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ClearSpan 500 Series Manual

Tall high tunnels - 30' wide with roll-up sides
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Photo may show a building of a different length and style. Frame shown includes roll-up 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–
30' Wide with Roll-Up Sides
30' 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 roll-up sides and customer- supplied baseboards. Actual cover material may differ. Building shown is equipped with an optional roll-up end. 30' 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 cover installation. Following the instructions as presented will help ensure 15. Install roll-up (or drop-down) sides and anti-billow proper assembly. Failing to follow these steps may result ropes. in an improperly assembled and anchored structure. 16. Complete and return all warranty information as instructed if present.
  • Page 4 Baseboards and Ribbon Boards A customer-supplied baseboard is recommended for roll- RIBBON BOARD FOR ROLL-UP SIDES—OPTIONAL up sides that include the stabilizer bar. A baseboard runs the length of the frame and provides a seal between the In some instances, a ribbon board is installed along finished grade and the stabilizer bar.

  • Page 5: Parts Identification

    Parts Identification The following graphics will help identify the basic parts of the frame. (Some parts are not shown.) FA4482B 100441 and 100443 FAG363B FAME08B FALB04B Tek Screw 3/8" Flat washer 3/8" Nut Magnetic Nut Setter 3/8" x 3" Hex Bolt AS1084 102546 Cross QH1070...
  • Page 6 Overview ClearSpan ™ Series 500 High Tunnel Structures Drawing may show a model of a different length. Refer to Quick Start section located near the back of this guide for on-center measurements and post layout. Sample building shows roll-up sides and optional roll-up door panel.
  • 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 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. Additional purchase required. Purlin Pipe After the first few rafters are set and connected by purlins, remove the end rafter bracing and...
  • 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—Recommended BASEBOARD INSTALLATION—RECOMMENDED 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 Ribbon Board—Optional RIBBON BOARD INSTALLATION—Optional for Roll- Up Sides Gather the parts: • 2" x 6" treated lumber (supplied by customer). • Fasteners supplied by customer to attach boards to metal rafter pipes. Length depends on material thickness. The size and type of material you choose may require the use of alternative steps.
  • Page 23 Install Ribbon Board Ribbon Board Photos above show ribbon board attached to the side Finished grade to of an assembled frame. Example shows using 2" Tek bottom of ribbon screws (additional purchase) to secure board to rafters. board is 72". Screw heads are countersunk below board surface to allow for the installation of the 111613Z144 aluminum Finished Grade...
  • Page 24 Attach 111613Z144 Channel to Ribbon Board 111613Z144 Buildings with roll-up side panels require 111613Z144 channel for installation. The Channel for photos below show where to install the channel. Roll-Up Sides. Secure channel to ribbon board (if present) using FAH005B (1/4" x 2") carriage bolts, FAMF01B (1/4") fender washers, and FALB01B (1/4") nut.
  • Page 25 Optional RidgeVent Installation Install the framing for the ridge vent before you continue with the installation of the main cover. 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 and roll-up side panels require u-channel for installation. 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 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 Curtain Stabilizer Bar Installation CURTAIN STABILIZER BAR INSTALLATION—111924Z096 The curtain stabilizer bar secures the lower end of the roll-up side panel when it is closed (or down). It is installed just above the baseboard attached to the frame and ground level. Secure the stabilizer bar to each ground post using an FA4482 Tek screw.
  • Page 39 Roll-Up Side Panel Installation Revision date: 07.11.14...
  • Page 40 Roll-Up Side Panel Installation INSTALL ROLL-UP PANELS ASSEMBLE ROLL-UP SIDE PANEL CONDUIT Gather the parts: • Film: Single roll of 108655: Field cut length in half. • Pipe 1.315'' x 75'' swaged (#131S075) • 5.2 oz: Two identical panels: D080H0xxxxxx. •...
  • Page 41 Roll-Up Side Panel Installation ATTACH CONDUIT TO ROLL-UP PANEL Gather the parts: • Assembled conduit from previous procedure • Fabric clips #CC6212 (Divide quantity in half.) • Tek screws (#FA4482B) CC6212 Fabric Clip To this point, the roll-up side panel along one side is secured to and hanging down from the double u-channel.
  • Page 42 Roll-Up Side Panel Installation TWIST-OF-THE-WRIST ASSEMBLY 3. Select the aluminum channel, drill a 3/8" hole through the channel approximately 2" from the end, and attach Gather the parts: a threaded rod using a 3/8" nut on each side of the •...
  • Page 43 Roll-Up Side Panel Installation TWIST-OF-THE-WRIST ASSEMBLY (continued) 6. Select the bearing bracket and attach the bearings as 10. Attach the Twist-of-the-Wrist gearbox to the mounting needed. (In some instances, the bearings may come plate using hex head bolts. already attached.) Assemble as follows if needed: NOTE: Single bearings are attached to the sides of the bracket and double bearings to the middle portion of the bracket.
  • Page 44 Roll-Up Side Panel Installation INSTALL THE ANTI-BILLOW ROPES TWIST-OF-THE-WRIST ASSEMBLY (continued) The anti-billow rope is installed along the outside of the 13. Slide the Twist-of-the-Wrist assembly onto the frame and stretches between the ribbon board and the aluminum channel from the ground end. (This is the baseboard.
  • Page 45 • 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 46 Quick Start Guide 30' Wide Frame Frame length of your building may differ from what is shown. Revision date: 07.11.14...
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