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ClearSpan Pro Solar Star R035 Manual

Greenhouse
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ClearSpan
™
Pro Solar Star
Greenhouse
™
Corrugated Polycarbonate
Photo may show a building of a different length. Frame is shown with an optional end wall and customer-
supplied baseboards. End wall is not included and requires an additional purchase.
©2012 ClearSpan™
STK#
DIMENSIONS
All Rights Reserved. Reproduction
R035
35' W x L (length varies)
is prohibited without permission.
1
Revision date: 06.19.12

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Summary of Contents for ClearSpan Pro Solar Star R035

  • Page 1 Corrugated Polycarbonate Photo may show a building of a different length. Frame is shown with an optional end wall and customer- supplied baseboards. End wall is not included and requires an additional purchase. ©2012 ClearSpan™ STK# DIMENSIONS All Rights Reserved. Reproduction...

  • Page 2: Table Of Contents

    WIND AND SNOW LOAD Do not prepare the site without first consulting the diagram for the proper dimensions! In addition, Many Clearspan™shelters and greenhouses can be consult the MUST READ document for anchoring designed to meet wind and snow loading in your area.

  • Page 3: Important Information

    • Identify whether underground cables and pipes are present before preparing the site, setting ground Thank you for purchasing this ClearSpan™ greenhouse. posts (if equipped), or anchoring the structure. When properly assembled and maintained, this product will provide years of reliable service. These instructions •...
  • Page 4 These words and phrases are common to most ClearSpan™ shelters and identify the different parts of the shelter. (Some are used in this document. Others may not apply to this particular shelter.) These terms describe the shipped parts and can also be found on the materials list/spec sheets included with the shipment.
  • Page 5 Important Information REQUIRED TOOLS SPECIAL NOTE: Baseboards for Frame The following list identifies the main tools needed to These instructions describe installing a baseboard assemble the shelter. Additional tools and supports may be (recommended) at ground level along each side of the needed depending on the structure, location, and frame.

  • Page 6: Parts Identification

    Parts Identification The following graphics and photos will help identify the different parts. (Some parts are not shown.) 108867 108939 Aluminum End Cap Aluminum Trim (curved) (straight) FAG340B FAME09B AS2167 104773 108503 1/2" Flat washer 5/16" x 3-1/2" Hex Bolt Anchor Shackle 1/2"...

  • Page 7: Overview

    Overview ClearSpan ™ Pro Solar Star Greenhouse ™ Corrugated Polycarbonate Frame above shown with optional end wall and customer- supplied baseboards. OVERVIEW Drawing may show a model of a different length. Refer to Quick Start section located in the back of these instructions This section describes assembling your greenhouse.

  • Page 8: Prepare And Square The Building Site

    Prepare and Square the Building Site SQUARE THE SITE: GENERAL STEPS PREPARE THE BUILDING SITE A level site is required to accurately and safely construct Identify a corner where a building rafter will be the building. Consult the services of a qualified contractor positioned, drive in a stake, and string a line the exact to properly grade and prepare the site.

  • Page 9: Set The Ground Posts (Option)

    Set the Ground Posts (option) MARK THE SITE AND DIG POST HOLES These steps describe marking all post hole locations and digging the holes. For some sites, it may not be possible to complete the procedure in this manner. An alternative procedure such as working from one end of the building toward the other may be necessary.
  • Page 10 Set Ground Posts (option) SET GROUND POSTS DIAGRAM SHOWS A TYPICAL POST HOLE This procedure describes setting the ground posts in Consult the MUST READ document before you set your holes, bracing in place, and adding concrete. If your ground posts for important anchoring and concrete details. building includes mounting feet, skip this procedure and continue with the installation of the mounting feet.

  • Page 11: Mounting Feet (Option)

    Mounting Feet (option) SETTING THE MOUNTING FEET In those instances where optional mounting feet have been ordered, secure the feet to a customer-supplied baseboard prior to attaching the rafter legs and assembling the frame. Customer is responsible for the necessary baseboards and fasteners used to secure the feet to the site.

  • Page 12: Rafter Assembly

    Rafter Assembly RAFTER ASSEMBLY After setting the ground posts or anchoring the mounting feet, continue with the rafter assembly. NOTE: All rafter assemblies consist of four rafter sections joined by a single chevron at the peak. Consult the rafter CFG030PINSS03 Chevron diagram in the Quick Start section of these instructions before and during the rafter assembly process for details.

  • Page 13: Frame Assembly

    Frame Assembly FRAME ASSEMBLY Position 108503 Gather the parts: bracket to the inside. • Assembled rafters, 1/2" x 3" mounting bolts with nuts (104773), and flat washers (FAME09B) • Purlins (see diagrams in Quick Start section for your building and for purlin identification/position) and 1/4"...
  • Page 14 Frame Assembly ASSEMBLY NOTE: INSTALLING THE 108938 DIAGONAL STRUT (mounting feet only) For all frames that include the 108500 mounting feet and rafter legs, complete the following procedure after each rafter is assembled and attached to the rafter legs and before you add purlins to the entire frame. Completing these steps will help maintain a uniform result when assembling each rafter and the entire frame.
  • Page 15 Frame Assembly RAFTER STRUT INSTALLATION Complete the steps on the previous page to set the rafter and continue with the steps that follow to install the struts. Required parts and tools: • 108938 struts for mounting foot; 108964 struts for ground post. Rafter Strut •...
  • Page 16 Frame Assembly FRAME ASSEMBLY (continued) Move to the next set of ground posts (or mounting feet), attach that rafter (and rafter legs if needed), and brace in place. As previously described, use the 1/2" bolts to secure the rafter to the tops of the ground posts or rafter legs. Install the 108938 or 108964 struts.
  • Page 17 Frame Assembly FRAME ASSEMBLY (continued) Set the next rafter in place, secure it to the ground posts or rafter legs, brace in place as needed, and install the struts if equipped. Secure the rafter to the previous purlin, or install another purlin section. View diagrams below for details. Depending on the rafter spacing, either of the configurations below will apply.
  • Page 18 Frame Assembly FRAME ASSEMBLY (continued) FA4484B Tek screw With the first three (3) rafters assembled, take the first top purlin and secure it to the rafters using Tek screws. See Diagrams D and E at Purlin the right. Consult the Over-the-Top Measurements diagram in the Quick Start section for purlin spacing dimensions.

  • Page 19: Install Hat Channel

    Install Hat Channel INSTALL THE HAT CHANNEL Consult the following information before you begin to install the recommended baseboards. • The hat channel runs are perpendicular to the rafters and are spaced evenly on the outside of the frame. • Hat channel runs are parallel to each other.

  • Page 20: Recommended Baseboard Installation

    Recommended Baseboard Installation RECOMMENDED BASEBOARD INSTALLATION Gather the parts: • 2" x 6" or 2" x 4" treated or recycled plastic lumber (supplied by customer) • 5/16" x 5" carriage bolts (FAH325B) (additional purchase required) • 5/16" nuts (FALB32B) (additional purchase required) The following procedure describes one way to install the baseboards.

  • Page 21: Cable Installation

    Cable Installation CABLE ASSEMBLY Anchor Shackle Each cable assembly includes the following: • One (1) length of cable: Measure from point-to-point on the frame and cut cable as needed. Remember to account for the extended turnbuckle and the cable needed to add the cable clamps when determining cable length.
  • Page 22 Cable Installation CABLE ASSEMBLY (continued) Move to the next cable position and repeat the previous steps to measure and cut cable and to create the next turnbuckle assembly. If the distance is the same, use the first assembly as a pattern. Continue building cable assemblies until all have been completed and attached to the frame as shown in the diagrams.

  • Page 23: Diagonal Strut Installation

    Diagonal Strut Installation STRUT INSTALLATION For additional support, attach diagonal struts to the frame between the end rafter and the first interior rafter at each end. Collect the Diagonal Strut needed parts and install the diagonal struts as instructed below. Required parts and tools: •...

  • Page 24: Anchor The Assembled Frame

    Anchor the Assembled Frame ANCHOR THE ASSEMBLED FRAME: MOUNTING FEET At this point, anchor the assembled frame. If you chose one of the anchoring methods described in the MUST READ document, you can continue with the next procedure. If you choose the method shown in this manual for building equipped with mounting feet, continue with the steps on this page.

  • Page 25: Ridge Cap Installation

    Ridge Cap Installation INSTALL FIRST RUN OF RIDGE CAP Top View Ridge Cap Complete these steps to attach the metal ridge cap. 108505 Required parts and tools: Wafer Head Screws • 108505 Corner Cap Sections used for the ridge cap: Refer to the Side Profile diagram in the Quick Start section for your building to identify the Edge of part number and placement of cap on the frame.

  • Page 26: End Cap Installation

    End Cap Installation INSTALL ALUMINUM END CAP 108867 End Cap Gather the parts: • Aluminum end c aps (#108867) and Tek screws (#FA4484B) With assistance, position one section of end cap on top of the purlins and the installed ridge cap. Align the inside edge with the inside edge of the end rafter.

  • Page 27: Install Corrugated Panels

    Install Corrugated Panels INSTALL CORRUGATED PANELS: OVERVIEW Components needed: If optional end frame or end panels have been ordered, install • Corrugated panels and clear ridge cap (#106478) the end frame and end panels before attaching the sidewall panels of the main greenhouse. Consult the end frame and end •...
  • Page 28 Install Corrugated Panels INSTALL THE UPPER ROOF PANELS Corrugated Panel Tek Screw & Washer ATTENTION: Tek screws (#FA4484B) and neo-bonded washers (#102921B) are used to secure all corrugated panels to the purlins and side runs of hat channel. Take two (2) 104709 closure strips and remove one (1) rib from 111983 each using a scissors or utility knife.
  • Page 29 Install Corrugated Panels INSTALL THE UPPER ROOF PANELS (continued) 108505 Cap Corrugated Ridge Cap Confirm that the length of the first upper panel is Tek screw (106478) and washer correct. If it was, choose another 146" panel, cut it to 128", and move to the other side of the frame between the same rafters.
  • Page 30 Install Corrugated Panels INSTALL THE UPPER ROOF PANELS (continued) Once the first set of roof panels is secured, install the next set of roof panels. ATTENTION: These panels overlap the inside edge of the installed panels by one (1) rib and must be square on the purlin.
  • Page 31 Install Corrugated Panels INSTALL THE LOWER ROOF PANELS Gather the parts: • Corrugated panels (50" x 146") – Full (Do not cut!) • Tek screws ( #FA4484B) and Neo-bonded washers (#102921) ATTENTION: Verify you have selected the correct panels for the lower roof. Some frames include panels of different sizes.
  • Page 32 Install Corrugated Panels INSTALL SIDEWALL 108939 TRIM APPLY SEALANT Complete these steps to attach the 108939 aluminium In addition to the installation the individual corrugated trim to each corner of the building. panels, applying sealant at different joints and seams throughout the greenhouse can help seal the structure.
  • Page 33 Install Corrugated Panels CORRUGATED SIDE PANEL INSTALLATION INSTALL CORRUGATED SIDE PANELS The instructions that follow describe how to install the Install all side panels with the ribs running vertically. corrugated side panels of the greenhouse. Measure the sidewall, take a 50" x 146" panel, and cut it to the required length.
  • Page 34 Install Corrugated Panels INSTALL CORRUGATED SIDE PANELS (continued) Once the first side panel is secured, install the next side panel using Tek screws and neo-bonded washers (see photo A). This panel overlaps the edge of the installed panels by one (1) rib. Continue installing panels until the both sides of the frame are covered.

  • Page 35: Shelter Care And Maintenance

    • Depending on the contents, construction of the shelter, shelter materials, and shelter location, the potential for condensation exists. ClearSpan™ offers several items that can be used to alleviate a condensation condition. Please contact a ClearSpan™ representative for additional information.

  • Page 36: Quick Start Guide

    Quick Start Guide QUICK START GUIDE 35' Wide Greenhouses ATTENTION: Shelter to the right shows mounting feet and corrugated panels installed. Actual building may differ in length or design or both. Ground Level Building is shown with customer-supplied baseboards. Frame includes mounting feet. Frame length and width of your building may differ from what is shown.

  • Page 37: 35' Wide Front Profile Grid With Ground Posts

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  • Page 38: 35' Wide Front Profile Grid With Mounting Feet

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  • Page 39: 35' Wide Front Profile With Ground Posts

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  • Page 40: 35' Wide Front Profile With Mounting Feet

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  • Page 41: 35' Wide Purlin Locations

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  • Page 42: Side Profile - 36' Length

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  • Page 43: Side Profile - 48' Length

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  • Page 44: Side Profile - 60' Length

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  • Page 45: Side Profile - 72' Length

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  • Page 46: Side Profile - 84' And 96

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  • Page 47: Connections

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  • Page 48: Connection Details (1-4)

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  • Page 49: Connection Details (5-8)

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  • Page 50: Connection Details (9-12)

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  • Page 51: Main Cover Details

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  • Page 52: Mounting Feet Layout

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  • Page 53: 35' Wide Over-The-Top Measurements

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