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ClearSpan Pro Solar Star R035, Manual

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ClearSpan Pro Solar Star R035 Manual Download Page 30

30

Revision date: 06.19.12

Frame length of your building may differ 
from what is shown.

Ground Level

Do not install any screws 
into this purlin until the lower 
panel is installed.

Maximum length extending 
beyond purlin is 6".

Installed Ridge Cap 

106478

Once the first set of roof panels is secured, install the 

12. 

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

. Verify that the lower end of the panel is 

aligned with the end of the adjacent panel. 
 
Install the horizontal closure strip (104709) between the 
panel and purlins and continue as previously described. 
Install the strip from inside the greenhouse for easier 
access and to align it with the purlin.

Continue installing the corrugated polycarbonate roof 

13. 

panels and ridge cap (106478). Remember to secure 
the overlap seams for all installed panels. If the length 
and overlap dimensions were correct, cut all remaining 
upper panels to 128". 
 

NOTE:

 If the final roof panel is too wide and extends 

beyond the end rafter, trim the panel to the correct width 
or 

overlap the previous panel as needed

.

With the roof panels attached, continue with the 

14. 

installation of the lower roof panels. 

INSTALL THE UPPER ROOF PANELS (continued)

Install Corrugated Panels

Overlap panels by one (1) rib as shown above.

Corrugated Panel

Rib

Corrugated Panel

Overlap adjacent 
panel and slide 
under the lip of the 
corrugated ridge cap.

Summary of Contents for Pro Solar Star R035

Page 1: ...permission 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 STK DIMENSIONS R035 35 W x L length varies ...

Page 2: ...nt Profile with Ground Posts 39 35 Wide Front Profile with Mounting Feet 40 35 Wide Purlin Locations 41 Side Profile 36 Length 42 Side Profile 48 Length 43 Side Profile 60 Length 44 Side Profile 72 Length 45 Side Profile 84 and 96 46 Connections 47 Connection Details 1 4 48 Connection Details 5 8 49 Connection Details 9 12 50 Main Cover Details 51 Mounting Feet Layout 52 35 Wide Over The Top Measurements...

Page 3: ... structure under power lines Identify whether underground cables and pipes are present 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 Al...

Page 4: ... found on the materials list spec sheets included with the shipment To aid in the assembly read through the following definitions before you begin Conduit An assembly of pipes used to secure the main cover and end panels if equipped Some strut assemblies also consist of connected pipes to form a conduit Each pipe joint of a conduit assembly is secured with a self tapping Tek screw Hat Channel Fram...

Page 5: ...nd all diagrams for clarification or contact Customer Service NOTE At this time you do not need to open the plastic bags containing smaller parts such as fasteners or washers if equipped SPECIAL NOTE Baseboards for Frame These instructions describe installing a baseboard recommended at ground level along each side of the frame The baseboard runs from the front to the back of the frame The baseboar...

Page 6: ...lat washer FALF37B 5 16 Locknut 108873 Rafter Cable Plate 108874 Rafter Cable Plate 36 48 60 Long Only 104189 Turnbuckle 108503 Cable Bracket FAG340B 5 16 x 3 1 2 Hex Bolt 104773 1 2 x 3 Hex Bolt Nut AS2167 Anchor Shackle FAME09B 1 2 Flat washer CFG030PINSS03 Chevron 108500 Mounting Foot Use depends on application Foot is not used with ground posts AS1004 Cable Clamp AS1084 3 16 Cable Thimble 1089...

Page 7: ...ments and post layout OVERVIEW This section describes assembling your greenhouse See illustration below to identify main parts of the greenhouse Set the ground posts or mounting feet as equipped 1 Locate the required parts for each assembly procedure 2 Assemble the rafters and frame 3 Anchor the frame Consult instructions for details 4 Install end walls and end panels purchased separately 5 Assemb...

Page 8: ...ipped with rafter mounting feet Read the information on the Mounting Feet if equipped page for additional details Ground Posts If the frame includes ground posts set all ground posts as described within this manual Width of the shelter is measured from the center of one ground post to the center of the remaining ground post Length is also measured center to center If your building includes ground ...

Page 9: ...after mounting feet stop here and continue with the Mounting Feet section Consult the diagrams in the Quick Start section to verify the frame length and width dimensions and to accurately 2 position the ground posts Guided by the string line use a flag or stake to mark each ground post hole location 3 Move the string line and dig a post hole a minimum of two feet 2 deep or to a depth that is below...

Page 10: ...concrete remains below the finished grade Ground Post Toward the ends of the frame Toward the ends of the frame Ground Post Concrete Ground Level 2 Deep ATTENTION Position the pre drilled holes facing toward the ends of the shelter so they align with the bolt holes in the rafter sections Verify that the ground post is at the correct height Check that the corner post is straight plumb and 3 adjust ...

Page 11: ...t of 2 x 8 baseboards on the site at the required 1 on center width of the building frame Baseboards run parallel to each other Use the layout instructions to accurately and properly set the baseboards on the site Drive a short length of rebar or similar stake through a hole 2 drilled in the boards into the ground to keep the boards in place See diagram above If mounting on concrete use wedge anch...

Page 12: ...sition the installed studs of the chevron so they point up to accept the ridge purlins when these are installed See diagram B below Distance between the lower mounting holes at the end of the assembled rafter is the on center width of the frame Measure this distance before you tighten the bolts at the top of the rafter For example if your frame is 35 wide on center the distance between the mountin...

Page 13: ... onto a 1 2 x 3 bolt and insert a bolt into each mounting hole ATTENTION If mounting feet are used attach the first set of rafter legs to the mounted feet and secure with the 3 8 x 3 1 2 bolts and nuts With the legs installed set the first assembled rafter in place and secure Consult the connection diagrams located in the Quick Start section of these instructions for additional details See strut i...

Page 14: ...mbly Verify that both rafter legs are plumb and that the rafter is not twisted or leaning toward the front or back b Measure center to center between the tops of the rafter legs to verify that the on center measurement is equal c to the width of the building Adjust the brace as needed and use it to help secure the positions of the rafter legs NOTE If needed use a strap or rope to keep the tops of ...

Page 15: ...ghten bolts Complete these steps Take a strut and loosely attach it to the rafter foot or a ground post using the 5 16 fasteners listed above Swing the diagonal strut up into position until it reaches b the underside of the rafter Rafter Strut Frame Assembly Step b c Swing strut up and into position With assistance align the hole in the rafter with the diagonal strut Pre punched Strut Hole NOTE Us...

Page 16: ...ake the first purlin section consult Side Profile diagram for your building 5 for purlin identification align the holes with the studs of the rafter chevron and secure to the end rafter A and first interior rafter B using 1 4 nuts and 1 4 washers Repeat steps to set the next rafter in place and secure to the frame Attach the struts 6 NOTE Consult the Side Profile diagram for your frame for connect...

Page 17: ...on View diagrams below for details Depending 8 on the rafter spacing either of the configurations below will apply Frame Assembly C Ridge Purlin Studs Overlap ridge purlins and secure in place using 1 4 nuts and washers Diagram above shows how to connect the next purlin at the same chevron Use one set of 1 4 nuts and washers to secure both purlins Install another rafter if needed to support the fr...

Page 18: ... purlin and rafter install a 108874 rafter cable plate double to secure the cables G Consult the Quick Start guide for additional details regarding the location and installation of the rafter cable plates Use assistants when installing the plates Install and secure the remaining top purlins for the first few rafters as 10 previously described and as shown in the Quick Start section of these instru...

Page 19: ...are perpendicular to the rafters and are spaced evenly on the outside of the frame Hat channel runs are parallel to each other Use the RFB144ARSS004 frame members for the hat channel Complete these steps to install the hat channel On the outside of the frame at the first rafter mark the 1 location of the lower run of sidewall hat channel NOTE Refer to the Over The Top Measurements diagram located ...

Page 20: ...ernative steps When properly installed baseboard runs the length of the frame at ground level The baseboard and fasteners are supplied by the customer On the outside of the frame attach the first baseboard to the rafter using two 2 5 16 x 5 carriage bolts and nuts Countersink heads if needed Continue adding baseboards to complete the first run The boards should be at ground level or slightly into ...

Page 21: ... point on the frame Adjust length as needed Using the diagrams on this page and in the Quick Start guide attach the first cable to the frame in the location that 4 the cable was measured and created for Do not tighten at this time Cable Installation CABLE ASSEMBLY Each cable assembly includes the following One 1 length of cable Measure from point to point on the frame and cut cable as needed Remem...

Page 22: ... apply 7 one additional full turn using a small bar or screwdriver As you tighten each cable assembly inspect the rafters to verify they are not pulled out of plumb Work from one corner to the peak at one end of the frame and move to the remaining corner at the same end and repeat the tightening sequence After tightening the cables at one end of the frame repeat the same procedure at the other end...

Page 23: ...16 drill bit Complete these steps Using a vise grip or similar tool or a vice bend each flattened 1 end of the strut as shown in the diagram and photos to the right When installed ends are tight to the frame ATTENTION Verify you have selected the correct strut Some frames include struts of different lengths Consult the diagrams in the Quick Start section for your building for additional details Po...

Page 24: ...quipped with mounting feet continue with the steps on this page Call customer service for additional anchoring information if needed CAUTION The anchor assembly is an integral part of the frame construction Improper anchoring may cause instability and failure of the structure to perform as designed Failing to anchor the shelter properly will void the manufacturer s warranty and may cause serious i...

Page 25: ...f corner cap and align the edge of the cap with the 1 outside edge of the end rafter See Diagram A The other end of the cap will extend beyond the first interior rafter Have an assistant hold the cap in position Secure the cap to 2 the end rafter using 108553 wafer head screws DO NOT secure the free end of the corner cap until you overlap the cap with the next section Step 3 After installing the f...

Page 26: ...utting the aluminum Wear safety glasses and hearing protection when handling and cutting end caps Using one FA4484B Tek screw for the ridge cap and one for the 2 upper purlin attach the end cap to the frame Align the Tek screws with the center of the end rafter Slide the lower end cap section 3 under the first and secure both to the purlin using one Tek screws aligned with the center of the end ra...

Page 27: ... designed to span 48 on center which allows each panel to overlap the previous panel by one 1 rib only CONSULT THE MAIN COVER DETAILS DIAGRAM IN THE QUICK START SECTION OF THIS DOCUMENT FOR ADDITIONAL PANEL INSTALLATION DETAILS The diagram below shows the locations of the different panels Frame shown below may differ from the actual frame It is used to show panel locations only Read the following ...

Page 28: ...h the upper end of the end rafter See diagram on the next page Next align the 5 center of the first corrugated rib this is the rib with the weather stripping with the center of the end rafter B Using a Tek screw and washer secure the panel to the end 6 cap to hold in position Set this first screw 12 down from the top end of the panel so it will not interfere with the installation of the corrugated...

Page 29: ... where the next panel overlaps until that panel is installed The next panel overlaps the previous panel which is the repeated pattern throughout the length of the frame Take a section of corrugated ridge cap 106478 and 10 place it between the tops of the two adjacent panels Using Tek screws and neo bonded washers secure 11 the corrugated ridge cap section by driving the Tek screws through the ridg...

Page 30: ...nue as previously described Install the strip from inside the greenhouse for easier access and to align it with the purlin Continue installing the corrugated polycarbonate roof 13 panels and ridge cap 106478 Remember to secure the overlap seams for all installed panels If the length and overlap dimensions were correct cut all remaining upper panels to 128 NOTE If the final roof panel is too wide a...

Page 31: ...n as shown in the photo above Remember to remove one rib of the 104709 strip to get started See Step 1 of the upper panel installation steps Position lower panel square on the frame Align the lower end of the panel with the end of the end cap 108867 4 Align the center of the outer panel rib with the center of the end rafter Secure the lower panel using Tek screws and washers installed through the ...

Page 32: ...ing is desired At both ends of the building apply a bead of silicone 2 along the edge of the corrugated roof panel where it meets the 108867 end cap See dashed line in the diagrams below Seal all holes created during the assembly of the 3 greenhouse if any Continue by installing the sidewall trim and panels 4 INSTALL SIDEWALL 108939 TRIM Complete these steps to attach the 108939 aluminium trim to ...

Page 33: ...channels 2 over the installed corner trim and slide the panel up until it meets the underside of the roof panel Align the 3 center of the outer rib of the panel with the center of the rafter leg or ground post Outer rib should align with the outer rib of the roof panels After squaring the panel on the frame attach the 4 panel to the hat channel in the valleys using FA4484B Tek screws and neo bonde...

Page 34: ...im the last panel to the proper width if needed or overlap the required number of ribs and install using the previous steps as a guide If baseboards are installed return to each panel and install customer supplied wood screws and washers as shown in the photo B below Seal all holes in the corrugated panels that may have 7 resulted during panel installation and continue by reading the care and main...

Page 35: ...mage If the greenhouse is disassembled and moved inspect all parts and connections before it is reassembled 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 For re...

Page 36: ...gth and width of your building may differ from what is shown Building is shown with customer supplied baseboards Frame includes mounting feet Ground Level ATTENTION Shelter to the right shows mounting feet and corrugated panels installed Actual building may differ in length or design or both ...

Page 37: ...37 Revision date 06 19 12 35 Wide Front Profile Grid with Ground Posts CENTER TO CENTER 35 0 15 11 3 4 GROUND LEVEL ...

Page 38: ...38 Revision date 06 19 12 35 Wide Front Profile Grid with Mounting Feet 15 11 3 4 GROUND LEVEL 35 0 ...

Page 39: ...ont Profile with Ground Posts Ground Level Rafter Leg CFG096ANCS004 Rafter Leg CFG096ANCS004 Strut 108964 Strut 108964 Rafter Section CFG035PC18GS03 Rafter Section CFG035PC18GS02 Rafter Section CFG035PC18GS03 Rafter Section CFG035PC18GS02 ...

Page 40: ...ing Feet GROUND LEVEL Rafter Leg CFG072ANCS003 Rafter Leg CFG072ANCS003 Mounting Foot 108500 Strut 108938 Mounting Foot 108500 Strut 108938 Rafter Section CFG035PC16GS05 Rafter Section CFG035PC16GS04 Rafter Section CFG035PC16GS05 Rafter Section CFG035PC16GS04 ...

Page 41: ...urlin locations are the same for frame with ground posts Ground Level Purlin Purlin Purlin Purlin Purlin Purlin Purlin Purlin Purlin Purlin Purlin Purlin Hat Channel Hat Channel Hat Channel Purlin Hat Channel Hat Channel Hat Channel PURLIN HAT CHANNEL RFB144ARSS004 12 ...

Page 42: ...167 SHACKLE CABLE ASSEMBLY RAFTER CABLE PLATE 108873 RAFTER CABLE ASSEMBLY PURLIN TEK SCREW FA4484B CABLE ASSEMBLY RAFTER PURLIN RAFTER CABLE PLATE 108874 SHACKLE AS2167 SHACKLE AS2167 TEK SCREW FA4484B NOTE Side profile shows a frame with mounting feet Profile is similar for ground posts ATTENTION Purlins are also used for the side runs of hat channel needed to attach the corrugated panels All se...

Page 43: ...ble AS2167 SHACKLE CABLE ASSEMBLY RAFTER CABLE PLATE 108873 RAFTER CABLE ASSEMBLY PURLIN TEK SCREW FA4484B CABLE ASSEMBLY RAFTER PURLIN RAFTER CABLE PLATE 108874 SHACKLE AS2167 SHACKLE AS2167 TEK SCREW FA4484B NOTE Side profile shows a frame with mounting feet Profile is similar for ground posts ATTENTION Purlins are also used for the side runs of hat channel needed to attach the corrugated panels...

Page 44: ...73 RAFTER CABLE ASSEMBLY PURLIN TEK SCREW FA4484B CABLE ASSEMBLY RAFTER PURLIN RAFTER CABLE PLATE 108874 SHACKLE AS2167 SHACKLE AS2167 TEK SCREW FA4484B Purlin Hat Channel Runs 108505 x10 B A NOTE Side profile shows a frame with mounting feet Profile is similar for ground posts ATTENTION Purlins are also used for the side runs of hat channel needed to attach the corrugated panels All sections are ...

Page 45: ...LE ASSEMBLY CABLE ASSEMBLY AS2167 SHACKLE 108503 CABLE BRACKET DETAIL B FAME08B 3 8 FLAT WASHER 108505 x12 B A C AS2167 SHACKLE CABLE ASSEMBLY RAFTER CABLE PLATE 108873 RAFTER CABLE ASSEMBLY PURLIN TEK SCREW FA4484B NOTE Side profile shows a frame with mounting feet Profile is similar for ground posts Side runs of hat channel are not shown ATTENTION Purlins are also used for the side runs of hat c...

Page 46: ...n point rafter cable plate single AS2167 SHACKLE CABLE ASSEMBLY RAFTER CABLE PLATE 108873 RAFTER CABLE ASSEMBLY PURLIN TEK SCREW FA4484B ATTENTION Purlins are also used for the side runs of hat channel needed to attach the corrugated panels All sections are 12 long NOTE Side profile shows a frame with mounting feet Profile is similar for ground posts Side runs of hat channel are not shown ...

Page 47: ... VIEW 6 STRUT TO RAFTER CONNECTION VIEW 10 CABLE TO POST CONNECTION VIEW 4 HAT CHANNEL TO LEG CONNECTION VIEW 2 POST TO ARCH VIEW 5 DIAGONAL STRUT TO LEG VIEW 12 RAFTER SPLICE CONNECTION VIEW 9 CABLE TO RAFTER CONNECTION ATTENTION Frame shown includes mounting feet and rafter legs Connections are the same for frames with ground posts and no mounting feet See Connection Details for additional infor...

Page 48: ...LIN TOP STYLE RFB144ARSS004 1 4 WASHER FAME16B 1 4 HEX NUT FALB01B VIEW 2 POST TO ARCH 1 2 x 3 HEX BOLT NUT 104773 1 2 WASHER FAME09B 108503 CABLE BRACKET END RAFTERS ONLY COMMON ANCHOR POST COMMON PROFILE ARCH RAFTER CHORD PURLIN 14 x 1 1 2 TEK SCREW FA4484B VIEW 3 PURLIN TO RAFTER CONNECTION VIEW 4 HAT CHANNEL TO LEG CONNECTION HAT CHANNEL RAFTER RAFTER LEG 14 x 1 1 2 TEK SCREW FA4484B ...

Page 49: ... 6 STRUT TO RAFTER CONNECTION VIEW 7 RAFTER LEG STRUT TO FOOT CONNECTION VIEW 5 DIAGONAL STRUT TO LEG CONNECTION STRUT 108938 RAFTER 5 16 x 1 HEX BOLT FAG330B 5 16 LOCKNUT FALF37B RAFTER VIEW 8 PEAK CABLE CONNECTION CABLE ASSEMBLY CABLE ASSEMBLY AS2167 SHACKLE EYE BOLT 108868 LOCK WASHER FAMA38B 3 8 HEX NUT FALB04B ATTENTION Rafter leg and strut to foot connection detail applies only to frames equ...

Page 50: ...MPS AS1004 1 4 CABLE AR1060 1 4 THIMBLE AS1084 1 4 THIMBLE AS1084 CABLE ASSEMBLY RAFTER LEG RAFTER 108503 CABLE BRACKET VIEW 9 CABLE TO RAFTER CONNECTION VIEW 12 RAFTER SPLICE CONNECTION AS2167 SHACKLE CABLE ASSEMBLY RAFTER CABLE PLATE 108873 RAFTER CABLE ASSEMBLY PURLIN 14 x 1 1 2 TEK SCREW FA4484B 1 2 x 3 HEX BOLT NUT COMBO 104773 1 2 WASHER FAME09B SLEEVE 110136 ...

Page 51: ...polycarbonate panels during installation use blue chalk Blue chalk washes off and will not permanently mark panels Do not use red chalk or other material that will stain or permanently mark panels ATTENTION Cut all upper 146 panels to 128 Measure first to ensure that the panel will extend beyond the purlin so it can be attached to the purlin Maximum overlap upper panel over lower panel is 6 at the...

Page 52: ... Mounting Feet Layout 35 PROFILE C L C L 35 3 7 8 35 0 34 0 7 8 2 5 8 34 8 3 8 12 PIER Minimum diameter of concrete pier is 12 Hole for pier should extend below the geographic frost line Consult local building codes for details ...

Page 53: ...8 20 8 1 8 4 1 2 6 0 1 8 6 0 1 8 OVER THE TOP 53 9 645 GROUND LEVEL Dimensions identify the positions of the side runs of RFB144ARSS004 used to attach the corrugated panels to the outside surface of the rafter legs or ground posts ATTENTION The over the top dimensions are the same for frames with ground posts ...

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