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ClearSpan 500 Series Instructions Manual

Tall high tunnels 35' wide with drop-down sides
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35' Wide with Drop-Down Sides
Photo may show a building of a different length and style. Frame shown includes drop-down sides and customer-
supplied baseboards. Actual cover material may differ. Building shown is equipped with an optional roll-up end.
©2014 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
Revision date: 07.11.14
Series 500 Tall High Tunnels–
35' Wide Series 500 Tall High Tunnels:
All Standard Lengths.
1

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Summary of Contents for ClearSpan 500 Series

  • Page 1 Photo may show a building of a different length and style. Frame shown includes drop-down sides and customer- supplied baseboards. Actual cover material may differ. Building shown is equipped with an optional roll-up end. 35' Wide Series 500 Tall High Tunnels: ©2014 ClearSpan™ All Standard Lengths. All Rights Reserved. Reproduction is prohibited without permission.

  • Page 2: Safety Precautions

    Important Information LOCATION Choosing the proper location is an important step before you begin. The following suggestions and precautions will help determine whether your selected location is the best location. • Never erect the structure under power lines. READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLY •...

  • Page 3: Required Tools

    Important Information ASSEMBLY 15. Install roll-up (or drop-down) sides and anti-billow Following the instructions as presented will help ensure ropes. proper assembly. Failing to follow these steps may result in an improperly assembled and anchored structure. 16. Complete and return all warranty information as instructed if present.
  • Page 4 Baseboards, Retaining Boards, and Ribbon Boards BASEBOARD AND RETAINING BOARDS 2-PIECE RIBBON BOARD REQUIRED A customer-supplied baseboard and retaining board A customer-supplied two-piece ribbon board is required are required to attach the drop-down side panels. for the installation of the drop-down panels. Consult the Recommended baseboard dimensions are 2"...

  • Page 5: Parts Identification

    Parts Identification AS5020 Pulley 106734 Band Clamp The following graphics will help identify the basic parts of the frame. (Some parts are not shown.) FA4482B FAG363B FAME08B FALB04B 100441 and FA2155 & FA4652 Wood Tek Screw FA1960 Lag 3/8" x 3" Hex Bolt 3/8"...
  • Page 6 Overview ClearSpan ™ Series 500 High Tunnel Structures Drawing may show a model of a different length. Refer to Sample building shows drop-down sides and optional roll-up Quick Start section located near the back of this guide for door panel. (Wood for end frame is supplied by the customer.) on-center measurements and post layout.
  • Page 7 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 1. 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 8 Set Ground Posts 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 9 Set Ground Posts SET GROUND POSTS Stake Ground Posts for Concrete Required parts and equipment: Set all posts at the same height. Additional bracing may • Ground Posts (112430) and 103856 Band Clamps be needed to keep the post plumb while concrete sets. •...
  • Page 10 Set the Ground Posts Ground Level Ground Post 2’ Deep Concrete In areas where frost is common, dig each post hole so it falls below the frost line. Minimum hole depth for all areas regardless of frost is 24". Minimum hole diameter Optional: Before setting the is 12".

  • Page 11: Rafter Assembly

    Rafter Assembly RAFTER ASSEMBLY After setting the ground posts, continue with the rafter assembly. Do not set assembled rafters into position on the ground posts until concrete has set. Check with contractor for set times. NOTE: All rafter assemblies consist of three main rafter sections. Consult the rafter diagrams in the Quick Start section of these instructions before and during the rafter assembly process for details.
  • Page 12 Rafter Assembly–Optional Support Kit RAFTER ASSEMBLY—Optional Support Kits If the optional support kits were purchased, continue with the assembly steps that follow. Consult the diagrams supplied with the rafter support kits for additional details. See also the diagram in the Quick Start section of this guide. If the support kits were not purchased, continue with the frame assembly.

  • Page 13: Frame Assembly

    Frame Assembly FRAME ASSEMBLY Use the diagrams and information that follows to assemble the main frame. ATTENTION: Rafters are heavy. Always lift rafter from two separate points to prevent damage and injury. Examine the site to determine the best way to move the rafters into position and to set them onto the ends of each set of ground posts.
  • Page 14 Frame Assembly FRAME ASSEMBLY (continued) Use this diagram to properly position the purlins during the frame assembly. Side purlins will run just above the cross beam of the rafter support kit components if equipped. Center the ridge purlin on top of the rafters. Secure using the QH1070 and FA4482 Tek screws.
  • Page 15 Frame Assembly Frame shown may differ from actual frame. FRAME ASSEMBLY (continued) After setting the first end rafter and bracing it in place, set the second rafter and add the purlins and purlin clamps. Consult the techincal diagrams for connection details. Diagrams show the optional rafter support package.
  • Page 16 Frame Assembly FRAME ASSEMBLY (continued) End Rafter FA4482B Tek Screw QH1070 Pipe Strap Purlin FA4482B Tek Screw FA4482B Tek Screw Photo shows the installation of the side purlin and pipe Secure each QH1070 pipe strap to the purlin pipe strap at the end rafter. See Connection Details in Quick using one Tek screw.
  • Page 17 Frame Assembly FRAME ASSEMBLY (continued) Customer-supplied rafter-spacing jig. Revision date: 07.11.14...
  • Page 18 Frame Assembly FRAME ASSEMBLY (continued) Full Frame without Optional Rafter Support Components CABLE ASSEMBLY AND INSTALLATION IS SHOWN IN A LATER PROCEDURE. Full Frame with Optional Rafter Support Components NOTE: Some frames may also include support components on the end rafters. This example does not. ATTENTION: Example shows a 48' frame length.
  • Page 19 Baseboard Installation—Required BASEBOARD INSTALLATION—REQUIRED Gather the parts: • 2" x 6" treated lumber (supplied by customer). Baseboard • 5/16" carriage bolts and nuts supplied by customer. Length depends on the thickness of the baseboard. When properly installed, baseboard runs the length of the frame at ground level.
  • Page 20 Diagonal Cable Installation Using the diagrams and photos, install the diagonal cables at each end bay of the frame. Attach the lower end of each cable assembly to the band clamp approximately 4"- 6" above the top edge of the baseboard.
  • Page 21 Diagonal Cable Installation CABLE ASSEMBLY AND INSTALLATION (continued) Secure band clamp to pipe. Tighten all clamps, band clamps, turnbuckles, and shackles. Secure all band clamps to the rafter pipe using one Tek screw for each band clamp. CABLES Sample frame showing installed cables and baseboard.
  • Page 22 Install 2-Part Ribbon Board—Required 2-PART RIBBON BOARD INSTALLATION Gather the parts: • Part 1 of ribbon board: 2" x 6" treated lumber (supplied by customer) to attach to rafters. • Part 2 of ribbon board: 1" x 4" treated lumber (supplied by customer) to attach to the first part of the ribbon board.
  • Page 23 Install Ribbon Board Ribbon Board (Part 1) Photos above show Part 1 of a ribbon board attached to the side of a frame. Example shows using 2" screws (additional purchase) to secure board to rafters. Screw heads are countersunk below board surface to allow for the installation of the 102197 u-channel and Part 2 of the Finished grade up Finished Grade...
  • Page 24 Attach 102197 U-Channel to Ribbon Board Buildings with a film cover require the installation of the 102197 u-channel. Use the photos below to install the u-channel. Secure u-channel to ribbon board using FAH005B (1/4" x 2") carriage bolts, FAMF01B (1/4") fender washers, and FALB01B (1/4") nuts.
  • Page 25 Optional RidgeVent Installation Install the framing for the ridge vent before you continue with the installation of the main cover material. Consult the documentation and diagrams provided with the ridge vent and install that framing before you continue with this guide. See the following page for additional installation notes regarding the end frame and end cladding if equipped.
  • Page 26 Optional End Frame and Panel Installation Typically, end framing and end panels are installed before the cover is pulled onto the frame. If your building is equipped with an end wall and end wall covering, review the instructions sent with the end panel kit and end wall framing and proceed as instructed.
  • Page 27 Attach U-Channel (111613Z144) to End Rafters INSTALL U-CHANNEL Buildings with film (or 5.2 oz) covers require double u-channel attached to end rafters to secure cover. Photos show a building with an optional end wall and roll-up panel. Additional purchase required. If your building does not include a ridge vent, complete the steps on this page.

  • Page 28: Frame Check

    Attach U-Channel (111613Z144) to End Rafters—Ridge Vent Installed FRAME WITH A RIDGE VENT Buildings that include a ridge vent require additional steps during assembly. If your building includes an installed ridge vent, complete the steps on the previous page with the exception noted below. After attaching the 111613Z144 u-channel to the end rafters, complete the Frame Check procedure below and continue with the main cover installation procedure: Film (or 5.2 oz) Cover Installation with Ridge Vent.
  • Page 29 Film (or 5.2 oz) Cover Installation—No Ridge Vent WEAR EYE INSTALL MAIN COVER—SINGLE-LAYER FILM OR 5.2 OZ MATERIAL—NO RIDGE VENT PROTECTION If your building does not include a ridge vent, continue with the following procedure. If your WHEN building includes a ridge vent, continue with the Film (or 5.2 oz) Cover Installation with Ridge INSTALLING Vent procedure.
  • Page 30 Film (or 5.2 oz) Cover Installation—No Ridge Vent 2. Along the edge, clamp self-locking, duck-billed pliers to the cover material and Clamp self-locking, tie ropes or straps to the pliers. duck-billed pliers along the cover edge, tie NOTE: The ropes or straps must reach over the top of the building to the ropes or straps to the pliers, and then pull other side.
  • Page 31 Film (or 5.2 oz) Cover Installation—No Ridge Vent INSTALL MAIN COVER (continued) NOTE: Begin at one end of channel and work toward 5. Once main cover is in place and centered, begin at the other. Maintain an even length working along the the peak of one end and install the 102198 wire spring into the channel.
  • Page 32 Film (or 5.2 oz) Cover Installation with Ridge Vent INSTALL MAIN COVER—SINGLE-LAYER FILM OR 5.2 OZ MATERIAL—RIDGE VENT INSTALLED If your building does not include a ridge vent and you are installing the cover, return to and complete the previous cover installation procedure. If a ridge vent is present, continue with the following. Gather the parts: Main cover material and u-channel spring (#102198);...
  • Page 33 Film (or 5.2 oz) Cover Installation with Ridge Vent 4. After tying ropes/straps to main cover, throw them over the building and pull cover onto frame and up to the top edge of the closed ridge vent frame. See photos throughout this section. End Panel Photo above shows straps clamped to the edge of the cover material which is being pulled up to the installed ridge vent.
  • Page 34 Film (or 5.2 oz) Cover Installation with Ridge Vent 5. Have assistants pull the cover end-to-end and square the cover on the frame. Working from inside the frame on a lift, secure cover to the vent frame using the 102198 spring wire. See dashed line below. WEAR EYE PROTECTION WHEN...
  • Page 35 Film (or 5.2 oz) Cover Installation with Ridge Vent 6. After securing cover edge, continue installing spring wire and work down the vent frame to the end rafter channel. Continue to secure cover to the channel attached to end rafter and work down to side channel. Cover Panel B is installed in a later step.
  • Page 36 Film (or 5.2 oz) Cover Installation with Ridge Vent 7. Move to the other end rafter and attach the cover to that channel using the 102198 spring wire. Step 7 Panel A Step 8 Cut and use for Panel B. 8.
  • Page 37 Film (or 5.2 oz) Cover Installation with Ridge Vent 9. Take the remaining material and use it to cover the other side of the frame. Repeat steps to pull cover onto frame. Step 9 Step 10 10. Secure cover to 111613Z144 rail attached to frame. Open vent to gain access to the double channel as needed. Using the proper lifts, work from inside the frame to secure cover to the u-channel attached to the frame.
  • Page 38 Drop-Down Side Panel Installation Revision date: 07.11.14...
  • Page 39 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL 3. Mark plate mounting hole locations and drill the holes through the rafter pipe. Use a 3/8" drill bit for Locate these parts to attach the pulleys and drop-down the mounting holes. Drill through end wall cladding panel axle: (polycarbonate panels or fabric) if present.
  • Page 40 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL (continued) If an optional end panel has been installed, carefully 8. Take two (2) pieces of 131S075 (75") pipe, slide the insert the axle through the axle conduit hole in the swaged end of one into the plain end of the other and optional end wall cladding and attach to gearbox.
  • Page 41 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL (continued) NOTE: If an optional end panel is installed at the other end of the frame, do not allow the free end of 10. Move inside the frame and slide a 106734 band clamp the axle to touch the inside surface of the panel.
  • Page 42 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL (continued) Locate these parts to prepare the drop-down panel for 2" x 6" Ribbon Board installation and to attach it to the axle conduit: • 131S075 (75" pipe conduit) FA1960 • CC5505 (1/8" panel cord) AS5020 Pulley •...
  • Page 43 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL (continued) 5. Complete the panel conduit installation by cutting the conduit so that it extends from the panel pocket Install Panel Conduit and Attach Cord approximately 1" at each end. After installing all eye screws and pulleys, locate one of ATTENTION: Allowing the panel to extend beyond the two drop-down panels (D080Hxxxxxx52), 131S075 the end rafters offers a way to secure the panel to...
  • Page 44 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL (continued) 13. Repeat the above steps until all cords are attached to the first panel along one side of the shelter. 9. Move to the axle and drive two (2) FA4482 Tek screws with neo-bonded washers (102921B) into the axle conduit where the cord is located.
  • Page 45 Drop-Down Side Panel Installation INSTALL THE DROP-DOWN PANEL (continued) 5. Repeat the steps to secure the remaining lower edge of the panel to the baseboard along the side. Complete these steps to attach the lower edge of the panel to the customer-supplied baseboard. 6.
  • Page 46 • For replacement or missing parts, call 1-800-245-9881 for assistance. NOTE: With the exception of Truss Arch buildings, ClearSpan™ shelters and buildings do not have any tested loading criteria unless otherwise specified. Revision date: 07.11.14...
  • Page 47 Quick Start Guide 35' Wide Frame Frame length of your building may differ from what is shown. Revision date: 07.11.14...
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  • Page 61 Notes Space below is reserved for customer notes. Revision date: 07.11.14...