Premium Solar Star Greenhouse

Transcription

1 Premium Solar Star Greenhouse Assembly Instructions SKU# ClearSpan All rights reserved. Reproduction without permission is prohibited. Revision date: March 2006g

2 Contact your sales representative at for anchoring suggestions. YOU MUST READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLE THE GREENHOUSE. Thank you for purchasing this ClearSpan Greenhouse. 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 greenhouse. Please read these instructions before you begin. SAFETY PRECAUTIONS Wear eye protection. Wear head protection. Wear gloves when handling panels. Use a portable GFCI when working with power tools and cords. Do not climb on the greenhouse or framing during or after construction. Do not occupy the greenhouse during high winds, tornadoes, or hurricanes. Provide adequate ventilation if the structure is enclosed. Do not store hazardous materials in the greenhouse without proper ventilation. Provide proper ingress and egress to prevent entrapment. ANCHORING INSTRUCTIONS Prior to assembling this greenhouse, please read the MUST READ document included with the shipment. WARNING: The anchor assembly is an integral part of the greenhouse construction. Improper anchoring can cause greenhouse instability and failure of the structure to perform as designed. Failing to anchor the greenhouse properly will void the manufacturer's warranty and can cause serious injury and damage. ATTENTION: Strong winds will cause the greenhouse to shift if it is not adequately secured to the site. The site on which the greenhouse was constructed will determine the anchoring method that is required. Consult a professional contractor to determine the best and safest way to anchor the greenhouse. WARNING: To prevent property damage and serious personal injury, the assembled greenhouse must be anchored to the site. LOCATION Choosing the proper location is an important step before you begin to assemble the greenhouse. The following suggestions and precautions will help you determine whether your selected location is the best location. This greenhouse has a metal frame. NEVER ERECT THE GREENHOUSE UNDER POWER LINES. Identify whether underground cables and pipes are present before preparing the site or anchoring the greenhouse. Location should be away from structures that could cause snow to drift on or around the greenhouse. Do not position the greenhouse in a place where large loads such as snow and ice, large 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 greenhouse. The site must be level to properly and safely erect and anchor the structure. If the site is not level, use footings to provide a secure, level base to assemble the structure. Precast 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 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. Visit for additional products and customer assistance. 1 of 18

3 ASSEMBLY PROCEDURE Following the instructions as presented will help ensure the proper assembly of your greenhouse. Failing to follow these steps can result in an improperly assembled and anchored greenhouse. 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 if applicable), and assistance needed to assemble the greenhouse. 4. Re-evaluate the location and site based on the information and precautions presented in the documentation included with the shipment. 5. Prepare the site (if this has not been completed). UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin to assemble the greenhouse. 1. Unpack the contents of the box and place them where you can easily inventory the shipment. 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 for clarification, or contact customer service. NOTE: At this time, you do not need to open the plastic bags containing the fasteners. WARNING: FLASHING IS SHARP! USE GLOVES WHEN HANDLING AND DURING ITS INSTALLATION. PANELS ARE HEAVY. USE CAUTION AND ASSISTANCE WHEN LIFTING AND DURING INSTALLTION. 6. Assemble the base frame and greenhouse components in the order they are presented in these instructions. 7. Anchor the greenhouse. 8. Read the Greenhouse Care and Maintenance information at the end of these instructions. REQUIRED TOOLS The following list identifies the main tools needed to assemble the greenhouse. Tape measures or measuring devices Variable speed drill (cordless with extra batteries works best) Hammers and gloves Metal Snips or similar tool to cut flashing Adjustable pliers and self-locking pliers Ladders and/or work platforms Adjustable Clamps to clamp panels together during installation. Additional tools and supports may be needed depending on the structure, location, and application. Visit for additional products and customer assistance. 2 of 18

4 Pictorial Parts Guide Not all parts are shown. The following graphics help to identify the different parts and show how they are used. (Not all parts are shown.) Corner Bracket " x 3" Flat Bracket Pass- Through Connector Steel frame with corner bracket. View shows the inside of the greenhouse. Panel Frame Ridge Cap (CG96174) Metal Frame Recycled Plastic Base A-Angle (104642) to secure steel Neo-Bonded washers Roof Support Plates frame to recycled plastic base and Tek Screws (if recycled plastic base is used). Visit for additional products and customer assistance. 3 of 18

5 NOTE: The side base boards are positioned between (or to the inside) of the door and non-door end base boards as shown to achieve the required length and width. This base can be placed on the site before or after assembling the metal base. After all parts are identified, the site is prepared, and the Must Read document is read, assemble the base for the greenhouse. The following steps describe one way to assemble the greenhouse. RECYCLED PLASTIC BASE BOARDS ATTENTION: The longer boards may exceed 96" as shipped. Measure and cut these to 96" if needed. The door and non-door end base assemblies are identical. Each includes two (2) lengths of plastic lumber: 1 plastic board at 96" 1 plastic board at 32" The metal base is attached to the plastic lumber base using A-Angle brackets after securing the panels to the metal frame. This prevents placing the A-Angled brackets in a position that interferes with the installation of panel brackets. ASSEMBLE THE METAL FRAME BASE Locate the following brackets and tubes to assemble the metal base frame: Corner Bracket The side base assemblies are identical. Each includes two (2) lengths of plastic lumber: 1 plastic board at 96" 1 plastic board at 44" The boards for the recycled plastic base are positioned end-to-end. The joints are not secured with any brackets. See the following diagram. Door End Side Required tubes for each side/end: Sides of Greenhouse: Door End: Non-Door End: 1 48" (plain) 1 99" (swaged) 1 25" (plain) 1 61" (plain) 1 27" (plain) 1 99" (swaged) 1. Assemble the metal frame as shown below: Side Frame Tube Non-Door End Door End Door (or Non-Door) End Side Board NOTE: Do not seat or secure the plain pipe tightly to the swaged pipe at this time. The separate pipes must be allowed to adjust outward during assembly to allow proper panel fit. Visit for additional products and customer assistance. 4 of 18

6 Non-Door End Panel 2. Secure the frame tubes at each corner using a corner bracket and 3/4" Tek screws. Side Panel Side Panel Door End Base Frame NOTE: The angled end panel is installed first and is seated into the corner bracket. The short, side panel is installed next and is flush with the front of the angled panel. NOTE: To maintain the proper dimensions, seat the frame tubes for the door and non-door ends into the each corner bracket. See above and below illustrations. Door (or Non Door) End Angled Panel Side Panel Door (or Non-Door) Frame Tube Frame Base Side Frame Tube View is from the inside of the greenhouse looking at the corner where the panels meet. 4. With the panels set in the corner and the edges tight together, secure the panels to the corner bracket using 3/4" Tek screws. 5. Secure the corner with a 3" x 3" square plate. Top View of Frame Tubes and Corner Bracket NOTE: If the metal frame was not assembled on the recycled plastic lumber frame, set the metal frame in place on the plastic frame base and continue. 3. After assembling the metal base and securing it with the corner brackets, choose the first two panels (as shown in the following diagram) and set these on the metal frame. NOTE: Install the panels with the UV-protected polycarbonate to the outside and the frame to the inside. NOTE: All 3" x 3" square plates are attached to the greenhouse on the inside using self-tapping 3/4" Tek screws. See the photo that follows. Visit for additional products and customer assistance. 5 of 18

7 View shows the inside of frame. NOTE: The raised portion of the pass-through connector is positioned to the inside of the greenhouse. Side Panel 8. Choose the center, non-door end panel, set it in place, and install 3" x 3" square plates to secure the panel seams. See the X's for square plate locations. HINT: When installing panels, use a clamp at the top and bottom corners (when possible) to clamp the panels together before installing the flat brackets. NOTE: Adjust the base frame tubes as needed to allow the panels to fit properly. Reposition the pass-through connectors on the end frame tube as needed and fasten these to the non-door end panels. 9. Position an additional pass-thru connector on the side frame rail (see arrow below) and set the remaining rectangular side panels in place as shown. 6. Move to the remaining back corner and install another angled panel and a rectangular side panel as shown below and secure these as before. 10. Secure the panels to each other using 3" x 3" square flat brackets and to the pass-through connectors. DO NOT SECURE ANY PASS-THROUGH CONNECTORS TO THE METAL BASE FRAME AT THIS TIME. Pass-Through Connector 7. Using the above diagram, position a pass-through connector on the frame tube in the locations identified by the arrows. 11. Set the first angled, door end panel into position as shown above and secure the panel to the corner frame bracket and to the side panel. 12. Move to the other side of the door opening, place the final angled panel in position, and fasten it to the corner bracket. See diagrams on the following page. Visit for additional products and customer assistance. 6 of 18

8 13. Install a flat bracket a few inches in from each lower corner of each angled panel on the inside to secure the corner to the metal base frame. 17. Place one upper, triangle end panel in position on the non-door end, align the edges and ends of the panel with the lower panels, and secure the upper panel using 3/4" Tek screws and 3" x 3" square plates. (See the diagrams and photos that follow.) 18. Take the remaining triangular end panel, loosen the screws along the bottom of the panel used to secure the polycarbonate, and set the panel in position. Secure panel to corner bracket ATTENTION: The lip of the metal trim at the bottom of the triangular panel will overlap the top of the doorframe. Loosen these screws before installing panel. 14. Install the remaining smaller side panels as shown. Reposition the pass-through brackets as needed. NOTE: Brace the angled end panel in place (if needed). Adjust the bottom, side frame rail if needed. 15. To prevent interfering with the door installation, remove the screws from the angled panels along the door edges. See vertical dashed lines above. 16. Set the door in the door opening and slide the end panels together to sandwich the door in the opening. Figure 1 The open tube ends are covered with flashing later in these instructions. ATTENTION: Lock the deadbolt of the door before you slide the base rails together. Photo shows the upper triangular panel as installed. Visit for additional products and customer assistance. 7 of 18

9 Dashed line below shows where the trim of the upper panel overlaps the top of the doorframe. Retighten (Step 21) photo insert in the previous diagram. Remove strap after installing the roof panels. The distances indicated by the arrows in the previous diagrams must be equal before you continue. The metal base will move outward when the roof panels are installed if the frame is not secured. 19. Align the edges and ends with the lower panels and secure the triangular panel using flat brackets. See the diagrams above. 20. Secure the ends of each triangular panel to the lower panels using 3/4" Tek screws and neo-bonded washers. See Figure 1 (previous page). 21. Retighten the screws to secure the polycarbonate to the frame of the triangular panel above the door. DO NOT SECURE THE DOOR TO THE ASSEMBLED FRAME AT THIS TIME. 22. Move to the inside of the frame and measure the distance between the base rail at both ends and in the middle. See the arrows below. 23. Once the greenhouse is assembled to this point, return to each tube splice on the metal base frame and install a Tek screw through the tubes at each splice to secure the joint. This prevents separation of the metal base frame. Base Frame Tubes 3/4" Tek Screw 24. Return to each pass-through connector and secure these to the base rail before you continue. 25. After securing the base frame tube joints and passthrough connectors, square the frame by measuring diagonally from corner-to-corner. Top View of Frame Dashed line shows where to add a tie-down strap to keep the base rail from spreading. ATTENTION: Use a tie-down strap and ratchet (not included) to keep the center of the base in place. See View is from the top looking down on the frame. Visit for additional products and customer assistance. 8 of 18

10 NOTE: The distances indicated by arrows in the previous diagrams are the same when the frame is square. During the roof panel installation, periodically check the frame for square. The frame must remain square for the panels to install correctly. NOTE: To strengthen the side panel seams, the roof support plates are designed so that they join near the center of the smaller side panels. 26. After squaring the frame, locate a short section of roof support plate (26") and attach the support to the inside top of the first small side panel. Roof Support Plate Angled End Panel NOTE: In the above diagram, the smaller side panel (X) has been moved to better show the roof support plates and their locations. NOTE: The first roof support plate is installed with one end positioned past the edge of the short side panel and flush with the polycarbonate of the door or non-door angled panel. See the photo that follows. 29. After installing the lower roof support plates, move to the remaining side of the greenhouse and install the upper roof support plates. The upper roof support plates are attached in the same manner and pattern as previously described. See the photo that follows. Roof Support Plate Inside View Upper Roof Support Plate 27. Choose two (2) forty-eight inch (48") roof support plates and attach them to the tops of the short side panels and work toward the other end of the greenhouse. 28. Complete the installation of the lower roof support plates by installing another 26" section. 30. After installing the roof support plates, attach four (4) 3" x 3" square flat brackets to the underside surface of the end panel frame tubes in the locations shown in the diagrams on the next page. Repeat for the door end panels. Visit for additional products and customer assistance. 9 of 18

11 Diagram may show a greenhouse of a different length. Attach flat brackets in the areas identified by arrows. The following diagram shows the union of the long roof panel and the small side panel as seen from the outside of the greenhouse. The lower roof support plates and the 3" x 3" square brackets secure roof panels. Long Roof Panel Angled End Panel Panels are flush. 31. Set the first long roof panel in place (next diagram) and secure it to the lower roof support plates from the inside. Roof Support Plates Dashed line indicates the drip edge of the roof panel. Small Side Panel NOTE: Solid horizontal line shows the panels on the same plane. 32. Secure the roof panel to the end panels using Tek screws and the 3" x 3" flat plates (Step 30). 33. With the first long roof panel in place and secure, take one short roof panel and set it in place on the greenhouse. REMEMBER: The lower roof support plates are attached to the top edge of the small side panels. Long Roof Panel Roof Panel Drip Edge Angled End Panel Hinged Side Panel Install all roof panels with the extended polycarbonate drip edge at the lower end of the panel. ATTENTION: Roof panels are flush with the end panels. They do not rest on top of the end panels. See diagram in the next column. Panels are flush. NOTE: Diagram shows the union of the two roof panels at the peak of the greenhouse. Visit for additional products and customer assistance. 10 of 18

12 34. Secure the panel to the upper roof support plate and to the 3" x 3" square flat brackets as previously described. 38. Secure the panels at the peak on the inside using Tek screws and the 3" x 3" square flat brackets. 35. Install the square flat brackets at the peak on the inside to attach the panels at the top. 39. Attach 3" x 3" square flat brackets to the underside of the frame of the long roof panel in the locations shown in the next diagram for both panels (X). 36. Take a second long roof panel, set it in position, and attach as instructed. ATTENTION: Unlock the deadbolt of the door at this time if you have not done so. 37. Select another short roof panel (below) and attach it to the greenhouse. 40. Install the final long roof panel and attach it to the lower roof support plates and to the square flat brackets installed in the previous step. Drip Edge The polycarbonate drip edge of the short roof panels is installed as shown above. Visit for additional products and customer assistance. 11 of 18

13 41. Attach one section of ridge cap (CG96174) to the peak in the locations shown below using 3/4" Tek screws and neo-bonded washers (102921). Install ridge cap here 46. With the greenhouse assembled, return to the door and center and adjust it as needed to ensure proper operation. 47. Using the long Tek screws and neo-bonded washers, secure the door to the angled end panels. Tek Screw and Neo-Bonded Washer Ridge Cap CG96174 NOTE: Each ridge cap section is longer than the width of each roof panel and will extend beyond the roof panel seams to overlap with the next section of ridge cap. Angled End Panel Door 42. Attach the last section of ridge cap to the center long roof panel. This ridge cap section will overlap the installed ridge cap sections. 43. With all ridge cap sections installed, install the final vented roof panel. Vent panel is to the top. Tek screws are installed through the doorframe and into the square tubes of the angled end panels. ATTENTION: The screws of the angled end panels that were removed can be reinstalled. The doorframe of the door however will serve to secure these panels. 48. After the door is secured, attach the solar-powered vent openers to each of the vented panels. NOTE: Consult the directions included with the solarpowered openers to install these items. Install two (2) openers for the vented roof panel. 49. After installing the vent openers, read the Foil Tape and Silicone Sealant information and attach the greenhouse flashing as described. NOTE: The top of the vented panel is slipped under the ridge cap and into position. 44. Secure the vented roof panel to the upper roof support plate and install two square flat brackets to the underside of the panel to secure the adjacent panels to the vented panel. 45. Install flat brackets at the peak to secure the final roof panel to the frame. Visit for additional products and customer assistance. 12 of 18

14 FOIL TAPE AND SILICONE SEALANT Foil tape and silicone sealant are included with the greenhouse to seal the spaces between the panels if desired. Tape and sealant can be applied from the outside or the inside depending on the desired results. For some panels, tape can be applied at the seam between panels and under the polycarbonate by removing the screws and washers, installing the tape under the polycarbonate panels, and reinstalling the screws. ATTACH THE FLASHING The metal flashing is used to finish the outside panel edges. The flashing is shipped in 6' lengths and must be cut to fit. Consult the Additional Flashing Installation Photos at the back of these instructions. Use Tek screws (1 1/2") and neo-bonded washers to install the flashing. NOTE: Flashing is installed along the edges of the door and non-door end panels as identified by dotted lines in the diagram below. Tape or sealant can also be applied to the seam that will be under the flashing when that is installed. Foil Tape View above shows foil tape applied over the seam of two side panels on the inside of the greenhouse. ATTENTION: Before installing the flashing, remove the screws holding the polycarbonate panels to the panel frames. See the dashed lines above. Remove and Reinstall Tek Screws WARNING: FLASHING IS SHARP! WEAR GLOVES WHEN HANDLING AND INSTALLING ALL FLASHING. Flashing White dashed line shows the edge of the flashing under the polycarbonate of the roof panel. Visit for additional products and customer assistance. 13 of 18

15 Tek screws and washers are reinstalled through the flashing to secure it to the greenhouse. REMEMBER: Flashing is installed under the polycarbonate of the roof and side panels and it overlaps the polycarbonate of the end panels. Flashing will overlap the angled end panels as shown. Door (and Non-Door) End Panel Complete these steps to install the flashing. 1. To install the flashing, begin at one of the lower front corners and work to the other lower corner of the same end. 4. Continue to install the flashing until one end is complete. 5. Repeat the steps until all flashing is installed. 6. Continue with the final check of the greenhouse. FINAL CHECK OF ASSEMBLED GREENHOUSE 1. After all flashing is installed, inspect the assembled greenhouse and verify that all brackets are in place and secure. 2. Inspect all corner brackets to verify that all panel are secured to these brackets. 3. Remove any sharp corners or edges that are present to prevent injury. 4. Align the plastic lumber base (if needed) with the metal frame base and secure the plastic lumber to the frame base using the A-Angle brackets as shown, Photo shows installing the first section of flashing. Greenhouse may be a similar model. 2. Cut the flashing edge to allow it to bend at the correct angle as it is attached. ATTENTION: To prevent interference with the hinged small side panels and solar openers, additional "trimming" of the flashing is necessary along the edges of the hinged panels. 5. Read the MUST READ document and the anchoring information for the greenhouse. 3. After attaching the first section, install the next section and overlap the first section by a few inches. Visit for additional products and customer assistance. 14 of 18

16 ANCHOR THE GREENHOUSE Space below is reserved for customer notes. Strong winds will cause the greenhouse to shift. It must be anchored to the site. The site on which the greenhouse was constructed will determine the required anchoring method. Consult a professional contractor to determine the best and safest way to anchor the greenhouse. WARNING: To prevent property damage and serious personal injury, the assembled greenhouse must be anchored to the site. READ THE MUST READ DOCUMENT. ANCHORING EXAMPLES The diagrams below illustrate two possible ways to properly anchor the shelter to the site. The parts shown in the diagrams below are not included with the shelter and must be purchased separately. Contact Customer Service at to purchase additional parts to anchor the shelter. Anchoring System when on concrete ANCHORING SUGGESTIONS Ground Anchoring System ATTENTION: After anchoring the greenhouse, read the Care and Maintenance information that follows. Visit for additional products and customer assistance. 15 of 18

17 Greenhouse Care and Maintenance Proper care and maintenance of your greenhouse will help to ensure years of service. The following items identify areas that must be periodically checked to ensure that your greenhouse is maintained properly: Check the anchoring system to see that all components are tight and in good repair. Check connections and all fasteners to verify that they remain tight. Verify that all flashing is in place and secure. To prevent injury, bend sharp corners over so nothing catches on them. Check the polycarbonate panels (if equipped) to verify that these are in good repair. Do not climb or stand on the greenhouse at anytime. 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 panels that could cause damage. If the shelter is moved, inspect all parts and connections before reassembling. 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 help resolve 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. Visit for additional products and customer assistance. 16 of 18

18 ADDITIONAL FLASHING INSTALLATION PHOTOS WARNING: USE GLOVES WHEN HANDLING THE FLASHING! FLASHING IS SHARP. Remove Tek screws and insert flashing behind polycarbonate. Flashing is installed on the outside of the polycarbonate of the door and non-door end panels. Flashing Dashed lines above show the edge of the polycarbonate panel. Install Tek screws through the flashing at the edges of the door and non-door ends of the greenhouse. Edge of Polycarbonate Angled End Panel Edge of Flashing under the polycarbonate Angled End Panel Side Panel Photo shows the flashing as installed correctly behind (or under) the polycarbonate of the side panel and for all roof panels. Visit for additional products and customer assistance. 17 of 18

19 Customer Notes Visit for additional products and customer assistance. 18 of 18