ClearSpan 500 Series Instructions Manual Download Page 1

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Revision date: 07.11.14

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Series 500 Tall High Tunnels–

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.

35' Wide Series 500 Tall High Tunnels:

All Standard Lengths.

Summary of Contents for 500 Series

Page 1: ...all High Tunnels 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 35 Wide Series 500 Tall High Tunnels All Standard Lengths ...

Page 2: ... before preparing the site setting ground posts if equipped or anchoring the structure Location should be away from structures that could cause snow to drift on or around the building Do not position the structure where large loads such as snow and ice large tree branches or other overhead obstacles could fall Always check local building codes before you begin and follow codes as instructed SITE A...

Page 3: ... drawings for additional details 11 Install the optional ridge vent frame if equipped 12 Install end wall frame door frame and end wall cladding if equipped 13 Attach 111613Z144 aluminum channel to the end rafters 14 Install main cover If building is equipped with a ridge vent consult those instructions for additional steps 15 Install roll up or drop down sides and anti billow ropes 16 Complete an...

Page 4: ...ntative to purchase fasteners or purchase locally when lumber is purchased Ground Level Inside of Shelter Outside of Shelter Secure baseboard and ribbon board joints between rafters as shown for best results 2 PIECE RIBBON BOARD REQUIRED A customer supplied two piece ribbon board is required for the installation of the drop down panels Consult the Drop Down Side Panel Installation procedure for de...

Page 5: ...Grip Screws 102546 Cross Connector QH1070 Pipe Strap 103856 Band Clamp AS2167 Anchor Shackle AS1004 Clamp 104189 Turnbuckle FA4482B Tek Screw FAG363B 3 8 x 3 Hex Bolt FAME08B 3 8 Flat washer FALB04B 3 8 Nut 100441 and 100443 Magnetic Nut Setter The following graphics will help identify the basic parts of the frame Some parts are not shown AS1084 3 16 Cable Thimble 106734 Band Clamp AS5020 Pulley 1...

Page 6: ...shows drop down sides and optional roll up door panel Wood for end frame is supplied by the customer OVERVIEW This section describes assembling your building frame See illustration below to identify main parts 1 Prepare site and set the ground posts in concrete 2 Locate the required parts for each assembly procedure 3 Assemble the rafters and main frame Finished Grade End Rafter Interior Rafter Ri...

Page 7: ... section SQUARE THE SITE GENERAL STEPS 1 Identify a corner where a building rafter will be positioned drive in a stake and string a line the exact width of the building and stake in place Width of the rafter is measured from center to center of the rafter legs 2 After the first corner stake is in place string a line the width of the building center to center and drive the second corner stake into ...

Page 8: ...iagrams Complete these steps 1 Stake the outline of the building using string line and batter boards Set batter boards 3 back from the building corners Check to ensure that the building layout is square Cover or panels if equipped will not install properly if the building frame is not square once assembled 2 Consult the diagrams in the Quick Start section to verify the frame length and width dimen...

Page 9: ...e drilled holes in the ground post toward the ground 2 With assistance brace all posts in place See diagram below All posts to be plumb before adding concrete Use the baseboard mounting holes and customer supplied fasteners and stakes to hold posts in place 3 Add concrete to anchor posts in holes Fill hole so concrete remains below the finished grade Stake Ground Posts for Concrete Finished Grade ...

Page 10: ...eter is 12 Set all ground posts 24 below finished grade Consult local building codes and qualified contractors for additional details when digging the post holes and setting the ground posts Follow established codes and construction practices Optional Before setting the posts drill a hole through the bottom of each ground post 2 3 from the end and insert a 6 8 length of rebar through it This will ...

Page 11: ...the Quick Start section of these instructions before and during the rafter assembly process for details Assistance is required to assemble the rafters and frame Assemble all main sections of rafters as described below and set aside STEP 1 Select the rafter pipes to assemble one rafter STEP 3 Secure each rafter joint using two 2 Tek screws STEP 2 Slide the separate pipe pieces together STEP 4 Wrap ...

Page 12: ...099 190S099 CROSS BEAM CROSS BEAM 190S099 BAND CLAMP 103856 WEB BAND CLAMP ST06450D13G17S1 103856 QH1404 BAND CLAMP ST09275D13G17S1 QH1404 BAND CLAMP WEB 103856 BAND CLAMP QH1404 BAND CLAMP QH1404 103856 BAND CLAMP WEB ST09275D13G17S1 CROSS BEAM 190P099 BAND CLAMP 103856 BAND CLAMP 103856 BAND CLAMP WEB ST06450D13G17S1 RAFTER ASSEMBLY Optional Support Kits If the optional support kits were purchas...

Page 13: ... materials A spacing jig saves time and helps to evenly space the rafters Jig sets the on center spacing of rafters Examine the photo below and use it to build a jig to space rafters during purlin installation Use 2 x 4 lumber and wood fasteners Customer supplied rafter spacing jig Finished Grade 2 103856 Clamps 2 103856 Clamps 2 103856 Clamps 2 103856 Clamps Rope or Cable Slide two 103856 band cl...

Page 14: ...er support kit components if equipped Center the ridge purlin on top of the rafters Secure using the QH1070 and FA4482 Tek screws Install one Tek screw through the side of the strap and into the purlin pipe Finished Grade Approximately 11 Secure side purlins at 11 above the finished grade Secure purlin using QH1070 pipe straps at each end rafter Use 102546 cross connectors at each mid rafter posit...

Page 15: ...ort package Additional purchase required Frame shown may differ from actual frame After the first few rafters are set and connected by purlins remove the end rafter bracing and continue with the frame assembly FRAME ASSEMBLY continued IMPORTANT Secure each QH1070 pipe strap to the purlin pipe using one Tek screw Secure all 102546 cross connectors to the rafter and to the purlin pipe using Tek scre...

Page 16: ...e purlin and pipe strap at the end rafter See Connection Details in Quick Start section for additional information Ridge purlin is installed on top of the rafters unless noted Secure all 102546 cross connectors to the rafter and to the purlin pipe using Tek screws Secure each purlin pipe splice using two Tek screws FA4482B Tek Screws 102546 Cross Connector Purlin Mid Rafter Between End Rafters Pur...

Page 17: ...17 Revision date 07 11 14 Frame Assembly FRAME ASSEMBLY continued Customer supplied rafter spacing jig ...

Page 18: ...after Support Components 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 Actual frame may differ CABLE ASSEMBLY AND INSTALLATION IS SHOWN IN A LATER PROCEDURE ...

Page 19: ...nue adding baseboards to complete the first run Splices are made between posts as shown in the drawing below Use a short section of baseboard to secure separate baseboards at a splice See diagram below Repeat steps to install the second run of baseboard on the remaining side of the frame NOTE The boards should be at ground level or slightly into grade to create a good seal between the board and fi...

Page 20: ... 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 Secure each band clamp to the rafter using a Tek screw before tightening the cable turnbuckles See photos on the next page Live cable end Dead cable end ...

Page 21: ...E ASSEMBLY AND INSTALLATION continued Tighten all clamps band clamps turnbuckles and shackles Secure all band clamps to the rafter pipe using one Tek screw for each band clamp Secure band clamp to pipe CABLES Sample frame showing installed cables and baseboard ...

Page 22: ...me Use carriage bolts or countersink fastener heads Consult the photos on the next page for additional details 3 Continue adding boards to complete the first run Make splices between rafters as shown in the baseboard procedure Use a short section of material to secure the splice between separate boards 4 Repeat steps to install the second run of ribbon board along the other side 5 Next take a boar...

Page 23: ... 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 ribbon board Customer supplied exterior grade carriage bolts are also an option for fasteners Finished grade up to bottom of ribbon board is 72 Finished Grade Ribbon Board Part 1 Ribbon Board Bas...

Page 24: ... Install channel flush with the ends of the ribbon board and end rafters Pre drill bolt holes using 5 16 bit Space fasteners at 24 on center throughout the length of the building on both sides Rafter Leg or Ground Post 2 x 6 Ribbon Board Part 1 1 x 4 Ribbon Board Part 2 U Channel FAH005B 1 4 x 2 Carriage Bolt FAMF01B Fender Washer FALB01B 1 4 Nut FA4652 Wood Screw Customer Supplied Fasteners Clamp...

Page 25: ...re 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: ...er 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 After installing the end framing and cladding return to this guide and continue with the installation of the main cover and drop down sides ...

Page 27: ...ure 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 See next page if your building includes a ridge vent Secure the 111613Z144 u channel to top of both end rafters using FA4482 Tek screws spaced at 16 on center Install flush with the outer edge of end rafter See comm...

Page 28: ...he 111613Z144 channel here if a ridge vent is present FRAME CHECK Inspect the frame for sharp edges or fasteners that could damage the cover during installation 1 Verify that all frame members are properly secured and that all bolts and clamps are tight 2 Recheck the frame assembly for sharp edges or clamps and bolts that may interfere with the installation of the curtain File or tape sharp edges ...

Page 29: ...ach over the frame provided by customer After attaching u channel to end rafters and along the sides unpack the main cover and pull into place Ropes or straps are typically used to pull the main cover onto and over the frame Complete these steps 1 Take the cover material and position it along the base of one side of the building NOTE Unfold the cover and locate the edge Film or 5 2 oz Cover Instal...

Page 30: ... IMPORTANT To prevent damage to the main cover during installation use additional personnel and lifts as needed 4 Center cover side to side and end to end Some covers include additional material for the width due to standard material dimensions This material can be removed and recycled or it can be used by the customer Clamp self locking duck billed pliers along the cover edge tie ropes or straps ...

Page 31: ...one end and install the 102198 wire spring into the channel ATTENTION Ensure that enough cover material is present to lock into the end rafter channel Typically the cover material is cut longer wider than required to cover the building For easier anchoring allow approximately 10 to extend past the edge of the end rafter as the cover is anchored Remove the ropes after the cover is secure 6 Continue...

Page 32: ...nfold cover and locate edge Verify that the width and length are properly oriented with the width and length of the building Measure cover material and compare it to the over the top measurement of your building before installation and cutting Consult the diagram in the Quick Start section near the end of this guide for the over the top measurement 3 Along the edge clamp self locking duck billed p...

Page 33: ...rame See photos throughout this section End Panel IMPORTANT To prevent damage to the main cover during installation use additional personnel and lifts as needed Photo above shows lift inside building with assistants pulling cover into position Photo above shows straps clamped to the edge of the cover material which is being pulled up to the installed ridge vent Photo below shows the cover pulled i...

Page 34: ... the vent frame using the 102198 spring wire See dashed line below NOTE Small photo shows spring wire installed in the 111613Z144 channel Above assistants are shown standing in a lift inside the building securing the cover to the ridge vent frame Step 5 End Panel Cover Panel A Cover Panel B Step 4 Pull cover up to this point Step 5 Secure to edge of vent Step 5 WEAR EYE PROTECTION WHEN INSTALLING ...

Page 35: ...re 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 NOTE Dashed line shows cover attached to the end rafter Arrows show position of the side run of u channel Step 6 Step 6 End Panel End Rafter Cover Panel B is installed in a later step ...

Page 36: ... along the side and finish the installation of the first panel Panel A by stretching and attaching the cover to the u channel along the side Allow a few inches of material to extend below the u channel if desired This allows something to grip in the event that you need to re stretch the cover after installation Panel A Cut and use for Panel B Step 7 Step 8 Step 8 102197 U Channel Panel A ...

Page 37: ...nside the frame to secure cover to the u channel attached to the frame See dashed line below Work down each end rafter to side run of double channel Stretch cover and secure to 102197 u channel Trim excess material from installed cover Trim a few inches below the u channel Step 9 Step 10 Step 10 Step 10 Step 9 Photo above shows 102198 spring wire used to secure cover material to the u channel atta...

Page 38: ...38 Revision date 07 11 14 Drop Down Side Panel Installation ...

Page 39: ...at follow to install the drop down panel components 1 Take the 103544 mounting plate shown above and move outside the end wall where you want to position the gearbox 2 Measure 24 down from the bottom of the two piece ribbon board place the mounting plate against the rafter leg or ground post and align the plate mounting holes with the center of the end rafter leg ground post ATTENTION See the foll...

Page 40: ...eces Mounting bolts included with the mounting plate 5 16 x 5 carriage bolts and 5 16 nuts to mount plate to end rafter Diagram shows the assembled components 1 2 If an optional end panel has been installed carefully insert the axle through the axle conduit hole in the optional end wall cladding and attach to gearbox NOTE Diagrams shows gearbox mounted to the end rafter on the outside of the optio...

Page 41: ...mble and attach the gearbox and axle conduit to the other side of the shelter 10 Move inside the frame and slide a 106734 band clamp over the tapered end of the 131S075 pipe NOTE Verify that the axle pipe is level and secure the band clamp to the rafter leg or ground post using an FA4482B Tek screw Do not install a band clamp at the end rafter where the gearbox mounting plate is attached A band cl...

Page 42: ... pulley at each rafter including the end rafters 4 Continue installing lag eye screws and pulleys into the ribbon board until all pulleys are installed along both sides of the shelter 5 Install the panel conduit and attach cords as described in the next procedure Attach Drop Down Panel Pulleys Continue with the steps that follow 1 Gather the pulleys and the same quantity of lag eye screws FA1960 a...

Page 43: ... adding conduit sections and securing each joint until the conduit is as long as the panel 5 Complete the panel conduit installation by cutting the conduit so that it extends from the panel pocket approximately 1 at each end ATTENTION Allowing the panel to extend beyond the end rafters offers a way to secure the panel to the end rafter legs ground posts The customer can customize this installation...

Page 44: ...nduit 14 Continue by attaching the lower panel edge to the baseboard for the first panel installation Attach Lower Edge of the Panel to Baseboard After tying all cords to the panel conduit and axle for the first panel assembly secure the free edge bottom of the panel to the baseboard View shown from outside the shelter Finished Grade Drop Down Side Panel Optional End Wall Cladding Retaining Board ...

Page 45: ...l Pocket 1 x 4 Board Part 2 Rafter Leg or Ground Post 2 INSTALL THE ANTI BILLOW ROPES The anti billow ropes keep the drop down panel in place when it is fully or partially open Using the diagrams below complete the anti billow rope installation ATTENTION INSTALL THE ANTI BILLOW ROPE IN SHORT SECTIONS ALONG EACH SIDE TO KEEP THE PANEL SECURE IN CASE ONE ROPE BREAKS 1 Beginning at one end rafter tak...

Page 46: ... allow the drop down panels to remain in the open position for extended periods Raise the panel periodically to allow it to dry and for cleaning Replace anti billow rope immediately if worn or broken Remove debris and objects that accumulate on the building Use tools that will not damage the cover when removing debris Remove snow to prevent excess accumulation Use tools that will not damage the co...

Page 47: ...47 Revision date 07 11 14 Quick Start Guide Frame length of your building may differ from what is shown Finished Grade 35 Wide Frame ...

Page 48: ... 35 Wide Rafter Profile with Grid 35 0 CENTER TO CENTER OF GROUND POSTS 6 0 SIDEWALL HEIGHT 13 7 1 2 9 11 1 2 17 11 5 8 GROUND LEVEL TO STRUCTURE PEAK 2 0 EMBEDMENT GRID REPRESENTS 12 SQUARES OVER THE TOP 59 2 710 GROUND LEVEL ...

Page 49: ...CENTER TO CENTER OF GROUND POSTS PG500TC2316S352 RAFTER 103856 BAND CLAMP GROUND POST 112430 GROUND POST 112430 RAFTER PG500TC23G16S02 RAFTER PG500TC23G16S02 RAFTER PG500TC2316S351 PIPE STRAP QH1070 GROUND LEVEL SPLICE PIPE STRAP QH1070 SPLICE PIPE STRAP QH1070 SPLICE BAND CLAMP 103856 ...

Page 50: ...LL 6 0 HEIGHT 103856 BAND CLAMP IF APPLICABLE 103856 GROUND POST 112430 GROUND POST 112430 RAFTER PG500TC23G16S02 RAFTER PG500TC2316S352 RAFTER PG500TC23G16S02 GROUND LEVEL SPLICE CROSS CONNECTOR 102546 SPLICE CROSS CONNECTOR 102546 SPLICE IF APPLICABLE RAFTER PG500TC2316S351 BAND CLAMP PIPE STRAP QH1070 ...

Page 51: ... SPACING ON CENTER 36 0 CENTER TO CENTER OF GROUND POSTS 2 0 EMBEDMENT GROUND LEVEL PURLINS 131S147 PURLINS 131S147 131S075 7 CUT TO FIT ROLL UP OR DROP DOWN CONDUIT ASSEMBLY ATTENTION Baseboards ribbon boards and related fasteners are supplied by the customer ...

Page 52: ... CENTER TO CENTER OF GROUND POSTS 2 0 EMBEDMENT GROUND LEVEL PURLINS 131S147 PURLINS 131S147 131S075 9 CUT TO FIT ROLL UP OR DROP DOWN CONDUIT ASSEMBLY Side Profile 48 Length ATTENTION Baseboards ribbon boards and related fasteners are supplied by the customer ...

Page 53: ...Baseboards ribbon boards and related fasteners are supplied by the customer 6 0 RAFTER SPACING ON CENTER 60 0 CENTER TO CENTER OF GROUND POSTS 2 0 EMBEDMENT GROUND LEVEL PURLINS 131S147 PURLINS 131S147 131S075 11 CUT TO FIT ROLL UP OR DROP DOWN CONDUIT ASSEMBLY ...

Page 54: ... SPACING ON CENTER 72 0 CENTER TO CENTER OF GROUND POSTS 2 0 EMBEDMENT GROUND LEVEL PURLINS 131S147 PURLINS 131S147 131S075 13 CUT TO FIT ROLL UP OR DROP DOWN CONDUIT ASSEMBLY ATTENTION Baseboards ribbon boards and related fasteners are supplied by the customer ...

Page 55: ...Baseboards ribbon boards and related fasteners are supplied by the customer 6 0 RAFTER SPACING ON CENTER 96 0 CENTER TO CENTER OF GROUND POSTS 2 0 EMBEDMENT GROUND LEVEL PURLINS 131S147 PURLINS 131S147 131S075 17 CUT TO FIT ROLL UP OR DROP DOWN CONDUIT ASSEMBLY ...

Page 56: ...TER VIEW 5 VIEW 8 PURLIN END RAFTER CONNECTION VIEW 9 PURLIN SPLICE CONNECTION VIEW 1 RAFTER TO GROUND POST CONNECTION VIEW 2 RAFTER SPLICE CONNECTION VIEW 7 PURLIN MID RAFTER CABLE TO PURLIN AT MID RAFTER CONNECTION CONNECTION VIEW 4 VIEW 3 CABLE TO GROUND POST CONNECTION F i n i s h e d G r a d e ...

Page 57: ...ABLE ASSEMBLY VIEW 6 AS1084 1 4 CABLE CLAMPS AS1004 1 4 THIMBLE AS1084 1X 14 X 1 TEK SCREW RAFTER PURLIN CABLE ASSEMBLY BAND CLAMP 103856 CABLE BRACKET PGBRKAAS01 RAFTER CABLE ASSEMBLY 103856 BAND CLAMP PURLIN CABLE BRACKET PGBRKAAS01 1X 14 X 1 TEK SCREW VIEW 5 CABLE TO PURLIN AT END RAFTER CONNECTION GROUND POST RAFTER 1X 3 8 X 3 HEX BOLT 1X 3 8 NUT 2X 3 8 WASHER PGBRKAAS01 AS2167 GROUND POST 1X ...

Page 58: ...AFTER PURLIN 102546 CROSS CONNECTOR 1X 14 X 1 TEK SCREW VIEW 7 PURLIN MID RAFTER CONNECTION PURLIN END RAFTER CONNECTION END RAFTER PIPE STRAP QH1070 3X 14 X 1 TEK SCREW VIEW 8 PURLIN PURLIN AT THE PEAK IS PLACED ON TOP OF RAFTER VIEW 9 PURLIN SPLICE CONNECTION Frame Connection Details ...

Page 59: ... ST09275D13G17S1 QH1404 BAND CLAMP WEB 103856 BAND CLAMP QH1404 BAND CLAMP QH1404 103856 BAND CLAMP WEB ST09275D13G17S1 CROSS BEAM 190P099 BAND CLAMP 103856 BAND CLAMP 103856 VIEW 1 WEB TO CROSS BEAM CONNECTION WEB TO RAFTER CONNECTION VIEW 2 VIEW 3 WEB TO RAFTER CONNECTION BAND CLAMP WEB ST06450D13G17S1 VIEW 4 CROSS BEAM CONNECTION 35 0 CENTER TO CENTER OF GROUND POSTS 35 Rafter Profile with Opti...

Page 60: ...ON VIEW 2 VIEW 4 CROSS BEAM CONNECTION 1X 14 X 1 TEK SCREW CROSS BEAM CROSS BEAM WEB RAFTER WEB BAND CLAMP 103856 1X 14 X 1 TEK SCREW 1X 14 X 1 TEK SCREW CROSS BEAM QH1404 RAFTER BAND CLAMP BAND CLAMP 103856 1X 14 X 1 TEK SCREW WEB QH1404 CROSS BEAM WEB BAND CLAMP 1X 14 X 1 TEK SCREW Optional Support Kit Connection Details ...

Page 61: ...61 Revision date 07 11 14 Space below is reserved for customer notes Notes ...

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