ClearSpan Pro Solar Star User manual

1
Revision date: 05.28.10
©2010 ClearSpan™
All Rights Reserved. Reproduction
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).

3
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

5
Revision date: 05.28.10
105488120
Door Jamb
End wall as seen
from the outside.
105488120
Door Jamb
Ground Level
C
D E
(inside-to-inside)
96-1/2"
96-1/2"
If you are installing end
wall framing, install the
two lower girts after door
frame (see X).
X
X
X
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"
A
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
105488120
Header (cut to length)
92-1/2"
96-1/2"
HH
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
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 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
H

7
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.
X

9
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

11
Revision date: 05.28.10
Corrugated Double Swinging Doors
Install sections of the horizontal closure strips (104709)6.
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.
Repeat the required steps needed to assemble the10.
remaining door frame and installation of the panel.
With assistance, set the assembled doors in the end11.
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 doors 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 operation of the doors, adjust hinges as12.
needed, and install the remaining Tek screws to secure
hinges.
DOUBLE 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 13
STEP 9
Trim corrugated panel as needed
to install the door latch guide.
Horizontal
Position
Door Latch
Guide
Latching
Plate
STEP 7
Closure Strip

12 Revision date: 05.28.10
Corrugated Double Swinging Doors
DOUBLE CORRUGATED DOOR ASSEMBLY (continued)
Attach the 6" chain bolt to the inside, upper corner of13.
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.
Photos show the end cap as attached to the enda.
wall 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)
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 opening14.
on the inside of the frame, attach end cap and allow
it to extend below and into the door frame opening.
Consult the photos below.
After end cap profile is installed, install another15.
section of the same end cap on the inside frame of
the door that includes the chain latch.
NOTE: This length of end cap will act 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.16.
After installing the door to the frame, read the care17.
and maintenance section.
ATTENTION: This profile acts as a stop for the
double doors, which prevents undo stress on the
hinges.
End cap used for door stop
and seal.
Ground Level
Step 14c Step 14c
Step 15
Inside
View
Outside
View
Door
without
handle.
X

13
Revision date: 05.28.10
Space below is reserved for customer notes.
Shelter Care and Maintenance
SHELTER CARE AND MAINTENANCE
Proper care and maintenance of the doors is important.
Check the following items periodically to properly
maintain the doors and door frame:
Regularly check the polycarbonate panels to see that•
they remain secure and in good condition. Replace
damaged panels if needed.
Check connections and all fasteners to verify that•
they remain tight.
Check the contents of the shelter to verify that•
nothing is touching the polycarbonate panels that
could cause damage or interfere with the door
operation.
Do not leave the doors ajar. Close doors and•
secure with latch or prop doors open to avoid
personal injury or damage to the doors.
For replacement or missing parts, contact you sales•
representative for assistance.

14 Revision date: 05.28.10
QUICK START GUIDE
Double Swinging Door Kit (R035B00011A and R035B00011B)
Quick Start Guide
Twin-Wall Double Door Sample
R035B00011A
Ground Level
Corrugated Double Door Sample
R035B00011B
Ground Level
End frame and end rafter are not
included with any door kit.

15
Revision date: 05.28.10
Double Door Frame Layout
96-1/2"
92-1/2"
inside-to-inside
measurements
105488120
Door Jamb
105488120
Door Jamb
Ground Level
105488120
Header
Wafer Head
Screws
Wafer Head
Screws
Tek Screws
Drain Hole
Concrete
Wafer Head
Screws