GrowSpan Gothic Pro Greenhouses and Systems

Transcription

1 GrowSpan Gothic Pro Greenhouses and Systems Photo may show a different but similar model. Full Polycarbonate Roof Cover and Ends 2016 Growers Supply All Rights Reserved. Reproduction is prohibited without permission. STK# PC PC PC PC DIMENSIONS 20' W x 12' H x 28' L 20' W x 12' H x 36' L 20' W x 12' H x 48' L 20' W x 12' H x 72' L 1

2 LOCATION Choosing the proper location is an important step before you begin. The following suggestions and precautions will help determine whether your selected location is the best location. READ THIS DOCUMENT BEFORE YOU BEGIN Thank you for purchasing this GrowSpan 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. If you have any questions during the assembly, contact Customer Service at 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 greenhouse or framing during or after construction. Do not occupy greenhouse during high winds, tornadoes, or hurricanes. Provide adequate ventilation if structure is enclosed. Do not store hazardous materials in greenhouse. 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 may cause greenhouse instability and failure of the structure. Failing to anchor the greenhouse 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 greenhouse where large loads such as snow and ice, large tree branches, or other overhead obstacles could fall. Always check local building codes before you begin. SITE After choosing a location, proper preparation of the site is essential. The following site characteristics will help ensure the integrity of the structure. A level site is required. 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 base to assemble the structure. Pre-cast concrete blocks, pressure-treated wood posts, or poured footings are all acceptable when properly used. (Some shelters use ground posts or rafter feet.) 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. 2

3 ASSEMBLY PROCEDURE Following the instructions as presented will help ensure the proper assembly of your greenhouse. Failing to follow these steps may result in an improperly assembled and anchored greenhouse and can void all warranty and protection the owner is entitled to. Steps outlining assembly 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. 3. Gather tools, bracing, ladders (and lifts), and assistance needed to assemble 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 location and site based on information and precautions presented in the documentation included with shipment. 6. Prepare site (if applicable). 7. Assemble frame components in the order they are presented. 8. Assemble frame. 9. Consult the MUST READ document and properly anchor the assembled frame. 10. Install end wall. 11. Install end panels and doors. 12. Install polycarbonte roof panels. 13. Read the care and maintenance information at the end of these instructions. 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 GrowSpan shelters and identify the different shelter parts. (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 the following definitions before you begin. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS Band Clamp: Clamp used to connect end wall framing to rafter pipe. In some cases, band clamps are also used to connect diagonal struts. Clip or Fabric Clip: A short, half-section piece of conduit (cut lengthwise) used to secure end panel to rafter assembly. The clip or fabric clip is typically fastened in place using self-tapping Tek screw. Conduit: An assembly of pipes used to secure some 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 to prevent separation. Cross Connector: Any one of the metal brackets used to "connect" or secure a purlin to a rafter. Crossconnectors are typically pictured on the Pictorial Parts Guide page or in the Quick Start section (if present). End Panel: Fabric or material used to cover end walls. Must Read Document: This document includes building and shelter anchoring instructions, steps for end wall reinforcement, safety precautions, and notices and warnings. Must Read document is sent with all shelters and buildings. If you did not receive a Must Read document, contact Customer Service to request the document. 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: Pipe assembly that runs perpendicular to the rafters or framework that supports the main cover. Purlins are found on the sides and roof areas of the assembled frame, are evenly spaced, and typically run from the front to 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 and bolts. 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. Tek Screw: A self-tapping fastener used to secure pipe joints and to fasten brackets to rafters. 3

4 REQUIRED TOOLS SPECIAL NOTE: Baseboards for Frame 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 These instructions describe installing a baseboard (recommended) at ground level along each side of the frame. Baseboard runs from front to back of frame. This baseboard is not included with the shipment and must be supplied by the customer. Treated or recycled plastic lumber works well for a baseboard. Installed Roof Panel Baseboard The baseboard, when installed properly, helps prevent ground posts from sinking when frame is anchored. 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. Depending on building, it also provides a surface to attach struts or other building components. If used, install baseboard after roof panel installation. Consult these instructions, or contact customer service for additional information regarding baseboards. NOTE: At this time, you do not need to open the plastic bags containing smaller parts such as fasteners or washers (if equipped). STORING POLYCARBONATE PANELS DO NOT store or allow polycarbonate roof panels to remain in direct sunlight for an extended period of time with the protective film still intact. Damage to the panels can occur. Protective film, which must be removed prior to installation, may become difficult if not impossible to remove if panels are left uncovered and stacked in direct sunlight. Cover panels with cardboard or a light-colored tarp to reflect sunlight. Or, store panels in the shade until installation. 4

5 The following graphics and photos will help you identify the different parts and show you how they are used. (Not all parts are shown.) FA4482B Tek Screw QH1402 Band Clamp Aluminum 8' H-Channel Profile FAH009B & FALB01B Carriage Bolt & Hex Nut FAH320B & FALB32B Carriage Bolt & Hex Nut & FA4484B Neo-bonded Galvanized Washers and Long Tek Screws Aluminum U-Channel Profile End Cap Profile Doors/Fans/Vents H-Channel - Clear Cross Connector End Clamp Square-to-Round Tube Connect Bracket Plain QH1330 Angle Bracket Square Tube Fitting Swaged 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. Flat Side Channel 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 GrowSpan Gothic Pro Greenhouses and Systems OVERVIEW See illustration below to identify main parts of greenhouse. 1. Locate required parts for each assembly procedure. 2. Assemble rafters and frame, then square the frame. 3. Prepare and attach end panels. 4. Prepare and install polycarbonate roof panels. ATTENTION: Position purlins evenly during frame assembly. Refer to Grid diagram near the back of this guide (Quick Start section) to position purlins, end clamps, and cross connectors. End Rafter Interior Rafter Purlins Ground Post Baseboard is supplied by customer. Install after installing polycarbonate roof panels. Finished Grade 7

8 LAY OUT BUILDING SITE 3. Use a transit or line level to drive the second corner post to the same depth as the first ground post. After site is prepared, lay out building site. 4. Sting a line at least as long as the building from the first stake at 90. Taking these steps before assembling the shelter saves time and ensures that the structure is positioned as desired. Ground posts must be driven to the proper depth. Width of the shelter is measured from the center of one ground post to the center of the remaining ground post. SQUARE THE SITE Gather parts: Ground posts 5/16" x 2-1/2" hex bolts (FAG336B) 5/16" nuts (FALB02B) 1. Identify a corner where a ground post will be positioned and drive the first ground post into the ground. NOTE: Insert ground post driver into top of ground post to protect post and drive post. Top of post will be one (1) foot above finished grade when properly driven. 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. Ground Post Back Inside of Shelter Outside of Shelter Front ATTENTION: Position pre-drilled holes facing inside/ outside of shelter so they align with bolt holes in rafter pipes. To align bolt holes in ground posts with those in the rafter after driving posts, insert a tapered rod or pry bar into a ground post bolt hole and turn post. 2. After first corner ground post is in place, string a line the width of building (center-to-center) and drive the second ground post into the ground just enough to hold it in place. 5. After squaring the position of the building, measure the length (center-to-center) and drive the next corner ground post. 6. Repeat the same step for the last corner post. NOTE: Distance measured diagonally between corner posts must be equal for building to be square. 7. Check all dimensions (and adjust if needed) before driving remaining posts to the required height. 8. After all corner posts are accurately installed, tie a string line between tops of corner ground posts on the same side of the shelter. String is used to identify the tops of all remaining posts. String must remain tight and level. 9. Use a tape measure to mark the 48" on-center locations of the remaining ground posts. 10. Drive remaining ground posts at the required 48" oncenter width and the height identified by the string. NOTE: Verify that holes in posts are in the proper position and that each post is plumb and driven to the correct depth. 11. Continue with the Rafter Assembly steps that follow. 8

9 ASSEMBLE GREENHOUSE FRAME After site is prepared and an inventory of parts is complete, continue with rafter assembly. NOTE: All rafter assemblies consist of rafter tubes and purlin clamps. Consult the rafter diagram in the Quick Start section near the back of these instructions before and during assembly. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 2. Slide four (4) end purlin clamps (two on each side of the peak) onto rafter pipes. Position clamps as shown. Assistance is required to assemble the greenhouse. RAFTER ASSEMBLY Gather parts: Rafter Pipe (#20G166SS401D) Rafter Pipe (#20G166SS403) Rafter Pipe (#166S064) End Clamps (#102856) Tek Screws (# FA4482B) Nut Setter 3/8'' x 2-9/16 Magnetic END RAFTER ASSEMBLY End rafters include purlin end clamps and band clamps. Install purlin end clamps before the different pipes are connected. Band clamps for side struts are installed when the two (2) end rafters are set onto the ground posts. 1. Select the five (5) pipes needed to assemble the first end rafter and arrange on a level surface. End clamp as seen from inside the assembled frame. NOTE: Position all purlin clamps at or near rafter pipe joints. Consult Quick Start section for additional information. 3. After slipping clamps over rafter pipes, insert swaged end of rafter pipes into plain ends to assemble rafter. 4. Once rafter is assembled, install an FA4482B Tek screw through rafter pipes to secure each joint. (#20G166SS403) (#166S064) (#20G166SS401D) End clamp as seen from inside the assembled frame. IMPORTANT: To prevent damage to cover and end panels, position Tek screws so heads do not contact these covers when installed. 5. Repeat steps to assemble the remaining end rafter and set both end rafters aside. 9

10 RAFTER ASSEMBLY (continued) INTERIOR RAFTER ASSEMBLY Complete the following steps to assemble interior rafters. 1. Select pipes for first interior rafter assembly and position these on ground as shown. Space reserved for customer notes. (#20G166SS403) (#166S064) (#20G166SS401D) IMPORTANT: Interior rafters do not use end clamps. Instead, cross connectors are attached during the frame assembly. 2. Insert swaged ends of rafter pipes into plain ends and secure each joint with an FA4482B Tek screw. NOTE: For longer frames, it may be easier to assemble a few rafters at a time and then begin to assemble the frame. Position Tek screws so they will not contact any cover material when frame is assembled. 3. Once rafters are assembled, assemble frame. 10

11 FRAME ASSEMBLY 2. Secure rafter to ground posts using 5/16" x 2 1/2" (FAG336B) bolts and nuts (FALB02B). Use the top NOTE: Baseboards (strongly recommended) shown in the hole in ground post to secure rafter. diagrams throughout these instructions are installed after roof panels and are supplied by the customer. Rafter Contact customer service at to purchase Band baseboards, or for additional information. Clamp Outside of Gather parts: Shelter All rafter assemblies and purlin pipe Band clamps (#QH1402) Cross connector (#102548) 5/16" x 2-1/2" machine bolts (FAG336B) and 5/16" nuts (FALB02B) Lifts, ladders, and assistants Rope or cable 1. Carefully stand the first end rafter, slide a band clamp onto each rafter leg, and place rafter in first set of ground posts. Brace the rafter in place to keep it straight. Depending on the frame size, a lift and additional assistants may be needed. Consult Quick Start section for details. Back Inside of Shelter 3. Use rope or cable to keep the rafter in position. Ground Post Front Rafter shown differs in design. 4. Carefully position first interior rafter in place and secure to the ground posts as previously described. Rafter shown differs in design. ATTENTION: Stand the rafter so the nuts and bolts of the end clamps are to the inside of the frame. See diagram Step 8. 1st Interior Rafter End Rafter Rafter shown differs in design. 11

12 FRAME ASSEMBLY (continued) 5. As second rafter is steadied, take one section of purlin pipe (131S075). 6. Insert purlin pipe through an upper end clamp of the end rafter and through a cross connector placed in the same position on interior rafter. Consult Quick Start section (Grid diagram) for purlin location per frame. 10. Move to the interior rafter, verify that rafter spacing is forty-eight inches (48") on-center (adjust as needed), and tighten cross connector. Interior Rafter End Rafter Interior Rafter Purlin 7. Align plain end of purlin with center of end rafter. Do not allow the purlin to extend beyond the end rafter. 11. Secure cross connector to rafter and to purlin using FA4482B Tek screws. See details in Quick Start section if needed. 12. Repeat Steps 6-12 to install the first section of each purlin for the first two rafters. Dashed line shows finished grade. End rafter view Interior rafter view 8. Tighten end clamp and secure it to rafter with an FA4482B Tek screw. End Rafter 20' wide center-to-center Purlin 9. Install an FA4482B Tek screw through end clamp and into purlin pipe. NOTE: Actual frame may differ. Install baseboards after installing the polycarbonate panels. 13. Choose another interior rafter assembly and set it in position. Do not use the remaining end rafter. 14. Secure rafter legs to ground posts as previously described and steady the rafter. 15. Add another pipe and clamp to each purlin run. Verify that distance between rafters is 48" on-center. Adjust rafter forward or backward as needed to maintain this on-center dimension. 12

13 FRAME ASSEMBLY (continued) 16. Secure clamp and purlin pipe. Secure purlin pipe joint using an FA4482B Tek screw. 17. Repeat the above steps as needed to stand and secure the remaining interior rafters and purlins to complete the frame assembly. 18. Slide a band clamp onto each leg of remaining end rafter, secure rafter to ground posts, and attach purlins to it. Verify that end clamps are positioned with nut and bolt to the inside of assembled frame. Refer to Quick Start section and previous diagrams if needed. NOTE: If last end rafter is plumb and final purlin pipe extends beyond end of rafter, cut purlin pipe to required length. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS Space reserved for customer notes. Dashed line shows finished grade. Frame length and design may differ from actual frame. 19. Once all rafters are set and all purlins are in place and secure, return to each pipe splice of each purlin and verify that a Tek screw is installed. Install screw if needed. 20. Remove any temporary bracing (if needed) and continue with the next procedure. ANCHOR THE ASSEMBLED FRAME At this point, anchor greenhouse frame. Consult the MUST READ document for anchoring information and suggestions. Please call customer service at for additional anchoring information if needed. CAUTION: The anchor assembly is an integral part of the greenhouse construction. Improper anchoring may cause instability and failure of the structure to perform as designed. Failing to anchor the shelter properly will void the manufacturer s warranty and may cause serious injury and damage. 13

14 END WALL INSTALLATION The steps to install end walls for the greenhouse include the following: 1. Install end wall framing. (See the diagrams in the Quick Start section near the back of these instructions. Read the accessories note below.) 2. Prepare polycarbonate end panels and attach. 3. Assemble doors and attach. INSTALL END WALL FRAMING (Front and Back) DO NOT REPOSITION THE END WALL VERTICALS USED AT THE SEAM OF TWO (2) POLYCARBONATE PANELS. Always consult the installation guides that shipped with the accessory for additional precautions, recommendations, and safety requirements. Before installing any electrical accessory, consult a professional electrician for precautions and additional assistance. For gas heaters, a professional, qualified service technician must install the unit. Site variations and different methods for anchoring the greenhouse may require slight changes to be made to these instructions. It is the responsibility of the owner/ builder to adapt these instructions as needed to adjust for these and other differences. A NOTE ABOUT INSTALLING THE END WALL FRAMING FOR OPTIONAL HEATERS, VENT FANS, AND MOTORIZED SHUTTERS (if equipped): Optional accessories such as heaters, vent fans and motorized shutter units are typically installed in the end walls of this greenhouse. Additional horizontal framing (included) is installed between the vertical end wall frame tubes to mount these accessories. The spacing shown for the end wall supports on the end frame diagrams may be too narrow for the installation of some larger accessories. Diagrams do not show framing for the accessories. When framing the end wall, consult the installation instructions for the accessories (if equipped), or measure the width of the accessory to accurately space and position the end frame tubes. Consult the panel installation diagrams in the Quick Start section to identify the verticals that can be moved. Before installing any greenhouse accessory, adhere to the following: Consult the end frame diagrams before installing the accessory horizontal framing. If labeled, move only those verticals labeled as "NON- CRITICAL" on end frame diagrams when deciding where to install the additional horizontal framing for accessories. Consult the diagrams in the Quick Start section showing the polycarbonate panel locations and the locations of the aluminum trim and profile before repositioning any end wall vertical. Complete these steps to install the accessory framing: 1. Based on the installation requirements and precautions of the accessory, choose a location in the end wall to mount the accessory, and cut a 1.5" x 1.5" frame tube to the required length for framing. 2. Attach these horizontal frame tubes between the vertical frame tubes of the end wall (at the required height determined by the installation instructions included with that accessory) using angle brackets. INSTALL END WALL FRAME Refer to the end frame diagrams (Quick Start section). The materials and parts needed to assemble end wall frame include: Square Tube # and # Angle Brackets (#QH1330) & Band Clamp (#QH1402) Square Tube Fitting (#104624) Square-to-Round Tube Connect Bracket (#104074) Carriage Bolt (#FAH320) and Nut (#FALB32B) Tek Screws (#FA4482B) 1. Locate the square tubing for base tube. Base tube consists of 99" swaged tubes (102987) and one (1) square pipe cut-to-fit. 2. Insert the swaged ends of the tubing into the plain ends to connect the pieces, measure, and cut to length. 3. Position this assembled base tube on the ground between end rafter ground posts (front of greenhouse). Base tube will be directly below and in line with rafter. 14

15 INSTALL THE END WALL FRAME (continued) 4. Secure base tube using an angle bracket and FA4482B Tek screws at each end. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 10. On assembled frame member, mark length determined in Step 9 and subtract amount needed to account for square-to-round tube connect bracket, which will be attached to top of frame tube. See diagram below. End Rafter Ground Post Base Tube The bracket shown in this diagram can be installed with either its short section (as shown) or the long section attached to the ground post. Front (or outside) of the greenhouse Square-to- Round Tube Connect Bracket On the base tube surface facing the inside of the greenhouse, install an FA4482B Tek screw at each pipe joint. Next, locate and mark the center of base tube. 6. Consult the end frame diagram (Quick Start section) and mark the rough opening for the double door. 7. Place band clamps on end rafter above the door as shown below. DO NOT TIGHTEN THE BOLTS AT THIS TIME. Consult diagrams in the Quick Start section to view the frame for this shelter. Vertical Door Frame Tube 11. Cut the tube to length. FAH320 Bolt & FALB32B Nut 12. Select a square-to-round tube bracket and attach bracket to one end of frame member. Use a 5/16" drill bit to drill a hole through tube. Attach bracket to tube using a FALB32B nut and FAH320B bolt. 13. Repeat Steps 8-12 to construct the remaining vertical frame tube for the door. 14. Install the frame tubes. Use the bolt in the band clamp to attach the bracket to the band clamp. DO NOT TIGHTEN AT THIS TIME. NOTE: The heads of the bolts for each clamp are to the outside (or front/back) of the greenhouse. At this point, the two vertical door frame members should be loosely attached to the end rafter. Finished Grade 8. Next, consult end frame diagram in Quick Start section. Choose one (1) square tube (#102897) and insert the swaged end into a tube. 9. Measure the required length for the door frame tube. NOTE: Length is measured between top of base tube and band clamp (Step 7) on rafter. 15

16 INSTALL THE END WALL FRAME (continued) 15. Using the marks on the base tube for the rough door opening, attach bottom of each vertical frame member to base tube using an angle bracket and FA4482B Tek screws. Consult the end frame diagram if needed. Center of Door Frame Tube 18. Install an FA4482B Tek screw through the back side of each door frame tube to secure the tube splice. 19. Choose a tube for door header and cut length to the width of rough door opening. Cut off part of swaged end. Do not cut the plain end. 20. Using two angle brackets, attach header to end wall assembly between door frame tubes as shown. Angle Bracket Door Opening Base Tube Mark Header 16. With vertical door frame tubes attached to base tube, mark the height of rough door opening. 92-1/4" Height of rough door opening 96-3/4" Width NOTE: Inside dimensions are shown. Diagrams may show a different frame. Mark Here 92-1/4" Height of rough door opening 92-1/4" 21. Check width of rough opening at top and bottom. Adjust if needed. Check opening for square. Diagonal dimensions from corner-to-corner should be the same. 22. Cut the tube for the short, end wall supports between header and end rafter. NOTE: Consult the End Frame Diagrams in Quick Start section. Frame shown may differ from actual frame. 17. Using a level (or other means), plumb the door frame tubes and tighten the band clamp bolts to lock frame members in place. 23. Attach as shown above and in Quick Start details. 16

17 INSTALL THE END WALL FRAME (continued) 24. Using end frame diagram, determine the number of remaining vertical end frame supports. Place one band clamp on end rafter for each. 25. Using end frame diagrams (Quick Start section), mark locations of the remaining vertical end wall supports on the base tube. 26. Choose tubes for each remaining vertical support. 27. Use the steps presented earlier in these instructions and the end frame diagrams to measure and cut each section of square tubing for the remaining vertical frame members. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 30. Align center of frame member with center mark on base tube and attach top of frame member to band clamp on rafter. Do not tighten. FA4482B Tek Screw Position all screws, bolts and clamps so they will not damage the end wall panels when panels are attached to the end wall frame. Band Clamp Center Mark 31. Verify that frame member is plumb and use FA4482B Tek screws to secure fitting to base tube and frame member. Square-to- Round Tube Connect Bracket End Rafter Front (or outside) of the greenhouse FAH320 Bolt & FALB32B Nut ATTENTION: Remember to subtract the amount needed to account for the square-to-round tube connect bracket that will be attached to the top of each remaining frame member. 28. Choose a square-to-round tube connect bracket and attach bracket to one end of vertical frame member. Use a 5/16" drill bit to drill a hole through tube and attach bracket to tube using a nut and bolt. 29. Slide a way connector onto the frame tube and set assembly on base tube of end frame. Inside view of end rafter 32. Tighten band clamp and install an FA4482B short Tek screw through clamp and into rafter. 33. Repeat as needed to assemble and install remaining vertical end wall supports. 34. Return to each frame member and install an FA4482B Tek screw through the backside of each tube fitting to secure end frame support to tube fitting. 35. Return to each band clamp, connector, and square tube splice and verify that a Tek screw is installed through each. Install an FA4482B Tek screw if needed. See previous assembly steps. 17

18 INSTALL END WALL FRAMING (BACK) END PANEL INSTALLATION Greenhouse end walls (front and back) are identical except as noted below and on end frame diagrams. If back wall includes optional double door kit (additional purchase required), repeat End Wall Installation procedure and install framing for remaining end wall. If back wall does not include an optional double door kit, consult the end frame diagram to install the vertical frame tubes in the framed door opening. After end frames are assembled, install the polycarbonate panels. Steps that follow describe one way to complete the end wall panel installation. Materials and parts needed to install end panels include: Polycarbonate panels and white vent tape Aluminum U-Channel profile (#104213) Aluminum 8' H-Channel profile Tek screws (#FA4484B) Neo-bonded, galvanized washers (#102921B) Read the following information before starting: U-channel (104213) is used to finish sides and top edges of some polycarbonate panels. Aluminum 8' H-Channel is used to join two (2) separate polycarbonate panels at the seam. Dashed lines show where additional frame tubes are installed when the optional double door is not present. Consult the end frame diagram for additional information. 1. Read note regarding installation of optional accessories at the beginning of the end wall installation section. 2. Cut tubes to required length and attach to end wall framing. 3. Install frame tubes as previous described. FA4484B Tek screws and B galvanized washers are used to secure aluminum channel and panels to end wall frame. Install polycarbonate panels with UV-protected side to the outside toward the sun. Mark this side with a marker if needed after removing the protective film. ATTENTION: Protective film must be removed from the polycarbonate panels. Allowing film to remain intact and in direct sunlight will make the film difficult if not impossible to remove. During preparation, rest panel edges on cardboard or other material to protect them from dirt and damage. Seal bottom edge of panels with white vent tape. Consult polycarbonate panels (Quick Start section) for the location and lengths of each panel. The diagrams are located near the back of these instructions. ATTENTION: Panels must be positioned as shown on panel diagrams. Using a panel in the incorrect place can affect placement of subsequent panels. In addition, the amount of aluminum profile used between panels and to finish panel edges may not be adequate if additional seams are created. Begin at the door end of the building. INSTALLING ACCESSORIES Install all accessories (fans, vents, heaters, etc.) after installing all polycarbonate sheets. 18

19 Complete the following general steps to install end panels. 1. Consult panel location diagrams and select a panel. Begin at the edge of door opening and work toward outside edge of end wall. See X in diagram below for first panel. NOTE: Remove the protective film. When needed, an upper panel is cut to length after attaching it to the end wall frame and rafter. Use the rafter profile as a guide. 2. Apply vent tape to bottom of lower panel and then install aluminum u-channel profile (104213) along panel edge adjacent to door as shown on panel diagram. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS NOTE: When attaching any aluminum profile, remember to account for areas where different sections of profile intersect so that profile is cut to proper length. 4. Space FA4484B Tek screws evenly at 16" on-center when securing panels. DO NOT USE WASHERS WHEN SECURING H-CHANNEL TO END FRAME. DO NOT install profile on bottom of end wall panels. These edges are sealed with vent tape. END WALL FRAME TUBE END WALL FRAME TUBE TEK SCREW PANEL SPLICE "H" CHANNEL [ ] TEK SCREW & NEO-BONDED WASHER X 8MM POLYCARBONATE GLAZING PANEL Dashed line and small arrows (above) show where to install vent tape. Do not install tape in any other location on any other end panels. Diagram shows basic panel installation and fasteners used to secure polycarbonte panels. Secure all polycarbonat panels as shown in the photo. 3. Place panel in position, attach it to end wall framing using B neo-bonded washers and long, FA4484B Tek screws. Mark UV Side X Use an FA4484B Tek screw and washer to secure panel to end wall frame. Do not crush panel when installing screws. Always remove protective film. Mark and install the UVprotected side to the outside (toward the sun). 19

20 END PANEL INSTALLATION (continued) DOUBLE DOOR ASSEMBLY In photo below, top of panel is removed using a power Materials and parts needed to assemble doors include: tool equipped with a round cutting bit. Use rafter as a Door frames and polycarbonate panels guide for best results. Door hinges and latch hardware Cut upper panel to proper length. Aluminum U-channel (104213) End cap (104548) Tek screws (FA4482B & FA4484B)) Neo-bonded galvanized washers (102921B) ASSEMBLE AND ATTACH DOORS 1. Locate door panel (#102923) and place it on a flat surface. 2. Select one 4' x 8' polycarbonate panel and trim it so that length is one-quarter inch (1/4") shorter than length of door frame. 3. Trim width of polycarbonate panel so that it is onequarter inch (1/4") narrower than width of door frame. NOTE: Actual greenhouse frame may differ. 5. Continue installing panels and aluminum profile in the locations shown on the end panel diagrams (Quick Start section) for the front and back end walls. ATTENTION: U-channel profile is installed along the edges of the panels shown in the diagram below. NOTE: Trimming panels as instructed will keep panel flush with edge of door frame after aluminum profile (104213) is installed. 4. Remove protective film. Mark UV-protected side if needed. Install panels with UV-protected side to the outside (toward the sun). Install profile here. 6. Continue with the Double Door Assembly procedures. 5. Center panel on door frame so that approximately one-eighth of an inch (1/8") of the door frame extends beyond the edge of the panel. 6. Use FA4484B Tek screws and neo-bonded galvanized washers to attach panel to horizontal cross tube of the door frame. NOTE: Attach panel in the locations shown in photo to hold panel in place while installing aluminum profile (104213) to the perimeter edge of panel. 20

21 7. Install aluminum u-channel profile to all edges of the polycarbonate panel. Photo shows panel installed on door frame and finished with the aluminum u-channel (104213). Corners are cut at 45 angles. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 11. With assistance, lift door and attach hinges to end wall using FA4484B Tek screws. To keep panel and profile secure, install the FA4484B Tek screws and neo-bonded washers so screw drills through the longer edge of the U-profile (underside of the panel) and washer overlaps shorter edge of the U-profile (top) as shown above. 8. Repeat the above steps to attach panel and to install the aluminum profile to the remaining door frame. Locations of door hinges may vary. 12. Install 6" chain bolt to upper part of the inside of one door. Attach main latch assembly to the other door. 9. After assembling both doors, evenly space two hinges along each door frame. 10. Attach hinges using the FA4484B Tek screws. Inside View Outside View 13. At top and sides of end wall door opening on the inside of the frame, attach end cap (104548) and allow it to extend below header and into the frame opening. ATTENTION: This profile acts as a stop for the double doors and prevents undo stress on hinges. Consult the photos that follow. 21

22 DOUBLE DOOR ASSEMBLY (continued) a. Photo shows end cap as attached to door frame. View shows assembly from the outside. b. Cross section shows end cap (dashed line) attached to the inside/back of door frame. 14. After installing the end cap, attach another section along the inside frame of the door that includes the chain latch. Door Frame Tube End Cap (#104548) c. Dashed line identifies where to attach end cap. End cap extends beyond frame members and into the rough opening to stop the door and to help seal the gap between door and frame. Diagram may show a different frame used for illustration purposes only. NOTE: This section of end cap acts as a stop for the remaining door of the double door assembly when both doors are closed. 15. Check the operation of the latches and doors. 16. Continue by reading ridge cap installation information, then install the polycarbonate roof panels. End cap used for door stop and seal. Diagram may show a different frame used for illustration purposes only. 22

23 RIDGE CAP INSTALLATION NOTE GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 2. Install one section of ridge cap. If ridge cap is installed after installing all polycarbonate panels, it may be necessary to use a lift to reach the peak of the frame. CAUTION: Under no circumstances should weight be applied to the installed polycarbonate sheets! POLYCARBONATE SHEETS ARE NOT DESIGNED OR INTENDED TO SUPPORT EXCESS WEIGHT. FOR BEST RESULTS, USE A LIFT WHEN INSTALLING THE RIDGE CAP AFTER ALL PANELS ARE INSTALLED, OR FOLLOW THE PROCEDURE DESCRIBED IN THESE INSTRUCTIONS. Consult a professional contractor experienced with the installation and assembly of similar structures if needed for additional information. ATTENTION: Review the ridge cap installation steps on Page 28 for connection details. 3. Install two more panels and another ridge cap section. SPECIAL RIDGE CAP INSTALLATION NOTE There are different ways to install the ridge cap for this building. One is shown below as an alternative to the method shown on the following pages. Read through both procedures before you begin. Experience, available assistants, and equipment all affect installation. In the example that follows on this page, sections of ridge cap are installed after each pair of panels are installed. In the example shown on the roof panel installation pages, ridge cap sections are installed after all panels along one side of the frame are installed. Consult those steps and diagrams before you install the panels to better understand ridge cap installation. Use a lift when needed. The polycarbonate sheets are not designed to support weight. Alternative Ridge Cap Installation: 1. Install two panels and seal top edges with white vent tape. See dashed lines below. 4. Repeat the steps until completed. NOTE: Installing each ridge cap section after installing each pair of panels allows someone to work from inside the greenhouse frame. Consult the ridge cap installation steps (Page 28) to prepare each ridge cap section and continue as needed to attach each section to the greenhouse. 23

24 POLYCARBONATE ROOF PANELS Materials and parts needed: Polycarbonate panels (112980) and vent tape H-channel (#111929) and Tek screws (#FA4484B) Neo-bonded, galvanized washers (#102921B) DETERMINE REQUIRED PANEL LENGTH Each roof panel is shipped as a single panel. Differences in site preparation, frame assembly, and how site was (or will be) finished all affect required panel length. Before you begin, measure distance as shown in diagram to determine whether a panel needs trimmed to size or if entire panel will fit. After fitting a panel to a specific location on frame, install that panel in that location. After determining panel length and panel position on frame, continue with the steps that follow. These steps describe one way to install roof panels. Additional assistants and equipment can present alternative installation options. Contact a professional contractor experienced with the assembly of similar structures for additional informtation if needed. 1. Take one roof panel (112980) and remove protective film from UV-protected side. Mark the UV-protected side with a piece of tape (or with a non-permanent marker) so side can be idetified during installation. Typical panel installation shows panel starting 1" down from center of peak and terminating at finished grade. Bottom edge of all panels is covered with a customer-supplied baseboard attached to each rafter through panel. Complete these steps before installing any roof panel: 1. Beginning one inch (1") down from roof peak, measure along rafter to the finished grade where panel will end. See dashed line below. 1" from center of peak Mark here X Dashed line is length of roof panel. NOTE: Set panel on cardboard or other material to protect its edges and surfaces. 2. Remove protective film from remaining side. 3. Apply vent tape along both ends of each roof panel to cover open cells. 4. Take H-channel and attach it along both sides of the panel. Finished Grade H-Channel Install wider lip toward outside on top of panel. ATTENTION: Install wide lip of H-channel so it is on top and on UV-protected side of panel when panel is set into position. 2. Measure a roof panel and compare dimensions. Before cutting any panel, recheck measurement. Panels can be shifted a little toward peak if needed or cut to length. Leave at least 1/2" between top edges of adjacent panels at peak. If panel is too short, measure ridge cap to determine how far down you can shift panel. Also remember that the lower edge can be covered using a customersupplied baseboard. 24

25 POLYCARBONATE ROOF PANELS (continued) 5. With H-channel in place, use a rubber mallet or rubber hammer handle (shown below) to seat H-channel tightly onto panel edge flush with panel bottom. Install UV-protected surface toward sun. GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 6. With assistance, move panel to frame and set it place between the first two rafters to cover the end bay. Vent Tape NOTE: In some instances, it is best to use small pieces of duct tape to hold the H-channel in place until a few Tek screws are installed. Apply duct tape to the backside of the panel. 7. Square panel on rafters. Verify that UV-protected side faces up toward the sun. Finished Grade ATTENTION: DO NOT DAMAGE H-CHANNEL EDGE! Dashed lines show edges of H-channel. Vent Tape NOTE: Dashed line on panel ends identify vent tape. 25

26 GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS POLYCARBONATE ROOF PANELS (continued) 8. Using FA4484B Tek screws and washers, secure panel to rafters. Fin ish ed Gr 9. With assitance, press the lower edge down and against the rafters. Measure 12" down from the first set of screws and install another set of fasteners. ad e 10. Continue working down the panel along both edges and install Tek screws and washers at 12" on-center until the first panel is installed. Ridge Cap Install first set of fasteners below this line to prevent conflicts with the ridge cap installation. Fin ish ed Gr ad e NOTE: Install first set of fasteners below where ridge cap will set. Measure ridge cap to judge placement of screws if needed. Ridge cap is installed after adjacent panel is installed for the first frame bay. 26 NOTE: Arrows show H-channel location. Space screws at 12" on-center along both edges.

27 GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS POLYCARBONATE ROOF PANELS (continued) 11. Prepare next panel as previously described and install it next to first. 13. Continue this pattern until all panels are installed along the first side of the frame Fin ish ed Gr ad e ATTENTION: The H-channel can be installed before panel is placed on frame, or it can be installed after panel is slide into H-channel of adjacent panel. Diagram above shows H-channel installed on panel. CAUTION! Exercise caution when setting next panel into place. You must bend panel and work it into curved H-channel of adjacent panel. Have assistants hold panel in different places during the process. DO NOT LEAVE THE PANEL UNATTENDED WITHOUT FIRST INSTALLING FASTENERS TO HOLD IT IN PLACE. YOU MUST INSTALL H-CHANNEL ALONG THE FREE EDGE AND SECURE IT TO THE RAFTER. Fin ish ed Gr ad e PANEL IS UNDER TENSION AND CAN SPRING FREE OF H-CHANNEL IF CHANNEL IS NOT SECURED TO RAFTERS! Fin ish ed Gr ad e 12. Repeat steps to prepare and install the next panel. 14. Prepare and install the first panel to cover the remaining side of the first frame bay. 27

28 POLYCARBONATE ROOF PANELS (continued) 15. Take a section of ridge cap and place it as shown below. NOTE: Verify that vent tape covers the open cells along top edges of both panels. 16. Consult and follow the Ridge Cap Installation steps on next page to attach first section of ridge cap. 18. Attach next ridge cap section. Sections overlap each other. Seal each overlap using silicone sealant. Finished Grade Finished Grade ATTENTION: This procedure describes installing all ridge cap sections as panels are installed. Depending on availability of equipment and assistants, installation of ridge cap can occur after installing all panels. That procedure is not shown. Finished Grade 17. After attaching the first section of ridge cap, prepare and install the next panel. Finished Grade Finished Grade NOTE: Remember to install vent tape on top and bottom of all roof panels. 19. Continue by installing customer-supplied baseboard as shown on page

29 RIDGE CAP INSTALLATION The steps, diagrams, and photos that follow describe one way to attach ridge cap sections. These steps are required regardless of whether you install all sections after panels are installed, or you install ridge cap in sections during panel installation. Complete these steps to prepare and attach a ridge cap section. Basic Tools: Ladder (or lift) to reach peak of frame Hack saw or metal-cutting tool Power driver and ¼" drill bit Utility knife to cut gasket GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS 2. Along both edges of ridge cap, evenly mark locations to drill four (4) holes for mounting screws. Position all holes between the rafters. Remove cap from panel and drill a ¼" hole in each marked location. See diagram. Ridge Cap Top View NOTE: Dashed line in diagram above shows portion of ridge cap that is overlapped by next section. Ridge Cap Components needed: Ridge Cap Sections (#CG96174) End Cap - 8' Sections (#104548) Foam Gasket Material (#104710) Silicone Sealant View shows a picture of ridge cap attached at the end of the greenhouse. End wall is not shown. 3. Using one (1) end cap (104548) section, cut two (2) pieces that fit between rafters on the underside of roof panel where ridge cap will be installed. End Cap (104548) Underside of Ridge Cap Ridge Cap H-Channel Roof Panel End Cap End Rafter 4. Underside the ridge cap, apply a bead of sealant along both edges to seal cap to top of panel. See dashed line in photo below. 5. Place ridge cap on roof. NOTE: For this installation, first section of ridge cap is installed flush with edges of H-channel attached to tops of each end rafter. Each section of installed ridge cap is overlapped by next section during installation. 1. Take first section of ridge cap and place it in position on panels. Align one end flush with H-channel attached to end rafter. NOTE: If a Tek screw is under the ridge cap, remove the screw and reposition cap. RIDGE CAP MUST SIT TIGHT TO THE TOPS OF ROOF PANELS. ATTENTION: Do not climb on polycarbonat panels. 29

30 RIDGE CAP INSTALLATION (continued) 6. Position an assistant, with the two (2) cut end cap sections, inside greenhouse on a ladder to reach the roof peak. 7. Take one (1) end cap section, place it against the underside of panel, and align it with edge of ridge cap. 10. After installing all ridge cap sections, return to each end, cut a few pieces of foam gasket material and use it to seal the opening at the peak of each end rafter. Foam Gasket Material End cap cut to fit between rafters inside the frame. NOTE: End wall not shown. Customer can also supply different material to seal peak. Ridge cap ends can remain open to ventilate greenhouse. Cover with customer-supplied screen to prevent pests. NOTE: Lip of end cap should face toward peak. Upper edge of panel will be sandwiched between end cap and ridge cap when end cap is properly positioned. 11. Continue by reading baseboard installation notes and installing baseboards and side struts. Ridge Cap Lip Roof Panel Center of Peak End View 8. Hold end cap in position and, using Tek screws and washers inserted through pre-drilled holes in ridge cap, secure ridge cap to end cap. CAUTION: Use a short 2" x 4" wood block pressed firmly against the end cap to hold the cap in position and to prevent driving the screws into a hand or finger. Tek screw and washer driven through pre-drilled hole, through roof panel, and into end cap inside frame. 9. Repeat the steps to prepare and install remaining end cap sections. 30

31 BASEBOARD INSTALLATION (RECOMMENDED) The baseboard (strongly recommended) is supplied by the customer and is attached at ground level along both sides of the frame. It helps keep ground posts in place and also prevents frame from working into ground when anchored. Gather parts: Treated or recycled plastic lumber (supplied by customer). 1/4" x 4" carriage bolts and 1/4" nuts (included) NOTE: Procedure describes one way to install recommended baseboards. Size and type of baseboard chosen may require using alternative steps and fasteners. When properly installed, baseboards run length of frame. Install baseboards over panels outside the frame. 1. Attach first baseboard to ground posts using 1/4" x 4" carriage bolts and nuts. 2. Continue adding baseboards to complete the first run. Splice boards between posts as shown. Use a short section of baseboard to secure separate baseboards at a splice. See below. Inside Shelter GROWSPAN GOTHIC PRO GREENHOUSES AND SYSTEMS SIDE STRUT INSTALLATION There are four (4) side struts for the shelter. Struts are located between end rafters and first interior rafter on each side of shelter. Polycarbonate panels are not shown. Gather parts: Struts Band clamps (#QH1402) Lag screw or nut and bolt (supplied by customer) Complete these steps to install side struts: 1. Locate one strut and position it between one end rafter leg and leg of first interior rafter as shown below. End Rafter Strut Finished Grade Interior Rafter Baseboard is required for this procedure. Customer supplies baseboard. 2. Attach one end of strut to band clamp. Outside Shelter End Rafter Finished Grade Boards should be at ground level or slightly into grade to prevent the shelter from sinking or shifting and to create a seal along the bottom. After installing baseboards, continue with these instructions. NOTE: If recommended baseboard (customersupplied) is not used, secure diagonal struts to ground post using a Tek screw or other customer-supplied fastener. See procedure that follows. Band Clamp Strut NOTE: Position head of band clamp bolt toward the outside of shelter. 31

32 SIDE STRUT INSTALLATION (continued) SEAL POLYCARBONATE PANELS 3. Attach remaining end of strut to baseboard using a lag screw or nut and bolt (not included). See diagram. Photo shows strut attached to inside of customer- supplied baseboard. Attach strut as shown. End Rafter NOTE: The amount of sealant needed to complete the following steps will vary and depends on how thick sealant is applied. Call customer service at to purchase additional sealant if needed. 1. Move inside the greenhouse and run a thin bead of sealant between the lip of H-channel and roof panel. Dashed line identifies lip of the H-channel as seen from inside greenhouse. Baseboard Finished Grade Rafter NOTE: If no baseboard is present, attach strut to ground post using an FA4484B Tek screw, or other customer-supplied fastener. 2. Return to any holes in H-channel and add sealant. 4. Repeat steps to attach remaining struts. FINAL FRAME CHECK 1. After securing struts, verify that each frame clamp is secured to frame with a Tek screw. 2. Verify that each pipe splice (purlin and rafter) is secured with a Tek screw. 3. Complete the following steps to seal panels. 3. Apply bead of sealant to top edge of both end walls where panels meet H-channel attached to end rafters. See dashed line for location. 4. Read greenhouse care and maintenance information. 32