ClearSpan Pro Solar Star User manual

Revision date: 05.28.10

is prohibited without permission.

STK#

R035B00011A (Twin-Wall Polycarbonate)

R035B00011B (Corrugated Polycarbonate)

ClearSpan™

Pro Solar Star™Greenhouse Door Kits

(Double Swinging Door)

Diagram shows a corrugated double swinging door centered and installed in an end wall frame. The door

kit includes materials for the double door only. All other components shown in the diagram above and other

diagrams throughout this guide are not included and require additional purchase.

Ground Level

2Revision date: 05.28.10

Table of Contents

Important Information ..............................................3

Door Frame Assembly .............................................5

Twin-Wall Double Swinging Doors..........................7

Corrugated Double Swinging Doors.......................10

Shelter Care and Maintenance ................................13

Quick Start Guide .....................................................14

Double Door Frame Layout...............................15

DOUBLE SWINGING DOOR KIT: READ THIS BEFORE

YOU BEGIN

The double swinging door kit is designed to attach to

any of these end frame kits: R020B00001, R024B00001,

R030B00001, and R035B00001. These instructions and

the instructions for the end frame are written to be used

together.

If you have not installed your end frame kit, consult these

instructions as you assemble the framing for both the

door and the end frame. Adjust dimensions as needed to

accommodate the door installation and location.

NOTE: The end frame is designed to frame an end of one

of our roll-form buildings (20', 24' 30' or 35' wide). Some

end frame components may not be used when a door is

installed in the end frame.

If you have already installed the end frame kit, use these

instructions to determine the best location for the door

and remove the end framing as needed to install this door

kit. Reinstall end frame as described in this guide.

If you are installing this door kit in an end frame that is

not identified above, use these instructions for critical

dimensions and details.

Consult the services of a qualified contractor if needed. It

is the responsibility of the owner/contractor to adapt these

instructions to safely and competently install this door in

an end frame or building that it was not designed for.

Complete these steps to begin and to install the door:

Based on the dimensions of the door (or doors),1.

determine where you can position the door in the end

frame. Use the diagrams from both this manual and

the end wall assembly guide.

Return to the end wall instructions and frame the end2.

wall as needed based on the door location. Secure

the door framing to the end wall framing.

Assemble the door and attach the assembled door to3.

the door frame of the end wall.

NOTE: If you purchased a fabric end panel to cover

the end wall frame, install the panel before you install

the door; then remove the panel material as needed

to allow for the installation of the door.

If you purchased a polycarbonate package (8mm

twin-wall or corrugated), install those panels after

installing the door(s). Panels or parts of panels will

remain from the end panel kit resulting from the

installation of the door(s).

Revision date: 05.28.10

Important Information

YOU MUST READ THIS DOCUMENT BEFORE YOU

BEGIN TO ASSEMBLE THE DOOR KIT.

Thank you for purchasing this ClearSpan™ door kit.

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 doors. Please

read these instructions before you begin.

SAFETY PRECAUTIONS

Wear eye protection.•

Wear head protection.•

Use a portable GFCI (Ground Fault Circuit•

Interrupter) when working with power tools and

cords.

Do not climb on the framing during or after•

construction.

Provide proper ingress and egress to prevent•

entrapment.

WARNING: The individuals assembling these doors

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.

REQUIRED TOOLS

The following list identifies the main tools needed to

assemble the doors. Additional tools and supports may

be needed depending on the structure, location, and

application.

Tape measure or measuring device•

Fine point marker to mark the location frame•

members.

Variable speed drill and impact driver (cordless with•

extra batteries works best)

Tool to cut the polycarbonate panel•

Hammers, gloves, and eye protection•

Ladders, work platforms, and other machinery for•

lifting designed to work safely at the height of the

door and door frame.

ATTENTION: Consult the services of a qualified,

professional contractor if you are not familiar with the

construction of similar frame structures and components.

4Revision date: 05.28.10

Important Information

PARTS IDENTIFICATION

The following graphics and photos will help identify the

different hardware for each door kit. (Some parts are not

shown.)

Corrugated Polycarbonate Double Door Kit

(R035B00011B)

FA4482B

Tek screws

102921B

Neo-bonded washers

108553

Wafer head screw

Twin-Wall Polycarbonate Double Door Kit

(R035B00011A)

102921B & FA4484B

Tek Screws and neo-

bonded washers

104213

Aluminum

U-Channel Profile

108553

Wafer head screw

ASSEMBLY PROCEDURE

Following the instructions as presented will help ensure

the proper installation of the end frame and doors. The

steps outlining the assembly process are as follows:

Verify that all parts are included in the shipment.1.

Notify Customer Service for questions or concerns.

Read these instructions and all additional2.

documentation included with the shipment before

you begin.

Gather the tools, bracing, ladders (and lifts), and3.

assistants needed to install the doors and door

frame.

Read the care and maintenance information at the4.

end of these instructions.

Complete and return all warranty information as5.

instructed (if included).

UNPACK AND IDENTIFY PARTS

The following steps will ensure that you have all the

necessary parts before you begin.

Unpack the contents of the shipment and place1.

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/Spec2.

Sheets are present. If anything is missing or you

have questions, consult the 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 and clamps (if equipped).

QUICK START DIAGRAMS

For a quick overview of the end wall, doors, and

components, consult the diagrams located at the back of

these instructions.

104548

End Cap

104548

End Cap

Revision date: 05.28.10

105488120

Door Jamb

End wall as seen

from the outside.

105488120

Door Jamb

Ground Level

D E

(inside-to-inside)

96-1/2"

If you are installing end

wall framing, install the

two lower girts after door

frame (see X).

ASSEMBLING THE DOOR FRAME COMPONENTS

Consult the diagrams at the back of these instructions before you begin.

Assistance is required to assemble the door frame.

INSTALL THE DOOR JAMBS

The following steps describe one way to set the door jambs.

Using the dimensions from the1. Door Frame Layout located in the

Quick Start section, locate and mark the positions of the door jambs.

Dig a 10"-12" diameter hole at the locations found in previous step to2.

a depth that is below the geographic frost line. (Minimum depth: 24".)

Locate the 120" door jambs (105488120). Using a metal saw, cut and3.

remove the 2-1/2" sections from one end of each door jamb as shown

in photo A. This creates a lip and allows the jamb to be attached to the

girt (see photo B and C).

ATTENTION: Diagrams A-D show the left door jamb only. Adjust cuts

when cutting the end for the right jamb.

Using the diagrams as a guide, attach each jamb to the girts using4.

108553 wafer head screws as shown in photo C, D, and E. (Install

end wall girts if needed.)

ATTENTION: Position the door jambs so the open sides of the

C-channel face away from the door opening (as shown in the photo

C) and the lip overlaps the girt. When attached to the girt, the lower

end of each jamb extends into a ground anchor hole and is secured in

place using concrete. Consult a knowledgeable contractor if needed.

When installing the lower girts (if needed) of the end wall, verify that

the inside-to-inside dimension for the door frame remains consistent.

Door Frame Assembly

Cut along

dotted lines.

Remove

this section

Vertical

Support

2-1/2" 2-1/2"

Wafer Head

Screws

Left

Jamb

2-1/2" Lip

Left Jamb

Door Side

Front

108553

Wafer Head

Screws Toward

Door

Opening

Front

Wafer Head

Screws

Front

Right Jamb

6Revision date: 05.28.10

105488120

Header (cut to length)

92-1/2"

96-1/2"

Concrete Ground Level

(inside-to-inside)

(bottom of header to the

top of finished grade)

Door jamb in

concrete. Ground

Level

*Not shown

to scale.

End frame and rafter are

not included with any

door kit.

ASSEMBLING THE DOOR FRAME COMPONENTS (continued)

Door Frame Assembly

Cut along

dotted lines.

Bend this

section inward

Door

Header

With the door jambs attached, measure and mark the height of the5.

rough door opening. Consult drawing below and the Door Frame

Layout located in the Quick Start section located at the back of these

instructions. Measure from finished grade to underside of header.

Locate the 105488120 header, measure the6. outside-to-outside

distance of the door jambs and cut the header to required length.

Using a metal saw, cut two 2" sections and bend the lip inward from7.

both ends of the door header as shown to the right (see photos F and

G). This creates two (2) lips and allows the header to be attached to

the door jambs. Open channel of the header points upward.

Drill a 3/8" hole near each end of the header to create a drain hole for8.

the header. This helps prevent water from collecting inside the door

header (see photo H).

Position the header so that the two (2) lips on each side overlap the9.

door jambs (see photo H) and align the bottom of the header with

vertical support marks made in Step 5.

With the header level, attach the front and back of the header to10.

the door jambs using wafer head screws. Reinforce the header by

securing the bent lip to the vertical support using Tek screws as

shown in photo H. (Or, customer-supplied bolts can be used.)

After the door frame is square and assembled, secure the door jambs11.

in the ground using concrete.

NOTE: Concrete should remain at least 2"-4" below ground level so

that it does not interfere with construction, installation of other end

wall components (if equipped), or the operation of the door.

After assembling the door frame, continue with the door assembly.12.

Drain Hole

Wafer

Head

Screws

Tek screw

TOP VIEW

Revision date: 05.28.10

Twin-Wall Double Swinging Doors

DOUBLE TWIN-WALL DOOR ASSEMBLY

If your doors include corrugated polycarbonate

panels, skip this section and continue with the

assembly steps for those doors. The materials and

parts needed to assemble the R035B00011A double

door include:

Door frames (#102923), 8mm panels (102908), door•

hinges (FA5030), end cap (104548), and latches

(FA2410)

Tek screws (#FA4484B), neo-bonded washers•

(#102921B), and aluminum profile (#104213)

Assemble and Attach the Doors

NOTE: Install the polycarbonate panels with the

UV-protected side toward the outside/sun.

Locate one (1) door frame (#102923) and place it on1.

a flat surface.

Take one (1) polycarbonate panel and trim it so that2.

the length is one-quarter inch (1/4") shorter than the

length of the door frame.

Trim the width of the polycarbonate panel so that it is3.

one-quarter inch (1/4") narrower than the width of the

door frame.

NOTE: Trimming the panels as instructed will keep

the panel flush with the edge of the door frame once

the aluminum profile (104213) is installed.

Center the panel on the door frame so that4.

approximately one-eighth of an inch (1/8") of the

door frame extends beyond the edge of the panel.

Using Tek screws (FA4484B) and galvanized neo-5.

bonded washers, attach the panel to the horizontal

cross tube of the door frame. Evenly space Tek

screws and washers every 12".

Photo shows the polycarbonate panel attached to

the outside of the door frame and finished with the

aluminum (104213) U-channel profile.

To keep the panel and profile in place, install Tek7.

screws and neo-bonded galvanized washers so the

screw drills through the longer edge of the U-channel

(underside of the polycarbonate panel) and the

washer overlaps the shorter edge of the U-channel

(top) as shown above. Evenly space Tek screws

every 12".

Repeat the above steps to attach the polycarbonate8.

panel and to install the aluminum profile for the

remaining door frame.

Determine which door to install the handle, locate9.

the door latch hole (5" from edge of door in cross

member) and drill 1" hole through the polycarbonate

panel at the hole location.

Install aluminum U-channel profile to all edges of the6.

polycarbonate panel. The 104213 sections at the top

and bottom of the panel run to the panel edges to

seal the cells in the panel.

NOTE: Attach the panel in the locations shown in the

photo to hold the panel in place while attaching the

aluminum profile to the perimeter of the panel. DO

NOT INSTALL NEAR LATCH MOUNTING HOLE.

Handle

Sample

Frame

8Revision date: 05.28.10

Twin-Wall Double Swinging Doors

DOUBLE TWIN-WALL DOOR ASSEMBLY (continued) With assistance, set the assembled doors in the end14.

wall door frame and secure hinges to the door jamb

using one Tek screw per hinge at this time.

Locations of door hinges may vary.

Place one (1) main handle of assembly through hole10.

in door and twist main handle and front plate into

place as shown in the drawing below.

Mark the plate mounting hole locations on the panel11.

and drill a 5/16" hole through the panel and door

frame. Support frame with a block of wood if needed.

Slide back mounting plate into position, square it with12.

the mounting holes and front plate and secure using

two (2) ¼" x 3" bolts and lock nuts. Verify that latch

turns freely. Mount one (1) door latch guide (slotted

plate) using the remaining ¼" x 3" bolts. Position so

latch handle is level. See below.

Horizontal

Position

Door Latch

Guide

Latching

Plate

NOTE: Verify that there is sufficient clearance along

all door edges to allow the doors to swing freely in

the opening. If end panels are installed, either attach

to the outside of the end panels as shown above or

loosen the panels, secure the hinges directly to the

door jamb, and reinstall panel fasteners.

Test the door operation, adjust hinges as needed,15.

and install the remaining Tek screws.

Attach the 6" chain bolt to the inside, upper corner of16.

the door without the handle (see X in drawing below).

Mount the latching plate to the outside of the same

door (see drawing in step 12). The screws supplied

with the latch are not used for metal jambs.

After assembling the doors, evenly space the three13.

(3) hinges along the door frame of each door and

attach the hinges to each assembled door using Tek

screws.

Inside

View

Outside

View

Door

without

handle.

Revision date: 05.28.10

End cap used for door stop

and seal.

Ground Level

Step 17c Step 17c

Step 18

Twin-Wall Double Swinging Doors

DOUBLE TWIN-WALL DOOR ASSEMBLY (continued)

Photo shows the end cap as attached to thea.

door jamb. View shows the assembly from the

outside.

Cross section insert shows the end cap (dashedb.

line) attached to the inside/back of the door

jamb.

Dashed line below identifies where to attach thec.

end cap profile. The end cap extends beyond

the frame members and into the rough opening

to stop the door in the frame and to help seal the

gap between the door and frame.

Door Jamb

End Cap

(#104548)

Door

Frame

Opening

The installed polycarbonate end wall panels

have been removed to better show the door

jamb.

At the top and sides of the end wall door opening on17.

the inside of the frame, attach end cap and allow it to

extend below and into the door frame opening.

ATTENTION: This profile acts as a stop for the

double doors, which prevents undo stress on the

hinges. Consult the photos to the right.

After end cap profile is installed, install another section of the same end cap on the18. inside frame of the door that

includes the chain latch.

NOTE: This end cap serves as a stop for the remaining door of the double door assembly when both doors are

closed.

Check the operation of the latches and the doors.19.

After installing the door to the frame, read the care and maintenance section.20.

10 Revision date: 05.28.10

DOUBLE CORRUGATED DOOR ASSEMBLY

If your doors includes 8mm twin-wall polycarbonate,

skip this section and continue with the assembly steps

for that door. The materials and parts needed to assemble

the R035B00011B double door include:

Door frames (#102923), corrugated panels (104620C),•

door hinges (FA5030), end cap (104548) and latches

(FA2410)

Tek screws (#FA4482B), neo-bonded washers•

(#102921B), and foam closure strips (104709)

Assemble and Attach the Door

After installing the end frame for the doors, locate one (1) door frame (#102923), place it on a flat surface, and1.

attach the three (3) hinges (FA5030) using Tek screws. Evenly space the hinges along the side of the frame.

Select the corrugated panel (104620C) and trim it so that the length is approximately one-quarter inch (1/4")2.

shorter than the length of the door frame. (This helps protect the edges of the polycarbonate panel.)

Position the panel on the door frame so that a panel valley is placed over (or near) the door latch hole of the frame3.

as shown below. (Trim panel width–both edges if necessary–to align valley with door latch hole.) Mark the door

latch hole position on the corrugated panel, drill a 3/4" hole in the panel at that mark, set the panel aside, and

install the door latch as described in the diagram below and in the following step.

Center the latch mounting plate over the door frame hole, mark the bolt holes, and drill two 5/16" holes through4.

frame. With assistance, slide the latch and mounting plate assembly through the front side of the door frame, add

the mounting plate on the back side, and secure using two (2) ¼" x 3" bolts. Verify that latch turns freely.

Reposition the polycarbonate panel on the door frame by threading the latch through the hole drilled in the panel5.

(Step 3). Square panel on the frame as needed.

Corrugated Double Swinging Doors

Corrugated Panel

Valley

NOTE: Verify that the horizontal closure strip under

the panel is in place before attaching the panel to the

door frame. Read the notice on the corrugated panel

to install the panel correctly.

48"

92"

Handle

STEP 1

STEP 4 STEP 3

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