ClearSpan Majestic Greenhouse Film Roof with Polycarbonate Sides

Transcription

1 ClearSpan Majestic Greenhouse Film Roof with Polycarbonate Sides 84' Wide Photo may show a different but similar model ClearSpan All Rights Reserved. Reproduction is prohibited without permission. STK# PC PC PC PC DIMENSIONS 84' W x 48' L 84' W x 60' L 84' W x 72' L 84' W x 96' L 1

2 LOCATION Choosing the proper location is an important step before you begin to assemble the structure. The following suggestions and precautions will help you determine whether your selected location is the best location. YOU MUST READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLE THE SHELTER. Thank you for purchasing this ClearSpan shelter. When properly assembled and maintained, this product will provide years of reliable service. These instructions include helpful hints and important information needed to safely assemble and properly maintain the shelter. Please read these instructions before you begin. If you have any questions during the assembly, contact Customer Service for assistance. SAFETY PRECAUTIONS Wear eye protection. Wear head protection. Wear gloves when handling metal tubes. Use a portable GFCI (Ground Fault Circuit Interrupter) when working with power tools and cords. Do not climb on the shelter or framing during or after construction. Do not occupy the shelter during high winds, tornadoes, or hurricanes. Provide adequate ventilation if the structure is enclosed. Do not store hazardous materials in the shelter. Provide proper ingress and egress to prevent entrapment. ANCHORING INSTRUCTIONS Prior to assembling this shelter, please read the anchoring precautions and instructions included with the kit. Anchoring instructions are included in the MUST READ document. You must anchor the building after the frame is assembled and before the cover is installed. WARNING: The anchor assembly is an integral part of the shelter construction. Improper anchoring may cause shelter instability and failure of the structure. Failing to anchor the shelter properly will void the manufacturer s warranty and may cause serious injury and damage. Never erect the structure under power lines. Identify whether underground cables and pipes are present before preparing the site 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 shelter where large loads such as snow and ice, large tree branches, or other overhead obstacles could fall. SITE After choosing a location, proper preparation of the site is essential. The following site characteristics will help ensure the integrity of the structure. The support structure must be level to properly and safely erect and anchor the frame. If the site is not level, use footings to provide a secure base for the structure. Pre-cast concrete blocks, pressure-treated wood posts, or poured footings are all acceptable when properly used. Drainage: Water draining off the structure and from areas surrounding the site should drain away from the site to prevent damage to the site, the structure, and contents of the structure. WARNING: The individuals assembling this structure are responsible for designing and furnishing all temporary bracing, shoring and support needed during the assembly process. For safety reasons, those who are not familiar with recognized construction methods and techniques must seek the help of a qualified contractor. DOUBLE-LAYER FILM INSTALLATION Greenhouses equipped with a double-layer film include a layer that is Infra Red (IR) Retention film. IMPORTANT! During cover installation, the IR film must be installed first! Examine the film and install it according to the instructions printed on the film. 2

3 ASSEMBLY PROCEDURE Following the instructions as presented will help ensure the proper assembly of your shelter. Failing to follow these steps may result in an improperly assembled and anchored shelter and will void all warranty and protection the owner is entitled to. The steps outlining the assembly process are as follows: 1. Verify that all parts are included in the shipment. Notify Customer Service for questions or concerns. 2. Read these instructions, the Must Read document, and all additional documentation included with the shipment before you begin assembling the greenhouse. 3. Gather the tools, bracing, ladders (and lifts), and assistance needed to assemble the greenhouse. 4. Check the weather before you install the roof cover and any panels (if equipped). Do not install covers or panels on a windy or stormy day. 5. Re-evaluate the location and site based on the information and precautions presented in the documentation included with the shipment. 6. Prepare the site (if applicable). 7. Assemble the frame components in the order they are presented in these instructions. 8. Assemble the frame including the struts (if equipped). 9. Consult the MUST READ document and properly anchor the assembled frame. 10. Install the end wall framing and side panels. 11. Install, tighten, and secure the End Wall end panels and doors. (These are optional items for some shelters.) 12. Install, tighten, and secure the main cover. This applies to fabric and film covers that stretch over the frame assembly. 13. Read the Care and Maintenance information at the end of these instructions. 14. Complete and return all warranty information as instructed. LIST OF WORDS AND PHRASES Before you begin, it is important to become familiar with the words and phrases used in this instruction manual. 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. To aid in the assembly, read through the following definitions before you begin to assemble your shelter. CLEARSPAN MAJESTIC GREENHOUSES Chord: The assembly of pipes that spans from one rafter leg to the other (on the same rafter assembly). For strength, brackets are used to attach struts between the chord and the rafter. Conduit: An assembly of pipes used to secure the main cover and end panels (if equipped). Purlins and 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. Coupler or Fitting: A part of the frame assembly where legs, purlins and rafter pipes are inserted and secured. In most instances, 3-way and 4-way couplers are used. In some larger applications, couplers are used to secure the joints of the different rafter sections during the assembly of the rafters. Some shelters do not use couplers. Foot, Rafter Foot, or Base Plate: The part attached to and found at the base of the rafter or leg of the shelter. Depending on the shelter, the foot is an optional purchase. Some shelters do not offer an optional foot. Some use 1-way connectors; others use ground posts. Must Read Document: This document includes building and shelter anchoring instructions, steps for end wall reinforcement, safety precautions, and notices and warnings. The Must Read document is sent with all shelters and buildings. If you did not receive a Must Read document, contact Customer Service to request one. On-Center: Term used to describe a measurement taken from the vertical center of the rafter or frame member to the vertical center of another. Purlin or Angled (or Lateral) Bracing: The pipe assemblies that run perpendicular to the rafters or framework that supports the main cover. These assemblies are found on the sides and roof areas of the assembled frame, are evenly spaced, and typically run from the front to the back of the shelter. Plain or Straight Pipe: A term used to describe a pipe that has the same diameter or width throughout its entire length. Strut: A strut is usually a length of pipe with two flattened ends and is used for diagonal bracing of the shelter frame. A strut is typically secured to the frame work by special brackets, bolts, and/or clamps. Swaged End or Swaged Pipe: The term "swaged'' refers to the tapered end of the pipe or tube. Swaged ends of a pipe can be inserted into couplers and the straight ends of other pipes of the same diameter. Tek Screw: A self-tapping fastener used to secure pipe joints and to fasten brackets to rafters. 3

4 REQUIRED TOOLS The following list identifies the main tools needed to assemble the shelter. Additional tools and supports may be needed depending on the structure, location, and application. Tape measure or measuring device Marker to mark locations on the pipes Variable speed drill and impact driver (cordless with extra batteries works best) Metal-cutting saw Wrenches and impact socket set, or an adjustable wrench Scissors, utility knife, or tin snips Hammers, gloves and eye protection Adjustable pliers and self-locking pliers Ladders, work platforms, and other machinery for lifting designed to work safely at the height of the building Space below is reserved for customer notes. UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin to assemble the shelter frame. 1. Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets. 2. Verify that all parts listed on the Bill of Materials/Spec Sheets are present. If anything is missing or you have questions, consult the Pictorial Parts Guide and 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). 4

5 The following graphics and photos will help you identify the different parts of the building. Consult the Quick Start Guide for additional details and diagrams. (Some parts are not shown.) Butterfly Clamp FA4482B & FA4484B Tek Screw Nut Setter QH1070 Pipe Strap AS1003 3/16" Cable Clamp Neo-bonded Washer " Band Clamp " Cross Connector " Cross Connector QH " Band Clamp AS1094 1/4" Cable Thimble Pipe Fitting with Base Aluminum U-Channel Profile End Cap Profile Doors/Fans/Vents Aluminum U-Channel H-Channel Double U-Channel U-Channel Spring Plain Swaged Turnbuckle Swaged and Plain Rafter Sections 5

6 H-CHANNEL INSTALLATION INSTRUCTIONS The new H-channel design requires installation of the flat side facing out with channel side toward the building. Some diagrams and photos in this document show installation of original H-channel with channel side facing out. Design of new H-channel does not allow channel-side out installation. Use the diagrams on this page to install H-channel with flat side facing out. ATTENTION: Use only 1-1/2" Tek screws to attach H-channel to building frame. Do not use shorter screws. They will not hold. Do not use washers on Tek screws when installing H-channel. Poly Carb Flat Side Girt Channel 1-1/2" Tek Screw H-Channel with flat side toward the outside. Flat side toward the sun. UV-protected side toward sun. Install 1-1/2" Tek screws through H-channel into building frame. Center Groove H-Channel ATTENTION: Install all twin-wall poly carbonate panels with UV-protected side toward the sun. 6

7 ClearSpan Majestic Greenhouse Film Roof with Polycarbonate Sides OVERVIEW This section describes how to assemble your building. For details of each assembly procedure, consult the Quick Start Guide and the individual sections of these instructions. See illustration below to identify main parts of shelter. 1. Mark the location of the building and identify the required parts for each assembly procedure. 2. Assemble all rafters. 3. Assemble and anchor the frame. 4. Prepare and install all cable assemblies. 5. Install end walls and gutters. 6. Attach hat channel and side panels. 7. Install end panels. 8. Assemble and install double door. 9. Install the main cover. Interior Rafter End Rafter Strut 84' on-center Frame length of your building may differ from what is shown. Bottom Chord Rafter Leg Cable Assemblies Purlin Customer-Supplied Baseboard 7

8 LAY OUT THE BUILDING SITE After the site is prepared, identifying the location of the shelter corners helps to square the frame after it is assembled. Taking these steps before assembling the shelter saves time and ensures that the structure is positioned as desired. The following procedure is a suggested method. Its use depends on the size of the shelter, shelter application, the footings, and the method used to anchor the shelter. SQUARE THE SITE 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. String a line at least as long as the building from the first stake at 90. ATTACH RAFTER FEET TO BASEBOARDS The following is an example of one way to position the rafter feet after the site has been prepared. This is an example only. The site, anchoring system, and other factors affect preparing for the rafters. Consult a knowledgeable construction professional for suggestions and other safe and acceptable alternatives. ATTENTION: Placing treated baseboards under the rafter feet is strongly recommended when concrete is not present. WARNING: Securing the rafter feet to a baseboard as shown does not anchor the shelter. The shelter must be anchored as stated in the MUST READ document included in the shipment. NOTE: A transit can be used to ensure an accurate 90 angle, or the rule can be used. Refer to diagram. Using multiples of such as or helps to maintain an accurate 90 angle. Step 2 Step 4 6' on-center The above photo shows the rafter feet set at intervals of six foot (6') on center which is the rafter spacing of the shelter used in this example. 1. Position the boards on the site as needed to achieve the correct spacing. 3. After squaring the position of the building and placing a stake at all corners, string a line between the stakes to mark the base of the building. NOTE: The example that follows shows treated baseboards set on the site. After marking the rafter spacing on the boards, the rafter feet are secured in place. 4. Consult the Framework Assembly instructions for the building and mark on the ground (or treated baseboards as recommended) the positions of the rafter feet. 5. After marking the on-center positions of all rafters (on the boards or site), remove the strings and continue with the attaching rafter feet to the baseboards. 2. If possible, drive a short length of rebar inserted through a hole drilled in the boards into the ground to keep the boards in place as mounting feet and rafters are attached. 3. Secure each rafter foot base to the boards using the FAJ325B hex lag screw (included). 4. After the boards are set and the bases are fastened in place, attach the top of the rafter foot to the base. NOTE: At this time, DO NOT tighten the bolt that connects the two rafter foot parts. The upper part will be adjusted when the rafters are set in place. 5. Continue with the END RAFTER AND INTERIOR RAFTER ASSEMBLY procedures that follow. 8

9 ASSEMBLING THE STORAGE MASTER BUILDING COMPONENTS NOTE: Assistance is required to assemble the shelter. After the site is prepared and squared, the rafter feet are assembled and anchored in place (if applicable to your shelter), and an inventory of parts is complete, assemble the rafters. SPECIAL NOTE: Completely assemble the rafters and frame for one greenhouse bay before starting to assemble the second. CLEARSPAN MAJESTIC GREENHOUSES 2. Using a tape measure, measure the following clamp locations on the pipe and mark locations with a marker. 54" *not to scale 54" Mark these locations (shown below) on the remaining curved pipe for the opposite side of the rafter assembly. RAFTER ASSEMBLY Gather the parts: Rafter pipe (#20SM23P2) Rafter pipe (#28SM23S1) & rafter pipe (#2375S100D) Pipe 1.66'' x 99'' swaged (#166S099) Pipe 1.66'' x 40'' plain (#166P040) Band clamps (#QH1402 & ) Pipe strap (#QH1070) Tek screws (#FA4482) 21-1/2" 52" *not to scale Each rafter assembly consists of five (5) rafter sections: 1 curved center pipe (for the top or peak), 2 leg pipes that include drilled holes near the bottom to connect the rafter feet, and 2 curved pipes that connect the legs to the top center pipe. Interior Rafter Assembly Procedure 1. Select the five (5) pipes needed to assemble a rafter and arrange these on a flat surface as shown below for assembly. NOTE: Measurements are for reference only. Once the struts are attached, reposition the clamps as needed. 3. After marking the clamp locations, take six (6) of the larger band clamps (#103856) and slide these onto the different rafter pipes and position them near the marked locations. Do not secure these clamps at this time. 4. Slide the swaged portion of each rafter pipe into the plain end of the pipe. (#20SM23P2) (#28SM23S1) (#2375S100D) NOTE: DO NOT join sections at this time. Pre-drilled hole direction. IMPORTANT: The rafter foot mounting holes drilled in the sides near the bottom of each rafter leg must be parallel with the ground when viewed looking down at the rafter assembly on the ground. 9

10 RAFTER ASSEMBLY (CONTINUED) 5. With the main rafter pipes seated at each joint and the rafter positioned on a flat surface, secure each joint with a single self-tapping Tek screw. Position Tek screw approximately 2" from pipe joint. 8. After the rope (or cable) is cut, insert approximately 6" through the rafter foot mounting holes at the bottom of the rafter leg and clamp the rope in place with the clamp on the outside as shown below. 2 Tek screw 6. Move the band clamps into position by sliding each to its location marked on the rafter in Step 2. Band clamp locations may differ from actual locations. 9. Insert the remaining end of the cable through the other rafter bolt holes, measure the 28' on-center width dimension, and clamp the legs in place to prevent the rafter from spreading as the struts are attached. 10. Position three (3) sections of the 166S099 pipe (99" each) and one (1) 166P040 pipe (40") on the ground between the rafter legs, slide two (2) of the smaller band clamps (QH1402) onto one of the center pipe sections, and assemble the chord. Band Clamps 7. After assembling the rafter, securing the joints, and setting the band clamps in position, cut a length of rope (or cable) that is the width of the shelter plus and additional 12 inches. Chord 11. Secure each pipe joint of the chord with one FA4482 Tek screw. Standing on the chord assembly helps to keep the pipes from turning as the screws are installed. Be certain each joint is properly seated before installing the screw. 10

11 RAFTER ASSEMBLY (CONTINUED) 12. After the chord is assembled, slide one additional band clamp (QH1402) onto each end of the chord assembly. CLEARSPAN MAJESTIC GREENHOUSES 14. Select two (2) of the 5' struts (QH1304) and two (2) of the 7' struts (QH1308) and position them on the ground between the upper part of the assembled rafter and the assembled chord. Strut pattern shown may vary slightly from actual rafter. Additional Band Clamps Chord 13. Position the assembled chord between the rafter legs and connect the chord to the rafter as shown above. 7' 7' 5' 5' 15. Connect one end of a 5' strut to the clamp on the rafter. Do not tighten at this time. (Consult the connection details in the Quick Start section located at the back of these instructions.) Rafter 5' Chord Adjustable pliers can be used to squeeze the two band clamps if needed to thread the nut onto the bolt. NOTE: Remove one nut and bolt from either clamp. (It will not be used.) The top of the chord will be about 1-1/2" down from the band clamp as shown below. 16. Connect the other end of the same 5' strut and one end of a 7' strut to the band clamp on the chord assembly. Do not tighten. Chord 7' 5' 1-1/2" 17. Attach the remaining end of the 7' strut to the band clamp located near the peak of the rafter. Rafter NOTE: If the chord height needs to be lower, it can be slid down slightly at this time. 7' 7' 18. Repeat Steps to attach the remaining struts for this rafter assembly. 11

12 RAFTER ASSEMBLY (CONTINUED) 19. After attaching the struts and verifying that all band clamps are tightened, secure each band clamp to the chord using a FA4482 Tek screw. End Rafter Assembly Procedure Complete the following steps for the two end rafters only. 1. Assemble the two end rafters on a flat surface using the same procedure as an interior rafter. 2. Attach one pipe strap (QH1070) to each end rafter in the locations shown below. Pipe Straps Pipe Strap Pipe Strap Tek Screw The assembled rafter should resemble the rafter in the drawing shown below. The pipe strap is installed over the pipe joint on the inside of the rafter leg. (End Rafters Only) These pipe straps are located on the inside of the rafter legs, underside of the rafter pipe (peak), and on top of the chord. Do not tighten at this time. These will be tightened after the purlin is installed. Top of Rafter Chord Pipe Joint SPECIAL NOTE FOR LONGER SHELTERS: For longer shelters, conserve site space by assembling and setting the rafters as you work toward the end of the shelter. 20. Complete the next steps for END RAFTERS ONLY. NOTE: Except for the pipe strap located at the top of the rafter and on top of the chord, all remaining pipe straps shown above are installed over the pipe joints at that location. 3. Continue with the FRAME ASSEMBLY instructions that follow. 12

13 FRAME ASSEMBLY PROCEDURE After all rafters are constructed and placed in an orderly fashion for frame assembly, proceed with standing the first end rafter. CLEARSPAN MAJESTIC GREENHOUSES 2. Set the rafter on the first set of rafter feet at one end of the shelter and secure with 3/8" nut (FALB04B) and 3" bolt (FAG363B). WARNING: Rafter assemblies are heavy with most weight at the top. Forklifts and personnel booms are recommended for lifting and setting the rafters. Consult a construction professional if you are not familiar with construction techniques and erecting similar structures. The following instructions assume that the rafter feet are properly spaced and are secured to concrete or a level surface as shown in the example on the Lay Out the Building Site page of this document. If your site does not include a level surface as recommended and you will not be securing the rafter feet to concrete or wood planks as shown in the example on the Lay Out the Building Site page, alter these instructions to accommodate the variations and specifics of your building site. SPECIAL NOTE: Complete the Frame Assembly Instructions for one greenhouse bay before starting to assemble the second. Gather the parts: Assembled Rafters 1.315'' x 75'' swaged (#131S075) and 1.315'' x 73.5'' plain (#131P0735) pipe Marker, tape measure, and FA4482 Tek screws ATTENTION: Position the FAG363 bolt head to the outside of the building. Arrow in the above photo points to the outside of the frame assembly. Exercise caution when setting the rafter leg on the rafter foot. 3. Anchor the first rafter with ropes or other temporary bracing. Verify that the rafter is plumb (straight). NOTE: The purlins are part of the assembled frame and run perpendicular to the rafter assemblies. Each purlin consists of 1.315" x 75" (#131S075) swaged pipes (see Side Profile diagram in the Quick Start section for quantity) and one (1) 1.315" x 73.5" (#131P0735) plain pipe. Complete these steps: 1. With the proper lift, lift the first end rafter. This rafter includes pipe straps (installed earlier). NOTE: In the above photo, ropes (identified by white lines for clarity) were used to temporarily anchor the rafter in place. For this first end rafter, all temporary bracing must remain in place until other rafters are set in place and attached to the first rafter and to each other. 13

14 FRAME ASSEMBLY (CONTINUED) 4. Set the second rafter (first inside rafter) in place and secure it to the rafter feet. 7. With the purlin in position, tighten the pipe strap at the peak and secure the purlin in the pipe strap using a Tek screw. 1st Interior Rafter End Rafter End Rafter Tek Screw NOTE: After securing the inside rafter to the rafter feet, position someone at each leg to stabilize the rafter as the lift is removed. 5. Place a cross-connector (#102546) over the peak of the inside rafter. Photo to the right shows purlin inserted through the cross-connector at the top of an interior rafter. 8. Measure the on-center rafter width to achieve the proper rafter spacing and tighten the cross-connector (#102546). 6. Insert the first section of purlin (2 pieces of pipe) through the cross-connector on the inside rafter and the pipe strap at the peak of the end rafter. NOTE: If needed, use a hammer to tap the crossconnector and the purlin to center it between the brackets that secure the struts. 9. After tightening the cross-connector, install a Tek screw (FA4482) through the cross-connector and into the purlin. Position the Tek screw so that it also secures the joint of the purlin pipes if possible. IMPORTANT NOTE: The purlin should extend through the pipe strap at the peak of the end rafter by one-half inch. Do not allow the purlin to extend beyond the edge of the end rafter. NOTE: Secure all purlin splices using a Tek screw. Tek Screw 14

15 FRAME ASSEMBLY (CONTINUED) The first purlin and the first two rafters should appear as shown: CLEARSPAN MAJESTIC GREENHOUSES 13. Tighten the cross-connector and install a Tek screw as shown to secure the purlin pipe joint and to secure the purlin to the cross-connector. 14. Move to the other upper pipe joint on the inside rafter, place a cross-connector over the joint, and repeat the steps to install the first two sections of the last overhead purlin. NOTE: Position the cross-connector and purlin on the rafter pipe joint. Do not remove the temporary bracing until additional rafters are in place. To this point, the assembled frame includes two rafters and three top purlins as shown. 10. Move down the rafters to the first rafter joint and place a cross-connector over the inside rafter at that joint. 11. Assemble the first two sections of the second purlin and install it as you did the top/center purlin. Cross Connector 15. After attaching the last overhead purlin to the inside rafter, move down the rafter assembly to the pipe joint below the bottom chord and place a cross-connector (#102546) over the rafter pipe. 12. Position the cross-connector and the purlin over the pipe joint of the rafter assembly and set the on-center rafter spacing. Remember: To prevent damage to the main cover and end panels, do not allow the purlin to extend beyond the edge of the end rafter. This inserts shows the purlin, clamp and crossconnector as seen from the inside of the building. 15

16 FRAME ASSEMBLY (CONTINUED) 16. Assemble the first two sections of the another purlin and insert it through the cross-connector and into the pipe strap on the end rafter. Tighten the pipe strap and secure the purlin to the pipe strap using a Tek screw (FA4482). 17. Verify the on-center rafter spacing and tighten the cross-connector. The purlin should be saddled in the pipe joint on the rafter. 18. Install a Tek screw (FA4482) through the crossconnector and through the joint in the purlin to prevent separation of the purlin pipe joint. 19. Move to the remaining joint below the bottom chord on the inside rafter and attach the first two sections of the next purlin. ATTENTION: The last rafter to place in position will be the remaining end rafter. This end rafter includes the pipe straps attached during the rafter assembly procedures and is identical to the first end rafter set in place. 22. Set the end rafter in place and align the purlins with the pipe straps (previously attached to the rafter). Insert the rafter feet mounting bolts (bolt head to the outside) and tighten as previously instructed. 23. Begin with the top pipe strap and ensure that approximately half an inch of the purlin extends through the pipe strap and tightened the pipe strap mounting bolts. 24. Verify that the end rafter is plumb. NOTE: If the rafter is not plumb (straight up and down) and more of the purlin pipe needs to extend through the pipe strap and beyond the edge of the rafter, it may be necessary to cut the purlin to the required length. To prevent end panel damage, do not allow the purlin to extend beyond the edge of the rafter. 25. With all rafters in place and the top five (5) purlins installed and tightened, return to the rafter feet and tighten the main bolt that attaches the bottom plate of the rafter foot to the upper portion of the foot. The drawing above shows the 5 upper purlins in position. 20. Set the next inside rafter assembly in position and secure it to the feet as previously instructed. 26. Complete the ATTACH THE BOTTOM and ATTACH THE CENTER PURLIN procedures that follow. 21. Continue to add cross-connectors and purlin pipe and secure these to the rafter assemblies as previously instructed. 16

17 ATTACH THE BOTTOM PURLINS After installing the upper five (5) purlins, complete these steps to install the remaining purlins. CLEARSPAN MAJESTIC GREENHOUSES 6. After marking the location of the center of the bottom purlins on the legs, place a cross-connector at the base of each leg of each inside rafter assembly. Required tools: Tape measure Permanent marker ATTENTION: The bottom purlins run on the inside of the rafter legs near the bottom of those rafter legs. 1. Begin at one end of the frame assembly and measure up 13-1/2" from the rafter foot mounting plate on the end rafter and make a mark on the inside of the rafter leg. NOTE: This mark and the remaining marks identify the location of the bottom purlin for each side. The mark identifies the center of the purlin. 2. After marking the end rafter, attach a pipe strap to the inside of the rafter leg so that the strap is positioned with the mark at its center. Do not tighten the strap Tek screws at this time. Figure 1 Figure 2 ATTENTION: Attach pipe straps to the end rafters only (Fig. 1). Cross-connectors are used to secure the bottom purlins to the inside rafter assemblies (Fig. 2). 7. Assemble the first two sections of another purlin, insert through the cross-connector on the inside rafter leg, and insert the end into the pipe strap attached to the end rafter (see below). 8. Tighten the Tek screws to secure the pipe strap to the end rafter leg as described for the other purlins. 13-1/2" Tek Screw 3. Move to the remaining leg on the same rafter assembly and mark as instructed in the previous steps. 4. Repeat Steps 1-3 for the remaining end rafter assembly. 5. On the first inside rafter assembly, measure the same distance (13-1/2") up the rafter leg from the foot base and mark the location on the outside of the leg. 9. Install a Tek screw (FA4482) through the pipe strap and into the purlin to anchor the purlin in place. 17

18 FRAME ASSEMBLY (CONTINUED) 10. Using the mark on the inside of the rafter leg as a guide, slide the cross-connector (#102546) and purlin so that the center of the purlin pipe is in line with the mark on the rafter leg. 11. Tighten the bolts on the cross-connector to secure the purlin. 12. Install a Tek screw (FA4482) through the crossconnector and through the pipe joint of the purlin to keep the joint tight. 13. Continue to assemble and attach the remainder of the same bottom purlin until the entire purlin is secured to the frame. ATTACH THE CENTER PURLIN The center purlin is attached to the chord and runs on top of the chord the length of the shelter. As before, regarding all end rafter purlin connections, the center purlin is attached using a pipe strap. A cross-connector (#102548) is used to secure the center purlin to the chord of the inside rafters only. Complete these steps: 1. Locate the center of the chord of the end rafter and install a pipe strap at that location on top of the chord (if not installed earlier). Do not tighten at this time. Tek Screw 14. Repeat the above steps for the remaining bottom purlin. The frame with the purlins assembled to this point should resemble the drawing below. There are seven (7) purlins in the drawing. (See the arrows for location.) 2. Measuring from end-to-end on the chord, locate the center of the chord on the inside rafter and mark the location. 3. Position a cross-connector (#102548) over the chord and assemble the first two sections of the remaining purlin. 4. Insert the purlin through the pipe strap (#QH1070) on the chord (end rafter) and through the cross-connector on the chord of the inside rafter. Cross-connector Pipe Strap NOTE: The FA4482 Tek screw is used throughout this assembly. REMEMBER: The center purlin runs on top of the chord. 18

19 FRAME ASSEMBLY (CONTINUED) 5. Position the purlin as needed and tighten the crossconnector bolts. Center Purlin Tek Screw Chord 6. Install a Tek screw through the cross-connector and through the pipe joint in the purlin as shown above. 7. Return to the end rafter and verify that approximately half-an-inch of the center purlin extends through the pipe strap. Move the chord if needed and tighten the Tek screws that secure the pipe strap to the chord. REMEMBER: To prevent damage to the end panels, the center purlin must not extend beyond the edge of the chord. 8. Install a Tek screw through the pipe strap and into the center purlin. 9. Repeat the above steps for the remaining inside rafter assemblies and work toward the remaining end of the shelter. NOTE: Differences in how the rafters were assembled and how the center was located on the chord can cause the center purlin to appear off center. It may be necessary to "adjust" the center purlin so that its appearance is in line with the purlin at the top or peak of the rafter. CLEARSPAN MAJESTIC GREENHOUSES SQUARING THE ASSEMBLED FRAME SPECIAL NOTE: An additional bays are attached to the first bay. To ensure that the subsequent bays are square, the first bay must be square. The gutter system and connectors used to join the additional bays to the first bay will not install correctly if the frames are not properly squared after they are assembled. If the Lay Out the Building Site procedure was completed as presented near the beginning of this document, use the lines marked on the site to align the rafters and to adjust the width of the rafters as needed. Rafter width is measured from center of one leg to the center of the other leg on the same rafter assembly. If the framework was assembled on the site without using the recommended treated lumber, complete these step to square the assembled frame. 1. Align all rafters using a straight line (if needed) or the marks on the site from the Lay Out the Building Site procedure completed earlier. 2. Beginning with the first rafter, verify that the on-center rafter width is equal to the width of the building and adjust if needed. To insure that the proper on-center width is maintained for the length of the building and for each rafter, it is important to measure each rafter and to adjust the width (if needed) to maintain a consistent width. Pulling the feet together can do this. Width is measured centerto-center. 3. After adjusting the rafters, perform a final square of the structure by measuring diagonally (corner-to-corner), and verify that the two measurements are equal. Top View To achieve this, the cross-connectors can remain loose after the purlin is inserted to allow a final viewing to see if the purlin is centered. With the cross-connectors loose, the purlin can then be tapped into the desired position. When the purlin appears centered, return to each cross-connector, check to see that the pipes of the purlin are properly seated, and tighten the bolts. Once each cross-connector is tight, install a Tek screw through the cross-connector and into the pipe joint of the purlin. 10. At the remaining end rafter, repeat the steps to secure the center purlin to the chord of the end rafter. 11. After the final purlin is attached to the end rafter, continue with squaring the assembled frame. Frame may show a different but similar model. 19

20 SQUARING THE ASSEMBLED FRAME (continued) 4. Examine the framework and remove any sharp edges from the frame or reposition clamps and screws so they do not come in contact with the end panel or the panels of the main cover. 5. Verify that all clamps are secured to the rafter using a Tek screw. 6. Verify that all pipe splices are secured using Tek screws. 7. After the framework is squared, read or reread the MUST READ document and anchor the framework in place. ATTACH BAND CLAMPS FOR CABLING Cables attached to both ends of the shelter provide the diagonal bracing for the shelter. Band clamps secure the cable bracing to the shelter. SPECIAL NOTE: Complete the following steps, but DO NOT tighten the cable assemblies at this time. All cable assemblies for all bays will be tightened after the frames for each bay are assembled and connected. Ten (10) band clamps are used on each side of the frame to secure the cable ends. Consult the diagram below and in the Quick Start section for cable locations for your greenhouse. ANCHOR THE SHELTER At this point, anchor the frame. Once the frame is anchored properly, continue with these instructions. Band Clamp Band Clamp Band Clamps Band Clamp Band Clamp WARNING: Securing the rafter footings to wood boards set on the site is not a substitute for properly anchoring the shelter. You must anchor the shelter as described in the MUST READ document. Band Clamp Band Clamps Band Clamp FAILING TO PROPERLY ANCHOR THE SHELTER WILL RESULT IN DAMAGE TO THE SHELTER AND MAY CAUSE PERSONAL INJURY. READ THE MUST READ DOCUMENT TO PROPERLY ANCHOR THE SHELTER. The photo to the right shows how an auger anchor is attached to one rafter leg. Consult the MUST READ document for additional information about anchoring the shelter. Frame length of your building may differ from what is shown. Complete these steps to install the band clamps: 1. Remove the nut and bolt from the clamp, carefully bend the band clamp open, and slide it over rafter in the proper location. 2. With the clamp in place, use a channel lock pliers to squeeze the clamp back into shape and reinstall the bolt and nut. Do not fully tighten at this time. Lower Purlin Band Clamp Bottom Chord Band Clamp Band Clamp Location 3. Slightly tighten the nut and bolt or use a small piece of duct tape to hold the clamp in position. 4. Continue by assembling the cables. 20

21 CABLE ASSEMBLY Cable assemblies provide diagonal bracing for the building. Each cable assembly includes the following items: Two (2) lengths of cable (Measure from point-to-point on the frame and cut as needed.) Turnbuckle (1) Cable thimbles (4) and cable clamps (4) CLEARSPAN MAJESTIC GREENHOUSES SPECIAL NOTE: Complete the following steps, but DO NOT tighten the cable assemblies at this time. All cable assemblies for all bays will be tightened after the frames for each bay are assembled and connected. Dead CableEnd Cable Clamps Thimble Turnbuckle Turnbuckle Jaw Cable Clamps Cable Turnbuckle Jaw Typical Turnbuckle Assembly Thimble NOTE: For each cable assembly, two (2) additional thimbles and four (4) additional cable clamps are used to attach the cable assembly to the purlin clamps. Consult the Cable Diagram on the following page and the Side Profile Diagrams for clarification and cable locations. Cable Assembly Procedure: 1. Using the Side Profile diagram (and others) in the Quick Start section as a guide, measure the distance needed on the frame, allow extra for assembly, and cut the cable to the proper length for each assembly. Extra cable has been sent for the cabling. (Make a single assembly before making them all. This allows a check to be sure the correct length has been cut.) Make the necessary length adjustments as needed. 2. Place one cable thimble approximately twelve inches (12") from the end of a cable section and wrap the cable around the thimble as shown in the figure to the right. 3. Grasp both sections of the cable near the thimble and position one cable clamp one inch away from the thimble as shown above. NOTE: Position the clamp on the cable with its U-bolt portion over the short/dead section of the cable. 4. With the saddle portion of the cable clamp in position, thread the nuts onto the U-bolt section of the clamp and tighten slightly to maintain the position of the clamp on the cable. 5. Install a second cable clamp on the cable six to eight (6"-8") inches from the first clamp. 6. Tighten both clamps. 7. Remove the bolt from the jaw of the turnbuckle and position the cable end with the thimble into the jaw of the turnbuckle. 8. Insert the bolt through the eye of the turnbuckle and the cable thimble, thread the nut onto the bolt, and tighten. 9. Repeat Steps 2-8 for the remaining length of cable for this assembly. 10. Open the turnbuckle to its longest position. Thimble 11. Repeat the above procedure for all remaining side and upper cable assemblies. Cable 21

22 CABLE PLACEMENT The diagram and inserts below identify the placement and proper way to attach the cable assemblies to the building using band clamps ATTENTION: The cable positions are identical for both sides of the frame. All cable assemblies are positioned at the ends of the frame regardless of the frame length. Frame length of your building may differ from what is shown. Consult the Quick Start diagram for your shelter for additional details. All inserts show the circled locations as seen standing inside the frame. 1 Customer-Supplied Baseboard

23 CONNECTING THE BAYS FOR 3-BAY GREENHOUSES After assembling the rafters and the frame for the first bay and anchoring and squaring that bay, repeat the END RAFTER and INTERIOR RAFTER ASSEMBLY procedure and the FRAME ASSEMBLY INSTRUCTIONS to complete the next bay. Refer to the following procedure and diagrams for additional information when setting the second bay in position to be connected to the first bay. CLEARSPAN MAJESTIC GREENHOUSES INSTALLING THE BUTTERFLY CLAMPS and TIGHTEN ALL CABLE ASSEMBLIES 1. After assembling the adjacent greenhouse bay, locate the butterfly clamps and review the previous information. 2. Install the clamps in the locations shown below. Complete the following steps to connect the bays of the 3-Bay Greenhouses. 3. After tightening the butterfly clamps, anchor the bay, and tighten all cables. 4. Repeat steps for the third bay. 5. Continue with the End Wall Installation instructions. Two butterfly clamps are used to connect the adjacent rafter legs of the separate bays. The above drawing shows the placement of the lower butterfly clamp between the rafter legs of two separate bays. The upper butterfly clamp is placed between the two legs below the band clamps for the cables (side cable assemblies) and at a similar location on the legs that are without band clamps for the cables. ATTENTION: When setting the frame for the adjacent bay, use the butterfly clamps to set the position of the frame. You must be able to connect the two bays using the butterfly clamps. Do not set the distance between the bays too far apart. 23

24 END WALL INSTALLATION The end walls for the greenhouse are installed before the main cover is attached. The steps to install the end walls for the greenhouse include the following: 1. Install end wall framing. (See End Wall Diagram at the end of these instructions for dimensions.) 2. Install chord struts and diagonal wall bracing. 3. Assemble doors and attach to end wall framing. 4. Prepare polycarbonate end panels and attach to end wall framing. If the rafter feet are set on and anchored to 2" boards, use a QH1330 angle bracket to connect the base rail to the 2" board. Base connection with baseboard INSTALL END WALL FRAMING (Front and Back) Consult the End Wall Diagram at the back of these instructions for the rough opening dimensions for the door and the center-to-center dimensions for the end wall framing. ATTENTION: The end wall diagram shows the front wall and the sidewalls on the same plane. Site variations and different methods for anchoring the greenhouse will cause slight changes in these instructions. It is the responsibility of the owner to adapt these instructions as needed to adjust for these differences. 1. Locate the square metal tubing for the base rail of the end wall. The base rail consists of three (3) long 99" swaged sections of square pipe and one (1) short section cut from a long 96" piece of plain square pipe. 2. Insert the swaged ends of the tubing into the plain ends to connect the pieces. 3. Position this assembled base rail on the ground between the legs of the end rafter at the front of the greenhouse and anchor it in place. This base rail will be directly below and parallel with the chord of the end rafter. END FRAME ANCHORING SUGGESTIONS: If the greenhouse is setting on crushed rock or bare ground, the base rail can be bolted to ground anchors (not included) set into the ground. If the greenhouse includes a concrete floor or a perimeter concrete foundation, the end wall base rail can be anchored using anchor bolts (not included) set into the concrete. Photo shows a QH1330 angled bracket and base rail of the end wall. The bracket is fastened to the base rail using Tek screws (FA4484). Consult the End Wall Diagram for a suggestion to use the bracket to anchor the end wall frame. 4. After securing the base rail between the legs of the end rafter, locate the center of the base rail and mark the location. 5. Consult the End Wall Diagram (back of these instructions) and mark the rough opening for the width of the double door assembly. 6. Place five (5) band clamps (QH1402) on the chord of the end rafter as shown. Do not tighten the bolts at this time. Rafter Chord Door Opening QH1330 Bracket 7. Select the tubing for the two vertical frame supports for the sides of the double door. Each support includes: One (1) long 99" section of square tubing (swaged end): # One (1) short section of square tubing (plain end). This is cut from a 96" plain pipe (#) One (1) square to round tube bracket 24

25 END WALL INSTALLATION (continued) 8. Measure the distance between the top of the base rail and the QH1402 band clamp (Step 6) to determine the length of the first door jamb. 9. Choose one 96" plain square tubing, insert the swaged end of the long # tube into the plain end of the selected tube and tap with a hammer to properly seat the tubes at the joint. 10. On this assembled frame member, mark the length determined in Step 8 (above) and subtract 1-3/4" to account for the square to round tube bracket which is attached to the top of the frame tube (shown below and on the End Wall Diagram). 11. Select a square to round tube bracket and attach the bracket to one end of the vertical frame member. Use a 5/16" drill bit to drill a hole through the tube and attach the bracket to the tube using a nut and carriage bolt (FAH320). CLEARSPAN MAJESTIC GREENHOUSES 14. Using the marks on the base rail for the rough opening for the door, attach the bottom of each door jamb to the base rail using a QH1330 angle frame bracket. Consult the End Wall Diagram. Base Rail Door Jamb QH1330 Door Opening Mark Here QH FALB32B Chord of End Rafter 15. With the door jambs attached at the bottom and loose at the top, measure each frame member to locate the height of the rough door opening and mark the location on the inside of the door frame. Consult the End Wall Diagram if needed. FAH Insert is seen from the front (outside) of the greenhouse. 12. Repeat Steps 8-11 for the remaining door jamb. 13. With the bracket attached to the top of each door jamb, use the bolt in the QH1402 band clamp to attach the bracket to the band clamp. Do not tighten at this time. 96-3/4" 92-1/2" NOTE: The heads of the bolts for each clamp are to the outside (or front) of the greenhouse. At this point, the door jambs should be loosely attached to the chord of the end rafter assembly. Base Rail 25

26 END WALL INSTALLATION (continued) 16. Using a level (or other means), verify that one jamb is plumb and tighten the band clamp bolt to lock the first door jamb in place. 17. Measure the width of the rough door opening between the marks made in Step 15, and tighten the bracket for the remaining door jamb. 18. Verify that both door jambs are plumb and recheck the width of the rough door opening at the top and bottom. Adjust if needed. 19. Choose one 96" square tube for the only horizontal frame member (header) of the end wall framing used at the top of the rough door opening. NOTE: The 96" length of the tubing is 3/4" shorter than the actual rough opening of the door. The QH1330 angle brackets used to secure the tubing to the door jambs are designed to adjust for this difference. 20. Using two (2) QH1330 angle brackets, attach the header tube to the end wall between the door jambs as shown. Bottom Chord 22. Use the End Wall Diagram to determine the number of remaining vertical end wall supports and place one band clamp (QH1402) on the chord of the end rafter for each of the remaining vertical supports. Use the diagram for the location of these clamps. 23. Begin at the center of one door jamb and measure and mark (on the base rail) the locations of the remaining vertical end wall supports. Use the End Wall Diagram for the on-center locations. 24. Choose the parts for each remaining vertical support for the end wall framing. Each vertical support consists of the following parts: One (1) long section of square tubing (plain end) # One (1) short section of square tubing (plain end) cut from standard 96" length One (1) square tube connector to connect the two pipes: One (1) square tube fitting to attach the support to the bottom frame member of the end wall assembly. One (1) square to round tube connector to attach the tubing to the band clamp on the bottom chord. QH1330 QH Use the steps presented earlier in these instructions to measure and cut each short section of square tubing for the remaining vertical frame members. Top of Door Frame 21. Select the metal tubing () for the three (3) short, end wall supports (positioned between the top door frame and the chord of the end wall) cut to the proper length, and attach using the QH1330 angled brackets. ATTENTION: Remember to subtract 1-3/4" to account for the square to round tube bracket that will be attached to the top of each remaining frame members. 26. Once the short length is cut, join the two sections using Tek screws (FA4484) and the square tube connector. (See End Wall Diagram and Step 28.) Chord Tek Screws QH1330 Header Tube 26

27 END WALL INSTALLATION (continued) 27. Choose a square to round tube bracket and attach the bracket to one end of the vertical frame member. Use a 5/16" drill bit to drill a hole through the tube and attach the bracket to the tube using a nut and carriage bolt (FAH320). Position all screw heads so they do not touch the end wall panels when these are installed on the end wall framing Bottom Chord of End Rafter CLEARSPAN MAJESTIC GREENHOUSES INSTALL THE END WALL FRAMING FOR THE BACK OF THE GREENHOUSE The end wall framing for the back of the greenhouse is assembled in the same way as the front end wall. If the back wall includes the optional double door kit (additional purchase required), repeat the End Wall Installation procedure and install the framing for the remaining end wall. If the back wall DOES NOT include an optional double door kit, vertical frame members are installed in the framed opening. See the diagram below. 28. With the frame member secured at the joint with a square tube connector and the square to round tube bracket attached to the top of the frame member, place a square tube fitting on the bottom of the frame member. QH Cut the tubing (#) to the required length and attach to the end wall framing These additional vertical end wall supports are attached at the top using a QH1330 angled bracket. They are attached to the base rail using the square tube fitting. Continue with the INSTALL CHORD-TO-CHORD STRUTS AND DIAGONAL BRACING FOR THE END WALL after all end frames are attached to the remaining bays. 29. Align the center of the assembled frame member with the first center mark on the base rail and attach the top of the frame member to the band clamp on the chord. Do not tighten. 30. Verify that the vertical end wall frame member is plumb and use Tek screws (FA4484) to secure the bottom to the base rail. 31. Once the bottom is attached and the frame tube is plumb, tighten the top band clamp. 32. Repeat the procedure as needed to assemble and install the remaining vertical end wall supports. 33. Return to the bottom of each frame member and install a Tek screw (FA4484) through the backside of each tube fitting to secure the end frame support to the tube fitting. 27

28 INSTALL CHORD-TO-CHORD STRUTS AND DIAGONAL BRACING FOR THE END WALL The chord-to-chord struts and diagonal bracing provide additional support for the end wall. These are installed before the end wall panels and doors. Photos show a different shelter, procedures are the same. 3. Select and attach hat channel to the inside of the opposite side as shown in the greenhouse below. Complete the following steps to install the additional bracing and struts for one end of the greenhouse. NOTE: Hat channel may ship in 6' or 12' lengths or both. 1. Select one 12' (or two 6') lengths of hat channel and secure using Tek screws to the inside of the end wall in a location similar to that shown below. 4. Choose one of the 8' chord-to-chord struts and secure one end to the chord of the end rafter and the other end to the chord of the second rafter. Use Tek screws (FA4484) inserted through the pre-drilled, offset holes in the ends of each strut to attach the strut to the top of the chord on each rafter assembly. Chord Photo shows diagonal hat channel bracing as seen from the inside of the greenhouse. Hat channel is attached to the rafter leg and the chord of the end rafter. 2. After securing the hat channel to the rafter leg and the chord using Tek screws, attach the diagonal brace to each end wall vertical frame member. Strut Strut 5. Repeat the procedure to install the diagonal bracing and chord-to-chord struts for the remaining end wall of the greenhouse and remaining bays. 6. Continue with the gutter installation procedures that follow. 28

29 INSTALL GUTTER-CONNECT SYSTEM The 3-bay greenhouses use a gutter-connect system between the bays to efficiently divert water from the covers away from the greenhouses. The gutter-connect kits are installed before the main covers are installed and before installing the end panels. CLEARSPAN MAJESTIC GREENHOUSES Drawing below is a top view of the same. Connector Gutter Install gutter here. 3. After the two sections are connected and seated in place, locate the gutter mounting bolts and slide these into the channel that runs along the outside of each gutter section. Each Gutter Assembly (#104125) includes: (1) Ten (10') foot gutter section (4) Five (5') foot gutter rails (1) Connector FAG304B ASSEMBLE AND INSTALL THE GUTTER-CONNECT SYSTEM Complete the following steps to assemble the gutter sections. 1. Select a 10' gutter section and place it in position between the rafter legs of the two bays to determine which outside bolt channel will work the best. See Step 3. (Remove the gutter section.) 2. Select two gutter sections and connect them using the connector as shown in the following drawing. NOTE: A small hammer and wood block can be used to seat the connector in one gutter and to seat the remaining gutter section onto the connector. FALB01B NOTE: Two bolts are required to attach the gutter section to each rafter leg. (Actual bolts and locations may differ.) 4. When all mounting bolts are slide into the channel of the connected gutter sections, lift the connected sections into position between the greenhouse bays as shown below. Drawing above shows a connector and two gutter sections. 29

30 INSTALL GUTTER-CONNECT SYSTEM (continued) NOTE: Each gutter section is 10' in length. Rafter spacing is 6' on center. Extra gutter length is included so the gutter can extend beyond the ends of the greenhouse. 7. With the direction of the water drainage determined, place the clamps around the rafter legs, over the mounting bolts in the gutter channel, and tighten. The gutter system can be installed flush with the ends of the greenhouse, or the extra section can be installed (if desired) to extend the gutters beyond the ends. 5. Position the mounting bolts on each side of each rafter leg and place the clamps into position. 8. After securing the first section of gutter in place, install a connector on another 10' gutter section and add the section to the gutter system as described in Step Continue this process until all gutter sections are connected and attached to the frame of each greenhouse bay. The position of the gutter and clamps may vary from what is shown. 10. Continue with installing the hat channel for the side panels. 6. Determine how much gutter will extend beyond the end of the bay and which direction you want the water to drain. NOTE: The gutter must be installed with a gradual slope so water will drain properly from the gutter. 30

31 INSTALL THE HAT CHANNEL FOR THE SIDE PANELS Complete these steps to attach the hat channel runs to the outer side of the assembled bays. SPECIAL NOTE: Install the hat channel and the poly-latch U-channel to the two (2) outside walls only. The interior walls of the individual bays the walls that are adjacent to one another when the bays are connected DO NOT include hat channel and poly latch U-channel. 1. Beginning at one end of the frame along one side, measure down sixteen inches (16") from the joint where the leg pipe and the curved rafter pipe are connected and mark the location on the side of the end rafter leg. CLEARSPAN MAJESTIC GREENHOUSES 4. From the top mark, measure twenty-four inches (24") down on the outside of the rafter leg and mark. This identifies the location of the next run of hat channel. Snap a chalk line on these marks. End Rafter Dashed line showing the location of the side run of hat channel Frame length of your building may differ from what is shown. 16" 5. On the outside of each end rafter leg along the same side, measure 10" up the rafter leg from the top of the rafter foot and mark. Stretch and snap a chalk line between the marks to identify the top of the hat channel for the bottom run of channel on each rafter leg. Verify that the line is level. 2. Move to the other end rafter along the same side and repeat Step Stretch a chalk line end-to-end between the marks, verify that the line is level, and snap to mark the location of the first run of hat channel. Use a permanent marker if desired to mark the chalk line locations to ensure a uniform installation. 10" NOTE: Do not install the upper run of hat channel on the curve of the rafter. Hat channel must remain on the straight section of all rafters. 31

32 INSTALL SIDE RUNS OF HAT CHANNEL (continued) 6. Position the location of the final side run of hat channel between the bottom mark on the rafter legs and the mark made in Step 4. This identifies the location of the last run of hat channel. (There should be four (4) chalk lines on the outside of the rafter legs.) Space below is reserved for customer notes. NOTE: Adjust the position as needed to avoid conflicts with other frame components. Dashed line showing the location of the side run of hat channel Frame length of your building may differ from what is shown. 7. Select the hat channel sections, align the bottom edge of the hat channel with the chalk line, and attach to the frame using FA4484 Tek screws. Line showing the location of the side run of hat channel Frame length of your building may differ from what is shown. 8. Repeat the procedure to mark locations and attach the hat channel to the remaining outer side of the assembled bays. 9. With all hat channel attached to the sides, continue by installing the side panels. 32

33 INSTALL SIDE PANELS: OVERVIEW This procedure describes installing the polycarbonate side panels before the polycarbonate end panels. Read the following before you install the side panels: Do not install panels on a windy or stormy day. Use assistants when setting the panels in place. Tape both ends of all side panels using vent tape. Install the UV-protected side out and toward the sun Panels are secured to the hat channel using FA4484 Tek screws and neo-bonded washers (102921). Space Tek screws at 24" intervals. H-channel (104212) is used to join separate panels along the side. CLEARSPAN MAJESTIC GREENHOUSES INSTALL POLYCARBONATE SIDE PANELS Install panel cells vertically to allow condensation to properly drain from the cells. For each side panel use a full 6' x 8' sheet of polycarbonate. Complete these steps to prepare and install the polycarbonate side panels: 1. Take one 6' x 8' polycarbonate panel and remove the protective film and place a mark on the UV-protected side as a reminder to install this side toward the sun. Always remove the protective film and mark and install the Mark UV Side X UV-protected side to the outside of the greenhouse. Components needed: Polycarbonate panels (6' x 8') H-Channel (#104212) Neo-bonded washers (#102921) Tek screws (#FA4484B) and vent tape ATTENTION: DO NOT store or allow the polycarbonate panels to remain in direct sunlight for an extended period of time. Damage to the panels can occur. In addition, the protective film, which must be removed prior to installation, may become difficult if not impossible to remove. For clarity, the following diagrams show the main frame without end panels. Hat Channel 2. Using the white vent tape, tape the open cells as described below. Apply tape at the upper and lower end of all panels to seal the cell openings. Vent Tape Panel 3. Set the prepared panel, with its UV-protected to the outside of the building, on the hat channel and position the outer edge no more than 1/2" beyond the outer edge of the end rafter. Use assistants when setting the panels on the frame. To prevent interfering with the installation of the end panels and flashing, do not allow the roof panel to extend more than 1/2" beyond the end rafter. Side Panels Hat Channel Frame length of your building may differ from what is shown. 33

34 INSTALL POLYCARBONATE SIDE PANELS (continued) 4. Select an 8' section of the aluminum U-channel profile and install it on the edge of the polycarbonate panel that will be flush with the end of the greenhouse. Verify that the UV-protected side of the panel is to the outside of the greenhouse. NOTE: The edge of the panel must not extend beyond the edge of the end rafter leg. When the end panel is installed, the panels will be flush. See photo below. Top of Panel U-channel Edge of Side Panel Edge of End Panel 5. Select an 8' section of the H-Channel profile and attach it to the remaining long edge of the panel H-channel Top of Panel NOTE: The wide or flat side of the H-channel profile will be on the back of the panel (or to the inside of the greenhouse). 6. With the top and bottom end of the panel sealed with tape and the aluminum profile installed, use Tek screws and neo-bonded galvanized washers to attach the assembled panel to the hat channel on the frame. Photo shows polycarbonate side panel where it meets the panel of the end wall after the end wall is installed. (The poly latch U-Channel shown in the photo will be installed during the installation of the main cover.) 7. Select another 6' x 8' sheet of polycarbonate and install the white vent tape (as previously instructed) and install one length of H-Channel to the edge of the panel that does not join the first panel. 8. Once the panel is prepared, insert the edge (without profile) of the second panel into the H-Channel of the first side panel and fasten the panel in place using Tek screws and flat washers. 9. Repeat Steps 6-7 for the remaining interior side panels. 6' x 8' Side Panel H-Channel Frame length of your building may differ from what is shown. 34

35 INSTALL POLYCARBONATE SIDE PANELS (continued) SPECIAL NOTE for longer greenhouses: As the panels and H-Channel profile are assembled and attached to the frame, the seams where the panels join may not line up with and may run past the rafters of the greenhouse. CLEARSPAN MAJESTIC GREENHOUSES 11. Repeat these steps for the remaining side of the shelter. Continue attaching panels and work towards the end of the greenhouse, a few panels can be trimmed before they are prepared to maintain alignment with the rafters if this is a desired result. DO NOT trim every panel. The last panel must extend beyond the last rafter leg so that it meets the panels of the end wall. 10. When all interior side panels are attached to the frame, repeat Steps 1 6 to install the final end panel for the side. Photo of this similar greenhouse shows one side with side panels attached. 12. Continue with the end panel installation procedure. NOTE: Trim the final end panel if needed so that it is flush with the outside edge of the end rafter leg. The edge of the panel must not extend beyond the edge of the end rafter leg. When the end panel is installed, the two panels will be flush. See the previous photo. 35

36 END PANEL INSTALLATION After framing the end wall and installing the roof panels, attach the polycarbonate panels to the end wall framing. The steps that follow describe one way to complete the end panel installation.the materials and parts needed to install the end panels include: Polycarbonate panels and white vent tape Aluminum U-Channel profile (#104213) and aluminum H-Channel profile (#104212) End cap (#104548), Tek screws (#FA4484B), and neobonded galvanized washers (#102921B) Read the following information before starting: H-Channel profile (104212) is used to join two (2) separate polycarbonate panels at the seam. Tek Screws and neo-bonded washers are used to secure aluminum channel and panels to end wall frame. Install the polycarbonate panels with the UV-protected side to the outside. Mark this side with a marker or tape if needed after removing the protective film. ATTENTION: Remove the protective film from the polycarbonate panels. Allowing the film to remain intact and in direct sunlight will make the film difficult if not impossible to remove. Cover and store in the shade until installation. During preparation, rest the edges of the panels on cardboard or other material to protect them from dirt and damage. Seal the top and bottom edge of the panels with white vent tape. Consult the polycarbonate panels (Quick Start section) for the location and lengths of each panel. The diagrams are located at the back of these instructions. ATTENTION: Position the panels as shown on the panel diagrams. Using a panel in the incorrect place can affect the placement of subsequent panels. In addition, the amount of aluminum profile used between panels and to finish the panel edges may not be adequate if additional seams are created. Begin at the door end of the building. Install all accessories (fans, vents, heaters, etc.) after installing all polycarbonate sheets. INSTALLING END PANELS: These instructions describe one way to install the end wall polycarbonate panels. Diagrams show panels running from one end wall, across the joined bays, and continuing to the end of the end wall of the final bay. The end walls of each bay can also be covered separately. This installation method is not shown. Complete the following general steps to install the end wall panels. 1. Consult the panel location diagrams, select one 6" x 8" polycarbonate panel, begin at the edge of the opening for the double door, and work to the outside edge of the end wall. See the X in the diagram below for the first panel. 6 x 8 6 x 8 4 x 8 4 x 8 Dashed line and small arrows (above) show where to install the white vent tape. Install vent tape along the bottom and top edges of the lower panels. NOTE: Remove the protective film. When needed, an upper panel is cut to length after attaching it to the end wall frame and rafter. Always remove the protective film and mark and install the UV-protected side to the outside of the greenhouse. Mark UV Side 6 x 8 6 x 8 6 x 8 6 x 8 6 x 8 6 x 8 Apply vent tape to lower edge. 2. Apply white vent tape to the bottom and top edge of the lower panel and then install the aluminum U-channel profile (104213) to the edge of the panel adjacent to the door as shown on the Polycarbonate Panels diagram near the back of these instructions. X X 36

37 END PANEL INSTALLATION (continued) 3. Place the panel in position and attach it to the end wall framing using neo-bonded washers and the long Tek screws (FA4484B). End Panel End panel located above door opening. Door is installed later in these instructions. CLEARSPAN MAJESTIC GREENHOUSES 4. Continue installing the polycarbonate panels and aluminum profile in the locations shown on the end panel diagrams (Quick Start section) for the front and back end walls. ATTENTION: The U-channel profile (104213) for the top edge of all panels (dashed line below) is installed last and after all profile is installed along the edges and between each panel as shown on the end panel diagrams. Install U-channel NOTE: When attaching any profile, remember to account for the areas where different sections of profile intersect so that the profile is cut to the proper length. Space the screws evenly at 24" when securing the panels. Do not use washers when securing the H-channel to the end wall framing. DO NOT install profile on the bottom or top edge of the lower end panels. These edges are sealed with the white vent tape only. The upper edge of all lower panels is overlapped by the end cap profile attached to the lower edge of the upper panels when these are installed. Cut upper end panels flush with the edge of the installed roof panels. For best results, end panels should lap under the edge of the installed roof panels. Tape or seal with silicone the upper edge of the upper panels before securing them to the frame. In this photo, the excess upper end panel is removed using a power tool equipped with a round cutting bit. A utility knife can also be used. Exercise caution! Cut upper panel to proper length. Frame shown above may differ from actual frame. NOTE: The outside edges of the panels are finished with the aluminum U-channel profile. Consult the arrows above and the end panel diagrams at the back of these instructions. Aluminum U-channel profile is also installed at the bottoms of the panels above the doors to finish those edges. 5. After installing all panels, cut and attach the aluminum profile to the remaining upper edge of all polycarbonate panels. NOTE: For the rounded edges of the panels, prepare the U-channel profile as shown in the photos that follow: a. Cut angled notches from the aluminum profile to allow bending of the profile. The tighter the curve, the closer the notches. The greenhouse in this photo is used for illustration only. Actual model may differ. 37

38 END PANEL INSTALLATION (continued) b. The distance between the notches is determined by the degree of the bend required to fit the rafter. c. Bend the U-channel profile at the notches before installing it. 3. Trim the width of the polycarbonate panel so that it is one-quarter inch (1/4") narrower than the width of the door frame. NOTE: Trimming the panels as instructed will keep the panel flush with the edge of the door frame after the aluminum profile is installed. 4. Center the panel on the door frame so that approximately one-eighth of an inch (1/8") of the door frame extends beyond the edge of the panel. 5. Using the long Tek screws and neo-bonded galvanized washers to attach the panel to the horizontal cross tube of the door frame. 6. Repeat the procedure for the remaining end panels for the other end of the greenhouse and remaining bays. 7. Continue with the Double Door Assembly procedures that follow. DOUBLE DOOR ASSEMBLY The materials and parts needed to assemble the doors include: Door frames and polycarbonate panels Door hinges and latch hardware Aluminum U-Channel profile (#104213) End cap profile (#104548) Tek screws (#FA4482B & FA4484B)) Neo-bonded galvanized washers (#102921B) Assemble and Attach the Doors NOTE: Install the polycarbonate panels with the UV-protected side to the outside. 1. Locate door frame (#102923) and place it on a flat surface. 2. Select one polycarbonate panel this will be one 4' x 8' panel and trim it so that the length is one-quarter inch (1/4") shorter than the length of the door frame. NOTE: Attach the panel in the locations shown in the photo to hold the panel in place while installing the aluminum profile to the perimeter of the panel. 6. Install aluminum U-Channel profile to all edges of the polycarbonate panel. Photo shows the polycarbonate panel installed on the outside of the door frame and finished with the aluminum U-Channel profile. Corners are cut at 45 angles. To keep the panel and profile in place, the long Tek screws and neo-bonded galvanized washers are installed so the screw drills through the longer edge of the U-profile (underside of the polycarbonate panel) and the washer overlaps the shorter edge of the U-profile (top) as shown above. 7. Repeat the above steps to attach the polycarbonate panel and to install the aluminum profile for the remaining door frame. 38

39 DOUBLE DOOR ASSEMBLY (continued) 8. After assembling both doors, evenly space the hinges along the door frame of each door and attach the hinges to the assembled doors using the short Tek screws. CLEARSPAN MAJESTIC GREENHOUSES 10. Install the 6" chain bolt to the upper part of the inside of one door and the main latch assembly to the other door. Inside View Outside View 11. At the top and sides of the end wall door opening on the inside of the frame, attach end cap and allow it to extend below and into the door frame opening. 9. With the hinges attached to the doors, use the short Tek screws to attach the doors to the frame of the end wall. Assistance is required when hanging the doors. ATTENTION: This profile acts as a stop for the double doors, which prevents undo stress on the hinges. Consult the photos that follow. a. Photo shows the end cap as attached to the end wall door frame tube. View shows the assembly from the outside. See also diagram on next page. b. Cross section insert shows the end cap (dashed line) attached to the inside/back of the door frame. Door Frame Tube End Cap (#104548) Locations of door hinges may vary. The installed polycarbonate end wall panels have been removed to better shown the door frame tube. 39

40 DOUBLE DOOR ASSEMBLY (continued) c. Dashed line identifies where to attach the end cap profile. The end cap extends beyond the frame members and into the rough opening to stop the door in the frame and to help seal the gap between the door and frame. INSTALL POLY LATCH U-CHANNEL Gather the parts: Double U-channel (#104211) Tek screws (#FA4482B) space every 16" for the U-channel installation described below. SPECIAL NOTE: Install the double U-channel to the two (2) outside walls only. The interior walls of the individual bays the walls that are adjacent to one another when the bays are connected DO NOT include double U-channel. 1. Attach one section of the double U-channel to the top hat channel using Tek screws spaced every 16". Attach U-channel flush with the outside edge of the end wall panels. End cap used for door stop and seal. Diagram may show a different frame used for illustration purposes only. 12. After end cap profile is installed, install another section of the same end cap on the inside frame of the door that includes the chain latch. The double U-channel is attached to the sides of the rafters as shown in the photo to the right. 2. Continue to attach the double U-channel sections to the top hat channel and work toward the other end of the frame. Cut the last section of double U-channel to the required length so that it is flush with the end wall panel (if needed). Repeat these steps for the remaining side. 3. After attaching the U-channel, use Tek screws to attach the single U-channel to the top edge of the end rafters. Insert shows the installation of poly latch U-channel on top of an end rafter. The poly latch U-channel will bend with the curve of the rafter as it is attached. Top edge of the end rafter. Diagram may show a different frame used for illustration purposes only. NOTE: This length of end cap will act as a stop for the remaining door of the double door assembly when both doors are closed. 13. Check the operation of the latches and the doors. 14. Repeat steps for remaining bays and continue by installing the poly latch U-channel. SPACE TEK SCREWS EVERY 16" FOR THE INSTALLATION OF THE U-CHANNEL. 4. Continue to attach the U-channel until it has been installed on the top of all end rafters. 40

41 INSTALL MAIN COVER Gather the parts: Main covers and inflation fan kit U-Channel spring (#102198) Ropes long enough to reach over the frame (provided by customer) Box cutter or utility knife CLEARSPAN MAJESTIC GREENHOUSES The main covers are secured to the gutter using the 8' gutter rails which snap into the inside gutter channel. (Gutter rails may be shipped in two 4' lengths for each 8' section of gutter.) Assembly Procedure After the poly latch U-channel is attached to the frame, unpack the main cover and pull into place. Ropes or straps are typically used to pull the main cover onto and over the frame. WARNING: To prevent damage to the cover and to prevent serious personal injury, DO NOT attempt to install the main cover on windy or stormy days. Consult the Spec Sheets for cover identification. The greenhouse is equipped with double-layer main cover and an inflation fan kit. One cover is pulled into position and anchored to the frame, then the inflation kit is installed, and finally the last main cover is attached. The Gutter Rail shown above secures the two (2) layers of the same main cover into the same gutter channel. Main Covers The steps to install the main covers for the 3-bay greenhouses are presented to show how the covers are attached to the greenhouse bays. These instructions present suggestions for installing the main covers. As you read through the steps, your experience with similar structures may present alternatives to the suggestions that follow. NOTE: For the 3-bay greenhouse, the double layer cover is attached to the gutter of the center bay, stretched over that bay, and secured to the remaining center bay gutter. Once it is secured to the sides of each bay, the covers are secured to the top of one end rafter, stretched to the other end, and secured to the top of that end rafter. For the outer bays of the greenhouse, the double layer cover is attached to the center bay gutter, stretched over the outer bay, and secured in the double poly latch running near the top of the outside wall before securing to the covers top of the end rafters. Edge of Covers Main covers are between the gutter rail and the main gutter. The 2 layers of the main cover film are placed between the gutter rail and the gutter channel. The gutter rail is then pressed into the channel locking the cover film in place. INSTALL MAIN COVERS: 3-BAY NOTE: For the 3-bay greenhouse, covers must begin on either side of the center bay. 41

42 INSTALL MAIN COVER (continued) INSTALLATION OVERVIEW: NOTE: Each cover consists of TWO (2) LAYERS of cover film. Begin at the center bay for the 3-bay greenhouse. 1. Center Bay: Locate the main cover film, the gutter rail, and the poly-latch wire spring. Consult the Spec Sheets if needed for proper identification. Prepare the first layer of cover film for the first cover: unfold, mark, refold, and roll. ATTENTION: Install the IR film cover first! Examine the IR film and install with the correct side facing in the direction indicated on the film. 2. Prepare the second layer of cover film for the first cover: unfold, mark, refold and roll. 3. Place first layer in gutter and unroll towards each end of the center greenhouse bay. 4. Place the second layer of the main cover on the first layer in the gutter and unroll towards each end. 5. Align one length edge of the first cover film with one length edge of the second cover film and align the center marks with the center rafter leg of the greenhouse. 6. Secure the first edge of both cover layers to the gutter using the same gutter rails. 7. Pull the first layer over the greenhouse bay and temporarily anchor it in place. 8. Determine a position for the INFLATION FAN KIT and pull the second layer of cover over the bay. 9. Align the edges of both covers, pull the two layers tight, and lock the covers into the gutter using the gutter rails. DO NOT SECURE THE COVER COMPLETELY IN PLACE UNTIL THE INFLATION FAN KIT IS INSTALLED. 10. Install the INFLATION FAN KIT and finish locking the covers for the center bay in the gutter. 11. Stretch the cover layers from end-to-end and secure to the top of each end rafter using the poly-latch wire spring. Center cover is complete. 12. Second Bay: Locate the main cover film, the gutter rail, and the poly-latch wire spring. Consult the Spec Sheets if needed for proper identification. 13. Prepare the first layer of cover film for the second bay cover: unfold, mark, refold, and roll. 14. Prepare the second layer of cover film for the second bay cover: unfold, mark, refold and roll. 15. Place first layer in the gutter and unroll towards each end of the second greenhouse bay. 16. Place the second layer of the main cover on the first layer in the gutter and unroll towards each end. 17. Align one length edge of the first cover film with one length edge of the second cover film and align the center marks with the center rafter leg of the greenhouse bay. 18. Secure the first edge of both cover layers to the gutter using the same gutter rails. 19. Pull the first layer of cover over the bay frame and secure to the poly-latch channel on the outside of the greenhouse using the poly-latch wire spring. 20. Secure one end of the first layer to the top of the end rafter, stretch to the other end, and secure to the top of the remaining rafter. 21. With the first layer of the second cover stretched and secured to the greenhouse bay, install the INFLATION FAN KIT. 22. After installing the fan kit, stretch the second layer of the main cover for the second bay and secure it to the greenhouse. 23. Repeat the procedures to install the double-layer main cover for the remaining greenhouse bay. GENERAL INSTRUCTIONS FOR INSTALLING THE DOUBLE MAIN COVER FOR THE FIRST BAY Complete these steps to install the double main cover on the first bay. Verify that you have installed the IR film according to the markings shown on the film. 1. Take the first cover film and position it along the base of one side of the greenhouse. Partially unfold the cover, position it at the base of one side of the shelter, and center the cover from end-to-end. NOTE: Unfold the cover and locate the leading edge The frame shown in the photos that follow differs from actual frame. Procedure is the same. 42

43 INSTALL MAIN COVER (continued) 2. Locate both edges of the cover (length sides) and fold the film so that the edges are together. NOTE: The length edges are the edges of the cover that are attached to the gutters and to the outside of the greenhouse bay. 3. Place someone at each end and pull the cover (end-toend) to stretch the cover to remove folds and wrinkles in the cover. 4. Measure and mark the approximate center of the length of the rolled out main cover film. Only a small 2" mark is needed to use as a reference point. Mark Center NOTE: Both length edges should remain together and the center marked on these edges. (Measure the length of the cover film and divide by two. Mark the center location on the cover film.) 5. Keeping the two length edges together, fold the film beginning at the edge that is away from the two length edges. Keep folding in this manner until an overall width of 3-4 feet is achieved. CLEARSPAN MAJESTIC GREENHOUSES 7. Repeat the previous step and roll the film from the remaining end towards the center. The cover should now be approximately 3 or 4 feet wide and rolled from both ends. These ends will meet in the middle near the center mark made in Step 4. Photos shows a different cover, used for illustration purposes only. 8. Move the cover to the inside of the greenhouse (if needed) to the center rafter leg of the side where the gutter is located. 9. Repeat Steps 1-8 to prepare the second layer of the first main cover. 10. With assistance, lift one rolled cover layer and place it on the gutter at the center of the bay. Once the cover is resting in the gutter, the center rafter can be used to help support the cover as it is unrolled towards each end as described in the following steps. NOTE: The length edges of the cover those that are attached to the gutter and to the outside of the outside bays must be next to (or towards) the gutter when the cover is unrolled. 11. Unroll the cover in the gutter (but keep it folded) so that it is fully unrolled and extending from end-to-end of the bay. Use the center mark on the cover film and align it with the center rafter of the greenhouse. NOTE: The length edges of the film must remain accessible after the film is refolded. At this point, the cover should be about 3'-4' wide and as long as the greenhouse. 6. After refolding the cover film, begin at one end of the cover and roll the film towards the center mark made in Step After the cover is unrolled and resting against the rafters with the length edges in the gutter, take the second prepared cover and place it in the gutter on top of the first cover. 43

44 INSTALL MAIN COVER (continued) 13. Unroll the second layer (but keep it folded) over the first layer of the main cover. Verify that the length edges are aligned with the edges of the first layer. NOTE: The two cover layers are first secured to the gutter and then pulled over the greenhouse bay, stretched in place, and secured in the poly-latch U-channel on the outside of the bay. 14. Choose one length of the gutter rail and move to one end of the greenhouse bay. (Begin in the center and work towards each end if desired.) Gutter Rail 17. Continue to work towards the end (or ends) of the greenhouse bay. NOTE: As layers are secured to the gutter, verify that they remain even and that the same amount (a few inches) of film extends below the gutter rail channel and into the gutter. The cover layers must remain even as they are secured in place. 18. Once the first length edges of both layers are locked in the gutter, locate the remaining length edge of the bottom cover layer. This is the layer that will be in contact with the rafters of the greenhouse when it is stretched over the rafters. NOTE: The two remaining length edges are used to pull the cover layers over the bay and into position. They are secured using the poly-latch wire springs for the additional bay units. See the diagrams at the beginning of these MAIN COVER INSTALLATION INSTRUCTIONS for clarification. 19. Pull the bottom cover layer over the greenhouse bay and into place. 15. With both layers of the main cover for the first bay in place, align one length edge from one layer with one length edge of the other layer. NOTE: Verify that the layers are centered end-to-end regarding the greenhouse. Use the center mark if needed. 16. With a few inches of each layer extending below the gutter channel that the gutter rail clips into, begin to secure the two layers into the gutter. ATTENTION: To prevent cover damage, do not allow the cover film to catch on any component of the assembled frame when pulling the cover layer into place. Ropes can be attached to the cover through holes made in the cover a few inches from the edge. The cover is longer and wider than what is needed; this allows for attaching the ropes. Main Covers Edge of Covers Main covers are between the gutter rail and the main gutter. NOTE: You must have one edge from one cover layer and one edge from the other layer. DO NOT LOCK BOTH EDGES OF THE SAME COVER LAYER INTO THE GUTTER. If ropes are tied to the cover, they can then be tossed over the bay and used to help pull the cover into place. Photos (on the following page) show ropes used to pull a cover over a single bay greenhouse. 44

45 INSTALL MAIN COVER (continued) 20. After tying the ropes to the main cover, throw the ropes over the top of the greenhouse and pull the covers into place. CLEARSPAN MAJESTIC GREENHOUSES 27. After the covers are locked into the gutters, secure one end of the double cover to the top of an end rafter. Use the poly-latch wire spring to lock both cover layers into the poly-latch channel that runs on top of each end rafter. Use ropes to pull cover over the greenhouse and onto the frame. ADDITIONAL ASSISTANCE IS REQUIRED. 21. Center cover side-to-side and end-to-end. Photos show installing the spring into the U-channel on the outside of the greenhouse. IMPORTANT: To prevent damage to the main cover during installation, additional personnel and lifts may be needed. 22. Once the main cover is in place and centered, temporarily anchor the bottom layer in place (center bay only). NOTE: Small sand bags can be used and set on the cover in the gutter if desired. DO NOT USE ITEMS THAT WILL DAMAGE THE COVER! 23. Install the Inflation Fan Kit before installing the second layer of the double main cover. Consult the instructions included with the Inflation Fan Kit to install the kit. NOTE: The cover material is cut longer/wider than is required to cover the greenhouse. For easier anchoring, allow approximately 10" to extend past the edge of the end rafter as the cover is anchored into place. 28. After the cover is secured to the first end rafter, move to the remaining end rafter of the center bay, stretch the cover layers from end-to-end, and secure the cover to the top of end rafter. NOTE: To this point, the INFLATION FAN KIT should be installed for the center bay and the main cover for the center bay should be fully secured to both gutters and to the end rafters of the center bay. 29. Locate the cover film for the next bay and prepare the cover as described in Steps After installing the inflation fan kit, pull the second (or top) layer of the cover over the greenhouse bay. 25. Remove the temporary anchors (if needed) and align the length edges of the two layers of main cover for the center bay. 26. Pull the layers tight (towards the gutter) and begin to secure the layers to the gutter using the gutter rails. 45

46 INSTALL MAIN COVER (continued) 30. Once the cover is in place and centered, move to outside wall of the outer bay and install the wire spring into the top channel of the double U-channel to secure the first layer of the double cover. NOTE: Begin at one end of the U-channel and work toward the other. Another option is to begin at the middle of each side and work towards each end. Maintain an even length as working along the side. 33. Continue down both edges of the first end rafter until the entire length of the end of the cover film is secured in place. Film Cover Attach main cover to poly latch U-channel. Frame shown above may differ from actual frame. ATTENTION: Center the cover front to back and sideto-side to ensure that enough cover material is present to lock into the U-channel. Remove the ropes as the covers are secured to the greenhouse. 31. Once the first cover layer is in place and secured to the outside wall, begin at the peak of one end of the bay and install the wire spring into the U-Channel to secure the cover film. 32. As the spring is install into the U-channel at the top of the first end rafter, ensure that an even amount of the cover is exposed and maintained along the edge of the greenhouse. 34. Move to the other end of the bay and repeat the steps to secure the cover in the U-channel. NOTE: Begin at the peak and pull the cover tight as the spring is inserted into the U-Channel. It helps to have someone pull the cover tight while another person installs the spring into the U-Channel. 35. Once the first layer of the double cover is stretched and secure, install the inflation fan kit in the desired location and according to the instructions sent with the kit. 36. Install the Inflation Fan Kit before installing the second layer of the double cover. Consult the instructions included with the Inflation Fan Kit to install the kit. NOTE: The cover material is cut longer/wider than is required to cover the greenhouse. For easier anchoring, allow approximately 10" to extend past the edge of the end rafter as the cover is anchored into place. 37. After installing the inflation fan kit, repeat the steps to install the film for the second layer of the double cover. NOTE: When installing the second layer film, use the same U-channel used for the first layer film, and a second run of spring, which is installed on top of the first U-channel spring already in the channel. 46

47 INSTALL MAIN COVER (continued) 38. With the second layer of the double cover installed, test the operation of the inflation fan kit. IMPORTANT: If trimming the excess cover material at the ends and sides, DO NOT remove too much of the excess material. Some excess cover material (the material that extends beyond the end rafters) should remain in place to more easily re-stretch the film if needed. 39. After the second layer of the cover is installed for the second greenhouse bay, repeat the above procedures to install the double cover for the remaining greenhouse bay. SPECIAL NOTE REGARDING THE SECOND AND THIRD BAYS AND INSTALLING THE COVERS: Unlike the first cover, where you secured the cover by reaching through the rafters of the second bay and into the gutter, to install the second double cover, you must work entirely from the second bay as the first now has a cover installed. The procedure to secure the second main cover to the gutter of the remaining bay requires that you reach over the covers from inside the second bay as the unrolled covers rest along the rafters and in the gutter. It is important to keep the edges of the separate layers identified to avoid attaching the edges of the same cover layer to the gutter. 40. After installing all layers of all main covers, read the care and maintenance information that follows. For additional accessories, consult the installation instructions included with those items. CLEARSPAN MAJESTIC GREENHOUSES SHELTER CARE AND MAINTENANCE Proper care and maintenance of the shelter is important. Check the following items periodically to properly maintain the shelter: Regularly check the cover or covers to see that these are tight and in proper repair. Tighten and adjust the tension as needed to prevent damage and wear. Check connections and all fasteners to verify that they remain tight and in good condition. Check the polycarbonate panels to verify that these are secure and in good repair. Verify that nothing is touching the panels that may cause damage. Do not climb or stand on the greenhouse at anytime. Inspect the anchoring system to verify that all components remain tight and in good condition. Verify that the curtain components are in good working condition. Remove debris and objects that can accumulate on the greenhouse. Use tools that will not damage the cover when removing debris. Remove snow to prevent excess accumulation. Use tools that will not damage the cover when removing snow. Check the contents of the shelter to verify that nothing is touching the cover that could cause damage. If the shelter is dismantled and moved, inspect all parts and connections before using. 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 replacement or missing parts, call for assistance. NOTE: With the exception of Truss Arch buildings, ClearSpan shelters and greenhouses do not have any tested loading criteria. 47

48 QUICK START GUIDE 84' Wide Majestic Greenhouse Frame length of your building may differ from what is shown. 16'- 3/8" GROUND TO PEAK HEIGHT 28'-0" ON-CENTER WIDTH Approximately 84'-11" On-Center Width FRONT Grid Represents 12" Squares 48

49 FRONT PROFILE Rafter Note: Rafter profile is the same for all bays. Purlin Connection Note: Purlin connected to end rafters using QH1070 pipe strap. *One purlin run connected to end rafter using QH1070 pipe strap. Purlin connected to mid rafters using " cross connectors. *Purlin connected to mid rafters using " cross connectors. Corner cable connection 28SM23S1 Purlin Connection QH1304 strut 20SM23P2 QH1308 strut Purlin Connection QH1308 strut *Purlin Connection Purlin Connection QH1304 strut 28SM23S1 Corner cable connection Side cable connection Purlin Connection 166S S S P040 Purlin Connection Butterfly clamp connection 2375S100D 2375S100D Cable Connection Note: Clamps used for cable connections are not installed on every rafter. Side cable connection Purlin Connection Purlin Connection Ground Level Side cable connection Sidewall cable connections installed on end and 2nd from end rafters only. Corner cable connections installed on end rafters only. 49

50 SIDE PROFILE PC Wrap cables with duct tape at this point to protect film. Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp 6'-0" Rafter Spacing Band Clamp 48'-0" Shelter Length Band Clamp Band Clamp 131S S S S S S S P0735 PURLIN CONDUIT 50

51 SIDE PROFILE PC Wrap cables with duct tape at this point to protect film. Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp 6'-0" Rafter Spacing 60'-0" Shelter Length 131S S S S S S S S S P0735 PURLIN CONDUIT 51

52 SIDE PROFILE PC Wrap cables with duct tape at this point to protect film. Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp 6'-0" Rafter Spacing Band Clamp 72'-0" Shelter Length Band Clamp Band Clamp 131S S S S S S S S S S S P0735 PURLIN CONDUIT 52

53 Band Clamp Band Clamp Band Clamp 6'-0" on-center Rafter Spacing Band Clamp Band Clamp SIDE PROFILE PC Wrap cables with duct tape at this point to protect film. 96'-0" Shelter Length (center-to-center) 131S075 (15) & 131P0735 (1) PURLIN CONDUIT Band Clamp Band Clamp Band Clamp Band Clamp Band Clamp 53

54 ATTENTION: Cable positions and frame length shown may vary from the actual frame. Chord-Rafter View 2 Strut Connection View 3 Rafter-Rafter Gutter View 12 End Rafter-Purlin View 4 Rafter-Rafter Butterfly Clamp View 11 Foot-Rafter View 1 CONNECTIONS End Rafter- Chord Purlin View 5 Cable Assembly (Closed-Open) View 10 Cable-Band Clamp View 7 Cable-Over Rafter View 8 Mid Rafter-Purlin View 6 Cable Assembly (Closed-Closed) View 9 54

55 CONNECTION - DETAILS 1-6 Rafter Note: Similar connection for strut to chords using clamp # QH1402. Two struts will connect to clamp. FAG363B-3/8" x 3" Bolt & FALB04B-3/8" Nut Foot w/ Base " Band Clamp 2.375" Rafter QH " Band Clamp 1.66 Chord " Band Clamp QH1304-5' Strut Rafter Foot-Rafter View 1 Chord-Rafter View 2 Strut Connection View " Rafter 2.375" End Rafter 1.375" Purlin QH1070 -Pipe Strap *Secured with tek screws 1 thru clamp into purlin 2 thru clamp into chord * 1.315" Purlin * * 1.66" Chord (of end rafter) 1.375" Purlin QH1070-Pipe Strap -Secured with (3) tek screws " Cross Clamp *Secured with tek screws 1 thru clamp into purlin 1 thru clamp into chord Note: Similar connection for purlin to mid chords using clamp # End Rafter-Purlin View 4 End Rafter-Chord Purlin View 5 Mid Rafter-Purlin View 6 55

56 CONNECTION - DETAILS " Band Clamp Closed End of Cable Assembly Mid Length Rafter Some lengths may not have a rafter at exact center length, use closest rafter to mid length. Open end of Cable Assembly Cable-Band Clamp View 7 Note: Each cable assembly spans to the corners of the shelter, secure at top of straight side. Cable-Over Rafter View 8 Cable Clamps Thimble Turnbuckle Cable Clamps Thimble Closed End AS1003 Cable Clamp Thimble Cable Clamps Cable Assembly (Closed-Closed) View 9 AS1094 Thimble Used for closed ends and turnbuckle connections. Cable Clamps Turnbuckle (Jaw-Jaw) Cable Clamps Cable Clamps Thimble Thimble Cable Clamps Open End Cable Assembly (Closed-Open) View 10 56

57 CONNECTION - DETAILS Butterfly Clamp (105124) Gutter Assembly (104125) Rafter-Rafter Butterfly Clamp View 11 Rafter-Rafter Gutter View 12 57

58 1 1 2 CONNECTIONS- RAFTER QH1304 QH1402 QH1402 Bottom Chord QH

59 CABLE PLACEMENT CONNECTIONS- CABLES The diagram and inserts below identify the placement and proper way to attach the cable assemblies to the building using band clamps. ALL SIDE CABLE ASSEMBLIES ARE THE SAME LENGTH. ATTENTION: The side cable positions are identical for both sides of the frame. All cable assemblies are positioned at the ends of the frame regardless of the frame length. All inserts show the circled locations as seen standing inside the frame ATTENTION: Wrap this upper cable connection using duct tape to protect the cover. Upper Cable 2 3 Side Cable Customer-Supplied Baseboard 59

60 END FRAMING - FRONT (Cut to Fit) 92 1/2" NOTE: Diagram shows only one bay, repeat outline for other bays. (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) Inside-to-inside door dimensions are shown /4" 24" on-center Ground Level (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) 60

61 END FRAMING - BACK NOTE: Diagram shows only one bay, repeat outline for other bays. (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) " on-center Ground Level (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) (Cut to Fit) 61

62 END WALL DIAGRAM - FRONT NOTE: Diagram shows only one bay, repeat outline for other bays. ATTENTION: Connection views shown are the same for both front and back end walls. Front View Base connection with baseboard 96-3/4" 92-1/2" NOTE: All door dimensions are inside-to-inside. Ground Level Back View

63 NOTE: Diagram shows only one bay, repeat outline for other bays. END WALL DIAGRAM - BACK 1.50" x 1.50" Pipe Tek screws Insert the square tubes into the connector and secure using Tek screws " x 1.50" Pipe Base connection without baseboard using the middle connector. QH1330 Ground Level Insert the square tubes into the connector and secure using Tek screws " x 1.50" Pipe Tek screws 1.50" x 1.50" Pipe 63

64 H-CHANNEL INSTALLATION INSTRUCTIONS The new H-channel design requires installation of the flat side facing out with channel side toward the building. Some diagrams and photos in this document show installation of original H-channel with channel side facing out. Design of new H-channel does not allow channel-side out installation. Use the diagrams on this page to install H-channel with flat side facing out. ATTENTION: Use only 1-1/2" Tek screws to attach H-channel to building frame. Do not use shorter screws. They will not hold. Do not use washers on Tek screws when installing H-channel. Channel Flat side toward the sun. Flat Side Poly Carb Girt 1-1/2" Tek Screw H-Channel with flat side toward the outside. UV-protected side toward sun. Install 1-1/2" Tek screws through H-channel into building frame. Center Groove H-Channel ATTENTION: Install all twin-wall poly carbonate panels with UV-protected side toward the sun. 64

65 6 x 8 POLY POLYCARBONATE PANELS - FRONT VIEW Gutter 6 x 8 POLY Optional End Panel Installation: If you cover each end wall separately, use H-channel to connect the panels of different end walls. This procedure is not described in this manual. If desired, panels can run across the building seam without using H-channel. This procedure is shown below. 6 x 8 POLY 6 x 8 POLY H-Channel 4 x 8 POLY 4 x 8 POLY 4 x 8 POLY 4 x 8 POLY 6 x 8 POLY 6 x 8 POLY 6 x 8 POLY 6 x 8 POLY Cut all upper end wall panels to fit the opening. Install all profile and H-channel as instructed. After cutting each upper panel, seal the open cells using vent tape or silicone. All polycarbonate panels to be installed with UV protectant to the outside of the shelter. U-Channel: H-Channel: End Cap: Symboy Key (edges of panels X around door frame and along the outer edge of all the upper and outer panels) (vertical seams between end panels) (attach to the bottom of all upper panels will overlap the tops of lower panels.) 65

66 POLYCARBONATE PANELS - BACK VIEW 6 x 8 POLY 6 x 8 POLY 6 x 8 POLY 4 x 8 POLY 4 x 8 POLY 6 x 8 POLY 6 x 8 POLY 4 x 8 POLY 4 x 8 POLY 6 x 8 POLY Cut all upper end wall panels to fit the opening. Install all profile and H-channel as instructed. After cutting each upper panel, seal the open cells using vent tape or silicone. All polycarbonate panels to be installed with UV protectant to the outside of the shelter. U-Channel: H-Channel: End Cap: Symboy Key (along the outer edge of all the upper and outer panels) (vertical seams between end panels) (attach to the bottom of all upper panels will overlap the tops of lower panels.) 6 x 8 POLY 6 x 8 POLY 66