead to the form toppling over or cause injury to the personnel involved in the operation. It is recommended to use trolley jacks or wheeled carts to make it easier to drag the structure overboard. Keep in mind that the jacks or carts may be damaged or lost (sunk) as a result of this.

14 8. For all installation methods except for precise installation into the site with a crane, it is recommended to weld the F200 fitting to the structure beforehand so that it could be moved in case the first attempt to install the structure is unsuccessful. 9. Once the structure is installed in its final position, it is strongly recommended to have snorkel or scuba divers perform a total check of the structure for signs of any mechanical damage, deformation, bent pipes, large rocks hitting the structure’s horizontal beams or struts, or the structure’s spans being suspended without touching the bottom. Make sure there is no excessive tilting or buckling of any of the form’s elements. Also pay attention to any loose parts, ruptured weld seams, fallen out composite rods or unlocked concrete wire clamps. 10. Proceed to pouring in concrete only once you are absolutely sure the formwork is technically sealed (has acceptable expected volume of fresh concrete leakage) and can withstand the weight of fresh concrete without destruction, toppling over, or excessive deformation. 11. For systems with height adjustable struts, adjust them to the bottom features. 12. If concrete cannot be poured in immediately, it is recommended to add ballast to the structure (with a total weight of 200-300% of the structure’s own weight in air)

15 to avoid it being dragged across the bottom, toppled over, or caried away by a wave into open sea during a storm. 13. The part of the concrete line to be submerged when pouring concrete must be mounted on the shore in advance. 14. HYDRANTULA structures are compatible with standard cast-iron concrete lines, high- durability rubber hoses, and single-use concrete lines with special HYDRANTULA D2, D3 fittings and a plastic HDPE pipe or ∅150 fire hoses and a J5 fitting. Hybrid concrete lines with sections of various types may also be used. 15. All basic HYDRANTULA fittings (except for R3) have flanges compatible with Groovelock 5½ or 4½. Some of the fittings are also equipped with a Camlock 75 interface. 16. When installing structures in areas where high-slump concrete cannot be delivered (the nearest batch plant is over 90-120 min away) or local batch plants do not provide concrete of a sufficient enough quality, make concrete on-site from previously brought-in materials using your own portable mixers. 17. The concrete mix proportions depend on water salinity, climate, required longevity of the structure, the reinforcement quality of the formwork’s cavities, and the concrete pump’s specifications.

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