ClearSpan 500 Cold Frame Series User manual

1
Revision date: 08.08.14
©2014 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
Series 500 Cold Frame
42' Wide
42' Wide Series 500 Cold Frame:
All Standard Lengths.

2Revision date: 08.08.14
Important Information
READ THIS DOCUMENT BEFORE YOU
BEGIN TO ASSEMBLY
Thank you for purchasing a Series 500 cold frame.
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 structure.
Please read these instructions before you begin.
If you have any questions during the assembly, please
contact customer service for assistance.
SAFETY PRECAUTIONS
• Wear eye protection.
• Wear head protection.
• Wear gloves when handling metal parts.
• Use a portable GFCI (Ground Fault Circuit Interrupter)
when working with power tools and cords.
• Do not climb on the frame during or after construction.
• Do not occupy the structure during high winds,
tornadoes, or hurricanes.
• Provide adequate ventilation if the structure is
enclosed.
• Do not store hazardous materials in the structure.
• Provide proper ingress and egress to prevent
entrapment.
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.
• Never erect the structure under power lines.
• Identify whether underground cables and pipes are
present before preparing the site, setting ground
posts (if equipped), 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 structure 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
and follow codes as instructed.
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 and anchor the structure.
• Drainage: Water draining off the structure and from
areas surrounding the site should drain away from
the site to prevent damage to the site, 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 assembly. For safety reasons, those who are
not familiar with recognized construction methods
and techniques must seek the help of a qualified
contractor.
SETTING THE GROUND POSTS
The frame assembly of this building requires the
setting of all ground post in concrete. Review the
layout diagrams for additional details.
Enlist the services of a professional and competent
contractor to prepare the site and set the ground posts.
Failing to secure ground posts in concrete as required
may result in damage to the building, building contents,
and surrounding property.

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Revision date: 08.08.14
ASSEMBLY
Following the instructions as presented will help ensure
proper assembly. Failing to follow these steps may result
in an improperly assembled and anchored structure.
The steps outlining the basic frame assembly are as
follows:
1. Verify that all parts are included in the shipment.
Notify Customer Service for questions or concerns.
2. Read this guide and all additional documentation
included with the shipment before you begin.
3. Gather the tools, bracing, ladders, lifts, and
assistants needed to assemble the structure.
4. Check the weather before you install the roof cover
and any end panels (if equipped). Do not install
covers or panels on a windy or stormy day.
5. Re-evaluate the location and site based on the
information and precautions presented in the
documentation included with the shipment.
6. Prepare the site (if applicable) and set the ground
posts in concrete.
7. Assemble rafter components and rafter support kit
components (if equipped). Optional support kits
require an additional purchase.
8. Assemble main building frame (rafters, cabling,
purlins, etc).
9. Attach customer-supplied baseboards if used.
10. Install main cover if purchased.
11. Complete and return all warranty information as
instructed if present.
REQUIRED TOOLS
The following list identifies the main tools needed to
assemble the shelter. Additional tools and supports may
be needed depending on the structure, location, and
application.
• Tape measure or measuring device and marker to
mark locations on the pipes and rafters.
• Variable speed drills and impact drivers. (Cordless
with extra batteries works best.)
• Metal-cutting saws or tools to cut pipe and
aluminum.
• Wrenches and impact socket set, hammer, and
gloves.
• Adjustable pliers and self-locking pliers.
• Ladders, work platforms, and other machinery for
lifting designed to work safely at height of building.
• Safety equipment to protect head, eyes, hands and
feet.
UNPACK AND IDENTIFY PARTS
The following steps will ensure that you have all the
necessary parts before you begin to assemble the
shelter frame.
1. Unpack the contents of the shipment and place
where you can easily inventory the parts. Refer to
the Bill of Materials/Spec Sheets.
2. Verify that all parts listed on the Bill of Materials/
Spec Sheets are present. If anything is missing
or you have questions, consult the Pictorial Parts
Guide and all diagrams for clarification, or contact
Customer Service.
NOTE: Do not open plastic bags containing smaller
parts such as fasteners or washers at this time.
Simply verify quantity.
Important Information

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104189 Turnbuckle
Parts Identication
The following graphics will help identify the basic
parts of the frame. (Some parts are not shown.)
*107795
Box Bolt
*IMPORTANT: The installation of the blind
connection bolts cannot be reversed. Follow
the instructions when installing these fasteners.
103856
Band Clamp
FA4482B
Tek Screw
100441 Magnetic
Nut Setter
102546 Cross
Connector
QH1070
Pipe Strap
AS2167 Anchor
Shackle
AS1004
Clamp
AS1084
3/16" Cable Thimble
SHELTER CARE AND MAINTENANCE
Proper care and maintenance of the shelter is important.
Check the following items periodically to properly maintain
the shelter:
• Regularly check the cover (if purchased) to ensure
that it remains tight and in proper repair.
• Replace all damaged or broken components
immediately.
• Check connections and all fasteners to verify that they
remain tight and in good condition.
• Do not climb or stand on the building at anytime.
• Inspect the anchoring system to verify that all
components remain tight and in good condition.
• Remove debris and objects that accumulate on the
building. Use tools that will not damage the cover (if
equipped) when removing debris.
• Remove snow to prevent excess accumulation. Use
tools that will not damage the cover when removing
snow. Keep heated during non-growing season to
prevent snow and ice buildup.
• Check the contents of the shelter to verify that nothing
is touching the cover that could cause damage.
• If the shelter is dismantled and moved, inspect all
parts and connections before using.
• For replacement or missing parts, call 1-800-245-9881
for assistance.
FALB08B
1/2" Nut
105370B
1/2" x 4-1/2" Hex Bolt
108503
Bracket

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Revision date: 08.08.14
Overview
Drawing may show a model of a different length. Refer to
Quick Start section located near the back of this guide for
on-center measurements and post layout.
OVERVIEW
This section describes assembling your building frame.
See illustration below to identify main parts.
1. Prepare site and set the ground posts in concrete.
2. Locate the required parts for each assembly
procedure.
3. Assemble the rafters and main frame.
Finished Grade
End Rafter
Interior Rafter
Ridge Purlin
Cable
Ground
Post
On-Center
Rafter Spacing
Side
Purlin
Ridge
Purlin
ClearSpan™
Series 500 Cold Frame
Structures

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Prepare and Square the Building Site
PREPARE THE BUILDING SITE
A level site is required to accurately and safely construct
the building. Consult the services of a qualified contractor
to properly grade and prepare the site.
Site should slope away from the building for proper water
drainage.
After the site is prepared, mark the location of the frame
corners to square the frame position. Taking these steps
before assembling the shelter saves time and ensures
that the structure is square and positioned as desired.
The following procedures are suggested methods.
Their use depends on the size of the shelter, shelter
application, the footings (if applicable), and the method
used to anchor the shelter.
When in doubt, consult the services of a qualified
contractor experienced with the construction of similar
structures.
Ground Posts
If the frame includes ground posts, set all ground posts
as described within this manual. Width of the shelter
is measured from the center of one ground post to the
center of the remaining ground post. Length is also
measured center-to-center. If your building includes
ground posts, continue with the Setting Ground Post
section.
SQUARE THE SITE: GENERAL STEPS
1. Identify a corner where a building rafter will be
positioned, drive in a stake, and string a line the exact
width of the building and stake in place. (Width of the
rafter is measured from center-to-center of the rafter
pipes/ground posts.)
2. After the first corner stake is in place, string a line the
width of the building (center-to-center) and drive the
second corner stake into the ground.
3. String a line at least as long as the building 90° from
the line between the first and second stakes.
NOTE: A transit can be used to ensure an accurate
90° angle, or the 3-4-5 rule can be used. Refer to
diagram. Using multiples of 3-4-5 such as 6-8-10 or
12-16-20 helps to maintain an accurate 90° angle.
4. After squaring the position of the building, measure
the length and drive the third corner stake.
5. Repeat the same step for the last corner stake.
NOTE: The distance measured diagonally between
corner stakes must be equal for the building to be
square.
SETTING THE GROUND POSTS
The frame assembly of this building requires the
setting of all ground post in concrete. Review the
layout diagrams for additional details.
Enlist the services of a professional and competent
contractor to prepare the site and set the ground posts.
Failing to secure ground posts in concrete as required
may result in damage to the building, building contents,
and surrounding property.
IMPORTANT: Do not drive ground posts into the
ground! Doing so will damage the swaged end making
it difficult if not impossible to set rafter onto the posts
during frame assembly.

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Revision date: 08.08.14
on-center
on-center
on-center
on-center
Set Ground Posts
Drawing may show layout of a different length. Refer to
Quick Start section located in the back of these instructions
for on-center measurements and post layout for your frame.
MARK THE SITE AND DIG POST HOLES
These steps describe marking all post hole locations and digging
the holes. For some sites, it may not be possible to complete the
procedure in this manner. An alternative procedure such as working
from one end of the building toward the other may be necessary.
Determine the best procedure based on the site and other factors
and proceed as needed.
NOTE: Refer to the Quick Start Section located near the back
of these instructions for the Side Profile and related diagrams.
ATTENTION: Do not drive ground posts
into the ground! Doing so will damage
the swaged end making it difficult if not
impossible to set rafter onto the posts
during frame assembly.
Complete these steps:
1. Stake the outline of the building using string line and batter boards. Set batter boards 3' back from the building
corners. Check to ensure that the building layout is square. Cover or panels (if equipped) will not install properly if
the building frame is not square once assembled.
2. Consult the diagrams in the Quick Start section to verify the frame length and width dimensions and to accurately
position the ground posts.
3. Guided by the string line, use a flag or stake to mark each ground post hole location.
4. Move the string line and dig a post hole a minimum of two feet (2') deep or to a depth that is below the geographic
frost line. Consult local building codes. A power auger works best. Minimum hole diameter is 12".
5. After digging all holes, reattach the string line to the batter boards and use it as a guide to set and align the
ground posts.

8Revision date: 08.08.14
Set the Ground Posts — Diagrams
Ground Post
Concrete
Ground Level
2’ Deep
In areas where frost is common, dig each post hole so
it falls below the frost line. Minimum hole depth for all
areas regardless of frost is 24". Minimum hole diameter
is 12". Set all ground posts 24" in concrete.
Consult local building codes and qualified contractors for
additional details when digging the post holes and setting
the ground posts.
Follow established codes and construction practices.
CONCRETE PIER
GROUND LEVEL
CONCRETE PIER
12"
12"
42'-0" CENTER TO CENTER OF GROUND POSTS
Optional: Before setting the
posts, drill a hole through the
bottom of each ground post
2"-3" from the end and insert
a 6"-8" length of rebar through
it. This will help stabilize and
anchor the ground posts once
the concrete sets.

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Revision date: 08.08.14
SET GROUND POSTS
Required parts and equipment:
• Ground Posts (113102)
• Equipment and materials to level and brace posts
NOTE: Concrete (customer-supplied) is required to secure all
ground post in the holes. Set all posts at the same height for
proper assembly. Position all rafter mounting holes to point toward
the outside/inside.
Consult the services of a qualified contractor to properly set posts.
Here are the basic steps:
1. Take one ground post, measure 24" from the end opposite the
bolt holes, and mark the location on the ground post. Repeat
to mark all ground posts.
NOTE: The rafter mounting bolt hole is near the top of the
ground post and is drilled through the swaged section.
Baseboard holes are below the rafter mounting hole.
2. With assistance, set and brace all posts in place. See diagram
below. All posts are to be plumb before adding concrete.
Use the baseboard mounting holes and customer-supplied
fasteners and stakes to hold posts in place.
3. Add concrete to anchor posts in holes. Fill hole so concrete
remains below the finished grade.
Stake Ground Posts for Concrete
Finished
Grade
Set all posts at the
same height. Additional
bracing may be needed
to keep the post plumb
while concrete sets.
Customer-supplied braces
and fasteners.
SETTING THE GROUND POSTS
The ground posts include pre-drilled rafter mounting bolt
holes and holes to attach the baseboards. Position holes
so they point to the outside/inside of the frame.
Do not position holes to point toward the ends of the frame.
Set Ground Posts
Set top of posts at the same
height. Set lower 24" of post
in concrete.

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Rafter Assembly
RAFTER ASSEMBLY
After setting the ground posts, continue with the rafter assembly. Do not set assembled rafters into position on the
ground posts until concrete has set. Check with contractor for set times.
NOTE: All rafter assemblies consist of seven (7) main rafter sections. Consult the rafter diagrams in the Quick Start
section of these instructions before and during the rafter assembly for details. Assistance is required to assemble the
rafters and frame. If space allows, assemble all main sections of rafters as described below and set aside.
1. Select the seven (7) rafter pipes
to assemble one rafter
3. Secure each rafter joint using a
1/2" x 4-1/2" bolt (105370B) and
1/2" nut (FALB08B).
2. Slide the separate pipe sections
together to assemble rafter.
4. Verify that each bolt is tight and wrap each
splice and bolt with duct tape to protect the
cover during installation.
PG500TC3514S424
PG500TC3514S422 PG500TC3514S422
PG500TC3514S421 PG500TC3514S421
42' Wide Rafter
(no ground posts shown)
PG500TC3514S423 PG500TC3514S423

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Revision date: 08.08.14
Rafter Assembly
RAFTER ASSEMBLY (continued)
5. Use the diagram above and in the Quick Start section to mark the purlin clamp (QH1070) locations on the
underside of the assembled rafter.
ATTENTION: Measure from the mounting bolt to the rafter and mark the location.
6. Loosely install QH1070 clamps. Tighten clamps after purlins are installed. See connection details in the Quick
Start section at the back of this manual.
4'-25/8"
4'-7 3/16
4'-25/8"
4'-7 3/16
ATTENTION: Measure from the mounting
bolt to the rafter and mark the location.
QH1070
Pipe Strap
QH1070
Pipe Strap
1/2" Mounting Bolt
at Rafter Splice
1/2" Mounting Bolt
at Rafter Splice
See full Rafter Profile in Quick Start
section for all QH1070 bracket locations.

12 Revision date: 08.08.14
RAFTER ASSEMBLY—Optional Support Kits
If the optional support kits were purchased, continue with the assembly steps that follow. Consult the diagrams
supplied with the rafter support kits for additional details. See also the diagram in the Quick Start section of this guide.
If support kits were not purchased, continue with the frame assembly procedure beginning on the next page.
ATTENTION: Support kit components are typically not installed for the end rafters when end wall framing is present.
Complete these basic steps:
1. Slide six (6) 105238 band clamps into position on the assembled rafter. See locations above.
2. Assemble the 1.90" diameter cross beam.
3. Slide three (3) QH1404 band clamps onto the cross beam.
4. Secure each splice of the cross beam using a Tek screw. See support kit details in Quick Start Guide section near
the back of this guide.
5. Verify position of support kit clamps and install web components. Secure to the 3.50" band clamps using FAH322
(5/16" x 3-1/2") carriage bolts and FALB32B (5/16") nuts.
6. Secure each band clamp to rafter or cross beam using a Tek screw. Install Tek screw in a position that will not
contact the cover when it is installed.
ST09275D13G17S1
ST06450D13G17S1
(QH1404)
(105238)
BAND CLAMP
(105238)
BAND CLAMP
BAND CLAMP
(QH1404)
BAND CLAMP
(QH1404)
BAND CLAMP
(105238)
BAND CLAMP (105238)
BAND CLAMP
(105238)
BAND CLAMP
(105238
)
BAND CLAMP
(190S099)
CROSS BEAM
(190S099)
CROSS BEAM
(190S099)
CROSS BEAM
(190S099)
CROSS BEAM
WEB
WEB
ST09275D13G17S1
WEB
ST09275D13G17S1
WEB
ST06450D13G17S1
WEB
(190P036)
CROSS BEAM
Rafter Assembly–Optional Support Kit

13
Revision date: 08.08.14
Finished Grade
Rope or
Cable
Frame Assembly
FRAME ASSEMBLY
Use the diagrams and information that follows to assemble the main frame.
ATTENTION: Rafters are heavy. Always lift rafter from two separate points to prevent damage and injury.
Examine the site to determine the best way to move the rafters into position and to set them onto the ends of each set
of ground posts. Do not set rafters into position until the ground post concrete has set.
Optional, but recommended—especially for long buildings: Build a Rafter-Spacing Jig. (Customer supplies materials.)
A spacing jig saves time and helps to evenly space the rafters. Jig sets the on-center spacing of rafters. Examine the
photo below and use it to build a jig to space rafters during purlin installation. Use 2" x 4" lumber and wood fasteners.
Customer-supplied
rafter-spacing jig.
ATTENTION: Anchor the first rafter in place using bracing, rope/cable, or a lift. Do not allow the first rafter to stand
without bracing until additional rafters are set and purlins are installed.
Connect rafters to ground posts using 105370B (1/2" x 4-1/2") bolts and FALB08B nuts. Position nuts to the inside.
IMPORTANT: Plumb the end rafter before
bracing it in place and installing other rafters.
ATTENTION: Before adding
the nut to the 1/2" bolt, slide a
PGBRKAAS01 cable bracket onto
the bolt at each end rafter. Then
add the nut and tighten. See also
the details on the next page.

14 Revision date: 08.08.14
Frame Assembly
After setting and plumbing the end rafter and bracing it in place, set the second rafter and add purlin pipes. Consult the
technical diagrams for connection details.
Frame shown may differ from actual frame.
After setting the first few rafters and installing the purlins, continue with the frame assembly. Loosen QH1070 brackets
as needed to install the purlin sections.
NOTE: At the end bays only, attach two cable brackets to each rafter. Use rafter mounting bolts to secure brackets.
Close up shows the installed cable brackets. Attach brackets to inside surface of the first two rafters at each end
of the frame during assembly. Install 1/2" nuts to the inside of the frame/building. Cable assembly and installation is
shown later in this guide.
FRAME ASSEMBLY (continued)
Finished Grade
Rope or
Cable
Purlin Pipe
A
ATTENTION: Install ridge purlin
on top of the rafters when a ridge
vent will be installed.
Ridge Purlin
PGBRKAAS01
Ground Post Ground Post
On-Center Spacing
Rafter
PGBRKAAS01
A
END RAFTER

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Revision date: 08.08.14
Frame Assembly
FRAME ASSEMBLY (continued)
Customer-supplied
rafter-spacing jig.
Sample frame is shown. Actual frame may differ.
Purlin clamps shown may differ from actual clamps.

16 Revision date: 08.08.14
Frame Assembly
FRAME ASSEMBLY (continued)
Secure each QH1070 pipe strap to the purlin pipe using
one Tek screw.
ATTENTION: Ensure that the on-center spacing of the
rafters is maintained throughout the frame length.
Photo shows the installation of a purlin and pipe strap
at the end rafter. See Connection Details in Quick Start
section for additional information.
Actual rafter design may differ from what is shown.
Installation of purlin pipe and clamps is the same.
QH1070
Pipe Strap
Purlin
End Rafter
FA4482B Tek
Screw
FA4482B Tek
Screw
Purlin
FA4482B Tek
Screw
End
Rafter
IMPORTANT! Secure each QH1070 pipe strap to the purlin pipe using one Tek screw. See photos above. Secure all
purlin pipe splices using a Tek screw for each splice.
Finished Grade
Rope or
Cable
Purlin Pipe
ATTENTION: Install ridge purlin
on top of the rafters when a ridge
vent will be installed.
Ridge Purlin

17
Revision date: 08.08.14
Frame Assembly
FRAME ASSEMBLY (continued)
Full Frame without Optional
Rafter Support Components
ATTENTION: Example shows a 48' frame
length. Actual frame may differ.
All purlins run perpendicular to the rafters and parallel with each other. Verify that each purlin splice is secured with a
Tek screw. Verify that each QH1070 bracket is secured to purlin pipe with a Tek screw. See photo on previous page
and all connection details diagrams in the Quick Start section.

18 Revision date: 08.08.14
Baseboard Installation—Optional
BASEBOARD INSTALLATION—OPTIONAL
Gather the parts:
• 2" x 6" treated lumber (supplied by customer).
• 5/16" carriage bolts and nuts supplied by customer.
Length depends on the thickness of the baseboard.
When properly installed, baseboard runs the length of
the frame at ground level. The baseboard is supplied by
the customer. The following procedure describes one
way to install the baseboards. The size and type of the
baseboard may require the use of alternative steps.
On the outside of the frame, attach the first baseboard
to the rafter using two (2) 5/16" carriage bolts and nuts.
Countersink bolt heads if carriage bolts are not used.
Continue adding baseboards to complete the first run.
Splices are made between posts as shown in the drawing
below. Use a short section of baseboard to secure
separate baseboards at a splice. See diagram below.
Repeat steps to install the second run of baseboard on
the remaining side of the frame.
NOTE: The boards should be at ground level or slightly
into grade to create a good seal between the board and
finished grade. After installing the baseboards, continue
with these instructions.
Inside of
Shelter
Finished Grade
Ground Posts and Baseboard
Baseboard
The above diagrams present examples only. Actual installation
depends on customer-supplied materials and other factors.
Finished
Grade
5/16" Nuts
Splice
5/16" Carriage
Bolts
Outside of
Shelter
Photo shows
the inside view
of a baseboard
splice.
Use a small
piece of wood
to secure a
splice.
Place on the
inside of the
baseboard or
ribbon board.

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Revision date: 08.08.14
Using the diagrams and photos, install the diagonal cables at each end bay of the frame.
Hold box bolt collar with a wrench
and tighten center bolt using a
wrench or socket. Exercise caution
if using an impact driver and socket.
Sample
Bracket
Box Bolt
After drilling bolt hole, insert
bolt through bracket and into
hole in door frame (right).
Bracket
Seat components tightly
together (below diagram).
Rafter
IMPORTANT: The installation of the blind connection bolts
cannot be reversed. Follow these instructions when installing
the box bolt fasteners.
Drill 1/2" hole for
box bolt installation.
108503
107795
Purlin
Cable Assembly & Installation
Install upper
mounting bolt
1"- 2" above
purlin.
Turnbuckle Position
Ground Posts
Bracket and Shackle Connections

20 Revision date: 08.08.14
Live cable end.
Dead cable
end.
Cable Assembly & Installation
(continued)
Upper Cable Connection
Lower Cable Connection
See cable connection details in the
Quick Start section of this guide.
Upper Cable Connection