ClearSpan PolyMax Windbreak Wall Photo may show a different but similar model. 2007 ClearSpan All Rights Reserved. Reproduction is prohibited without permission. Revision date: February 2007ldg STK# DIMENSIONS 106474 10' High
YOU MUST READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLE THE WIND WALL. Thank you for purchasing this ClearSpan PolyMax Wind Wall. 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 wind wall. 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 wind wall during or after construction. 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. Never erect the structure under power lines. Identify whether underground cables and pipes are present before preparing the site or anchoring the structure. SITE After choosing a location, proper preparation of the site is essential. Follow the information below. A level site is required. The site must be level to properly and safely erect the wind wall. Drainage: Water draining from areas surrounding the site should drain away from the site to prevent damage to the site and 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. ASSEMBLY PROCEDURE Following the instructions as presented will help ensure the proper assembly of your wind wall. Failing to follow these steps may result in an improperly assembled wind wall and will void all warranty and protection the owner is entitled. The steps outlining the assembly process are as follows: 1. 3. 4. 5. 6. 7. 8. 9. Verify that all parts are included in the shipment. Notify Customer Service for questions or concerns. Read these instructions and all additional documentation included with the shipment before you begin assembling the wind wall. Gather the tools, bracing, ladders (and lifts), and assistance needed to assemble the wind wall. Check the weather before you install the panels. Do not install panels on a windy or stormy day. Re-evaluate the location and site based on the information and precautions presented in the documentation included with the shipment. Prepare the site (if applicable). Assemble the frame components in the order they are presented in these instructions. Install, tighten, and secure the panels. 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 ClearSpan fencing and identify the different parts of the wind wall. (Some are used in this document. Others may not apply to this particular wind wall.) 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 wind wall. Conduit: An assembly of pipes used to secure the wind wall panels. Each pipe joint of a conduit assembly is typically secured using a self-tapping Tek screw. On-Center: Term used to describe a measurement taken from the vertical center of the pipe to the vertical center of another. Plain or Straight Pipe: A term used to describe a pipe that has the same diameter or width throughout its entire length. 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 pipes at the joints and to secure ratchets to posts. UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin to assemble the wind wall. 1. Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets. 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). REQUIRED TOOLS The following list identifies the main tools needed to assemble the wind wall. Additional tools and supports may be needed depending on the structure, location, and application. Tape measure or measuring device Variable speed drill and impact driver (cordless with extra batteries works best) Drill bit (3/8") Wrench, ratchet and socket (recommended) C-clamps (or similar tools for clamping pipes) Scissors and gloves Box cutter or utility knife Ladders, work platforms, and other machinery for lifting designed to work safely at the height of the wind wall
PolyMax Windbreak Wall Photo shown may not reflect the design of the actual wind wall. OVERVIEW This section is an overview of the process for assembling your PolyMax Windbreak Wall. See illustration below to identify main parts of wind wall. 1. 3. Locate the required parts for each assembly procedure. Align and install wind wall posts. Install wind wall panel. Upper Pipe End Post Ratchet Lower Conduit
Lay Out the Site After the site is prepared, mark the location where the wind wall will be situated.taking these steps before assembling the wind wall saves time and ensures that the structure is positioned as desired. The following procedure is a suggested method. MARK the Site AND DIG ALL POST HOLES 1. Identify the locations of the end posts of the wind wall and drive a stake to mark the locations. Stakes should be spaced longer than the wind wall and off the actual wind wall line to allow for the digging of the post holes. 3. 4. Place first end post into the hole. Check that the post is straight (plumb), add fill, and tamper the post in place if concrete was not used. After setting the first end post, measure eight (8') feet along the string line from the center of the first post to mark the center of the next post. Repeat these steps until posts are set in place (8' oncenter. NOTE: If concrete was used as recommended, allow the concrete to set before installing the panel. NOTE: Length is measured from the center of one end post to the center of the other end post when the wall is a straight wall. After holes are dug, reposition the string line over all holes and mark the on-center locations of each wind wall post. ATTENTION: Consult the diagrams in the Quick Start Guide at the back of these instructions. Consult the Corner Installation comments and the end of this section before setting posts. POST INSTALLATION Gather the parts: Pipe 375'' x 168'' Plain (#2375P168) Frame Assembly Procedure: CORNER INSTALLATION OF WIND WALL If the wind wall includes an angled section, an additional post is set at the point where the angle begins. This additional post is set in the same hole as the end post that ends the straight portion of the wind wall. Depending on how the wind wall was ordered, the wind wall panel may be shipped as multiple panels or a single panel. If the panel is a single panel, additional steps may be needed to attach the panel to the posts. The panel can "bend" around the corner and is typically attached in the same manner as previously described. End Post (Straight Section) End Post (angled section) NOTE: For stability and best results, the use of concrete to secure all posts is strongly recommended. Use an auger to drill all holes and a mechanical tamper to pack backfill if concrete is not used. 10' Concrete 4' ATTENTION: At the point where the angle begins, set the two end posts flush at the top as shown in the diagram above. 1. 8' (center-to-center) Take one post (#2375P168), measure 48" from one end, and mark the location on the pipe. NOTE: Set all posts four (4) feet below ground level as shown in the diagram above. Multiple Panels: Allow a small gap to remain between the two posts set at the corner to allow each panel to be wrapped around and secured to the back of each post. Single Panel: If a single panel is used, set the posts tight against each other at the point where the angle begins, and allow the panel to "bend" around the corner and continue to the remaining end post where it is secured with fabric clips.
PANEL INSTALLATION After all posts are set, install the wind wall panel. The diagram below shows a typical wind wall panel. 3. Remove a section of the top pocket at each post to expose the upper pipe (when installed) to drill a bolt hole through the upper pipe and into each post. Do prevent damage or injury or both, do not attempt to hang the panel on windy or stormy days. POCKET Top of Cover 6" 6" Additional assistance is required to hang and secure the panel. Notch Upper Pocket Slide upper pipe section into pocket Gather the parts: Pipe 1.66'' x 99'' swaged (#166S099) Pipe 1.90'' x 99'' swaged (#190S099) Panel (or panels) Ratchets (#QH1061) and black strap Fabric clips and Tek screws 5/16" x 4-1/2" bolts and 5/16" locknuts 1. Use lifts designed to work safely at the height of the wind wall. Locate the panel and unfold it out on the ground along the posts. NOTE: Unfold the panel so that the lower pocket is toward the ground (or on the underside of the panel) away from the posts, and the upper pocket is positioned along the bottom of the posts. POCKET Bottom of Cover 4. 5. 6. 7. Take one section of the upper pipe (190S099) and insert the swaged (or tapered) end into the upper pocket. Pull the panel up to the top of the first two ground posts and reposition the panel as needed to align the panel notches with the tops of the posts. Dashed line shows the upper pipe inside the upper pocket Upper Pocket Pull panel up and into place Clamp or hold the panel and pipe in position and drill a 3/8" hole through the upper pipe and through the end post. Bolt the pipes together using a 5/16" bolt and 5/16" locknut. Verify that the end of the upper pipe does not extend beyond the edge of the post as shown below. 6" 6" Align the upper pipe with the outside edge of the vertical post. Panel is not shown. Line shows the lower pocket on the underside of the panel Upper Pocket Position the upper pocket against the posts and center the panel as shown above. NOTE: Allow six inches (6") of the panel to extend past each end post. This material is used to clip the panel to the end post later in these instructions. 8. Move to the next post, insert another upper pipe section into the upper pocket, and slide the plain end of this pipe onto the swaged end of the first upper pipe. NOTE: Remove any clamps that interfere with joining the two upper pipe sections and clamp or hold the upper pipe in position once the sections are joined.
PANEL INSTALLATION (CONTINUED) 9. Secure the upper pipe sections at the joint using a Tek screw. This prevents separating during installation. See the diagram below. Tape over the screws with duct tape (purchased locally). Tek Screw 15. Using the lower pocket and a 3' strap as a guide, attach the ratchets to the posts at the lowest position possible that allows the ratchet to operate properly. Use a Tek screw to attach each ratchet to each post. NOTE: The 3' strap is folded in half during installation. Read the steps below for clarification if needed. Panel Swaged End Plain End 10. 11. 1 13. 14. Drill a hole through the upper pipe and post and secure using a 5/16" x 4-1/2" bolt and locknut. Continue this pattern and work toward the remaining end post. NOTE: The installation of the upper pipe is complete when each upper pipe section is secured at each joint with a Tek screw, and the entire upper pipe assembly is secured to the tops of each post. After the upper pipe is installed and the panel hangs down from the upper pipe, assemble the lower conduit. The lower conduit is the same length as the upper pipe. a. b. c. Locate all swaged pipes (#166S099) needed to assemble the lower conduit. Insert the swaged end of each pipe into the plain end of another pipe until the conduit is assembled. Secure each pipe joint with a Tek screw and tape with duct tape (purchased locally). NOTE: If needed, temporarily secure the panel to the end posts at the bottom to keep the panel in place and prevent it from blowing in the wind. Take the assembled lower conduit and place it at one end post of the wind wall. Collect the QH1061 ratchets (see arrows below) and place one at the base of each post. See diagram below. 16. 17. 18. 19. Ratchet Slide the assembled lower conduit into the lower pocket of the panel and center it end-to-end. At one post, flip the panel skirt up and out of the way, and cut a slit in the lower pocket. NOTE: Panel shown below may differ from actual panel. Cut only the panel pocket; do not cut through the panel. Insert a 3' section of strap through the slit and around the lower conduit. Place the strap ends together, thread the ends into the ratchet, and slightly tighten. Lower Pocket 20. Repeat the steps for the remaining ratchets. 21. Using additional help (if needed), use the ratchets to tighten the panel. NOTE: Depending on ratchet location, it may be necessary to remove excess strap if it binds up in the ratchet. Loosen the ratchet, shorten the strap as needed, insert the strap ends into the ratchet, and retighten.
2 23. After all ratchets are tightened, divide the number of fabric clips in half; one half is used for each end pipe. At each end of the wind wall, fold the panel end around the end post and secure in place using fabric clips and Tek screws. Space below is reserved for customer notes. Wind wall CARE AND MAINTENANCE Proper care and maintenance of the wind wall is important. Check the following items periodically to properly maintain the wind wall: Regularly check the panel to see that it remains tight and in proper repair. Check connections and all fasteners to verify that they remain tight. Check all ratchets to ensure that they remain tight. Inspect all straps to verify that they are in good repair. Replace any damaged straps. Do not climb on the frame at anytime. NOTE: Evenly space the fabric clips along the end post as shown above. 24. Continue by reading the care and maintenance information that follows. Check the wind wall to verify that nothing is touching the panel that could cause damage. If the wind wall is moved, inspect all parts and connections before reassembling. For replacement or missing parts, call 1-800-245-9881 for assistance.
Quick Start Guide PolyMax Windbreak Wall Frame shown may differ in length from actual wind wall.
FRONT PROFILE 190S099 5/16"x4-1/2" HEX HEAD BOLT WITH LOCK NUT. (FIELD DRILL THRU BOTH PIPES) NOTE: COVER NOT SHOWN FOR CLARITY. (COVER CAN EITHER BE 15 oz POLYMAX OR 80% SHADE MATERIAL.) 1.90" PIPE 375" PIPE NOTE: COVER SHOULD BE SLID ONTO HORIZONTAL PIPES BEFORE BOLTING TO THE VERTICAL PIPES. 166S099 (BOTTOM POCKET PIPE) 1.66" PIPE 103620B 3' STRAP 375" PIPE TEK SCREW QH1061 RATCHET 2375P168 2375P168 GROUND LEVEL 10
WIND WALL DIMENSIONS 11