ClearSpan Pro Solar Star R035B00009A User manual

1
Revision date: 05.28.10
©2010 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
STK#
R035B00009A (Twin-Wall Polycarbonate)
R035B00009B (Corrugated Polycarbonate)
ClearSpan™
Pro Solar Star™Greenhouse Door Kits
(Single Swinging Door)
Diagram shows a corrugated swinging door centered and installed in an end wall frame. The door kit
includes materials for the 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 Single Swinging Door .............................7
Corrugated Single Swinging Door..........................9
Shelter Care and Maintenance ................................11
Quick Start Guide .....................................................12
Door Frame Layout ............................................13
SINGLE SWINGING DOOR KIT: READ THIS BEFORE
YOU BEGIN
The single 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).

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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 door. 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 this door 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 door. 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. (Some parts are not
shown.)
Corrugated Polycarbonate Door Kit (R035B00009B)
FA4482B
Tek screws
102921B
Neo-bonded washers
108553
Wafer head screw
Twin-Wall Polycarbonate Door Kit (R035B00009A)
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 door. 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, the Must Read document,2.
and all additional documentation included with the
shipment before you begin.
Gather the tools, bracing, ladders (and lifts), and3.
assistance needed to install the door and door frame.
Read the care and maintenance information at the4.
end of these instructions.
Complete and return all warranty information as5.
instructed (if present).
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, door, and
components, consult the diagrams located at the back of
these instructions.

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Revision date: 05.28.10
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"
A
105488120
Door Jamb
End wall as seen
from the outside.
105488120
Door Jamb
Ground Level
C
D E
(inside-to-inside)
48-1/2"
48-1/2"
If you are installing end
wall framing, install the
two lower girts after door
frame (see X).
X
X
X
X
Wafer Head
Screws
D
Left
Jamb
2-1/2" Lip
Left Jamb
B
Door Side
Front
108553
Wafer Head
Screws Toward
Door
Opening
Front
C
E
Wafer Head
Screws
Front
Right Jamb
E

6Revision date: 05.28.10
ASSEMBLING THE DOOR FRAME COMPONENTS (continued)
Door Frame Assembly
Cut along
dotted lines.
Bend this
section inward
Door
Header
F
G
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 10548872 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.
10548872
Header (cut to length)
92-1/2"
48-1/2"
H H
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.
Drain Hole
Wafer
Head
Screws
Tek screw
TOP VIEW
H

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Revision date: 05.28.10
Twin-Wall Single Swinging Door
SINGLE TWIN-WALL DOOR ASSEMBLY
If your door includes a corrugated polycarbonate
panel, skip this section and continue with the
assembly steps for that door. The materials and parts
needed to assemble the R035B00009A door include:
Door frame (#102923), 8mm panel (102908), door•
hinges FA5030, and latch (FA2410)
Tek screws (#FA4484B), neo-bonded washers•
(#102921B), and aluminum profile (#104213)
Assemble and Attach the Door
NOTE: Install the polycarbonate panel with the
UV-protected side toward the outside/sun.
Locate door frame (#102923) and place it on a flat1.
surface.
Take the polycarbonate panel and trim it so that the2.
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".
Locate the door latch hole (5" from edge of door8.
in cross member) and drill 1" hole through the
polycarbonate panel at the hole location.
Place main handle of assembly through hole in door9.
and twist main handle and front plate into place as
shown in the drawing below.
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 Single Swinging Door
SINGLE TWIN-WALL DOOR ASSEMBLY (continued) With assistance, set the assembled door in the end
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.
Mark the plate mounting hole locations on the panel10.
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 with11.
the mounting holes and front plate and secure using
two (2) ¼" x 3" bolts and lock nuts. Verify that latch
turns freely. Mount 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
After assembling the door, evenly space the three (3)12.
hinges along the door frame of the door and attach
the hinges to the assembled door using Tek screws.
NOTE: Verify that there is sufficient clearance along
all door edges to allow the door 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,13.
and install the remaining Tek screws.
Mount latching plate to door jamb frame using Tek14.
screws. The screws supplied with the latch are not
used for metal jambs. Trim end panels as needed.
After installing the door to the frame, read the care15.
and maintenance section.

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Revision date: 05.28.10
SINGLE CORRUGATED DOOR ASSEMBLY
If your door 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 R035B00009B door include:
Door frame (#102923), corrugated panel (104620C),•
door hinges (FA5030), and latch (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 door, locate the door frame (#102923), place it on a flat surface, and attach1.
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 Single Swinging Door
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

10 Revision date: 05.28.10
Corrugated Single Swinging Door
Install sections of the horizontal closure strips6.
(104709) under the panel before attaching the panel
to the door frame. Trim closure strips as needed.
Drive Tek screws and washers through the panel,7.
closure strip, and into the frame every 6" or so. Install
Tek screws and washers in the valleys of the panel.
Screws should be snug. Do not overtighten screws.
Attach the panel in the locations as shown to hold8.
the panel in place. If needed, secure the sides of
the polycarbonate panel to the door frame using Tek
screws only every 16".
Attach the9. door latch guide to the door frame using
the remaining 1/4" bolts. Trim the edge of the
corrugated panel as needed to allow free movement
of latch.
With assistance, set the assembled door in the end10.
wall door frame and secure hinges to the door jamb
using one Tek screw per hinge at this time.
NOTE: Verify that there is sufficient clearance along
all door edges to allow the door to swing freely in
the opening. If end panels are installed, loosen the
panels, secure the hinges directly to the door jamb,
and reinstall panel fasteners.
Test the door operation, adjust hinges as needed, and11.
install the remaining Tek screws to secure hinges.
Mount latching plate to door jamb frame using Tek12.
screws. The screws supplied with the latch are not
used for metal jambs. Trim end panels if needed.
After attaching the door to the frame, read the care13.
and maintenance section.
SINGLE CORRUGATED DOOR ASSEMBLY (continued)
Tek Screw
and Washer
Valley
Closure Strip
STEP 6
STEP 8
104709 strip
Horizontal
Position
Door Latch
Guide
Latching
Plate
STEP 11
Closure Strip
Closure Strip
STEP 12
STEP 9
Trim corrugated panel as needed
to install the door latch guide.
Horizontal
Position
Door Latch
Guide
Latching
Plate
STEP 7
Closure Strip