ClearSpan R030A00007 User manual

1
Revision date: 04.13.09
©2009 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
Diagram shows the end wall kit without a door. (Door purchased separately.)
ClearSpan™
Corrugated Polycarbonate End Panel Kit
30' Wide & 35' Wide
STK#
R030A00007 (30' Wide)
R035A00007 (35' Wide)

2Revision date: 04.13.09
CORRUGATED PC PACKAGE: READ THIS BEFORE
YOU BEGIN
The corrugated PC package accessory is designed to
attach to the end wall framing kit (R035A00001) after the
end frame is assembled.
Choose one of the following options to continue:
If you purchased but have not assembled the•
R035A00001 end frame, stop here, return to the
end frame instruction guide, and continue with those
instructions.
If you did not purchase the R035A00001 end wall•
kit but plan to construct an end wall using customer-
supplied materials, review these instructions before
constructing the end wall to better prepare for the
installation of the panels included in this PC package.
After assembling the end frame, continue with these
instructions to attach the corrugated polycarbonate panels
to the end wall.
ATTENTION: If you purchased an optional door kit,
consult those instructions and proceed as instructed. In
most instances, the end wall frame and door frame are
constructed before end panels are installed. This allows
for the placement of panels as determined by the position
of the door or doors.
It is the responsibility of the owner/contractor to adjust the
position of the end wall panels based on the end frame
and the position of the installed door or doors.
Table of Contents
Important Information ....................................... 3
End Panel Installation ....................................... 5
Shelter Care and Maintenance ......................... 8
Quick Start Guide .............................................. 9
Polycarbonate Panels - 30' Wide ............... 10
Polycarbonate Panels - 35' Wide ............... 11
IMPORTANT: Some diagrams throughout this manual
show the edges of the end panels installed in line with
the centers of the end rafter leg/ground posts.
For buildings that include sidewall polycarbonate panels
and hat channel secured to the frame, shift the position
of the end panels as needed so these panels meet the
sidewall panels and create a finished corner.
FRAMING: None of the frame members (rafter, ground
posts, etc.) supporting the end panels is included in
the end panel kit. Only those components needed to
attach the end panels to an existing frame are included.
Fasteners are designed for metal. If your end wall
frame requires different fasteners, contact your sales
representative to purchase additional fasteners, or
purchase the proper fasteners locally.

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Revision date: 04.13.09
Important Information
YOU MUST READ THIS DOCUMENT BEFORE YOU
BEGIN TO ASSEMBLE THE END WALL KIT.
Thank you for purchasing this ClearSpan™ Corrugated
Polycarbonate 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 panels. 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 shelter or framing during or after•
construction.
Do not occupy the shelter during high winds,•
tornadoes, or hurricanes.
Provide adequate ventilation if the structure is•
enclosed.
Do not store hazardous materials in the shelter.•
Provide proper ingress and egress to prevent•
entrapment.
WARNING: The individuals assembling this end
wall 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 end wall. 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 on panels.•
Variable speed drill and impact driver (cordless with•
extra batteries works best)
Scissors or utility knife and tool to cut the•
polycarbonate panels
Hammers, gloves and eye protection•
Ladders, work platforms, and other machinery for•
lifting designed to work safely at the height of the
building and end wall.
ATTENTION: Consult the services of a qualified,
professional contractor if you are not familiar with the
construction of similar frame structures.
SEALANT APPLICATION (OPTIONAL)
The application of sealant is left to the discretion of the
owner/contractor. If used during panel installation, apply
a sealant recommended for exterior use and that remains
flexible when cured. To create a better seal, apply sealant
between adjacent panels where the panels overlap each
another. Sealant is not included with the building and must
be supplied by the customer.
Sealant
Rib Overlap Corrugated Panel

4Revision date: 04.13.09
FA4482B
Tek Screw
104621C
Corrugated Polycarbonate Panels
102921B
Neo-bonded
Galvanized Washers
100441
Nut Setter
Important Information
ASSEMBLY PROCEDURE
Following the instructions as presented will help ensure
the proper installation of the end panels. 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 end panels.
Check the weather4. before you install the panels. Do
not install panels on a windy or stormy day or when
such conditions are expected.
Install the panels.5.
Read the care and maintenance information at the6.
end of these instructions.
Complete and return all warranty information as7.
instructed.
PARTS IDENTIFICATION
The following graphics and photos will help you identify
the different parts. (Some parts are not shown.)
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 on the next
page and all shelter 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.
QUICK START GUIDE
For a quick overview of the end wall and its components,
consult the Quick Start Guide located at the back of
these instructions.

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Revision date: 04.13.09
End Panel Installation
END PANEL INSTALLATION
The steps that follow describe one way to complete the
end wall panel installation.
The materials and parts needed to assemble the end
panels include:
Corrugated polycarbonate panels (#104621C)•
Tek screws (#FA4482B)•
Neo-bonded washers (#102921B)•
Read the following information before starting:
Tek screws and neo-bonded washers are used to•
secure panels to end wall frame.
During preparation, rest the edges of the panels on•
cardboard or other material to protect them from dirt
and damage.
Consult the polycarbonate panels (Quick Start•
section) for the location and lengths of each panel.
The diagrams are located at the back of these
instructions.
ATTENTION: Panels must be positioned as shown on the
panel diagrams. Using a panel in the incorrect place can
affect the placement of subsequent panels.
Install all accessories (fans, vents, heaters, etc.) after
installing all polycarbonate sheets.
Complete the following steps to install the end wall panels.
Consult the polycarbonate panels diagrams located in the
Quick Start section, select one panel, begin at the edge
of the end wall, and work toward the opposite edge of the
end wall.
NOTE: Set end panels in a position that prepares for the
installation of the sidewall panels if equipped. This may
include shifting the outside panels beyond the end rafter
leg/ground post so corner panels align with each other.
Set the first 50" x 12' 2" panel in place as shown with1.
the side edge aligned with the center of the end rafter
and the bottom edge flush against the ground. Do not
attach at this time.
If a door accessory was purchased, install the
door before attaching the end panels. Adjust the
panel position as needed to accommodate the door
installation. Consult the door installation manual (if
present) for additional details.
Actual end frame may differ from frame shown; end panel
installation is the same. Consult the panel diagrams located
in the Quick Start section for your end panel kit.
Trim excess
panel
Brace panel in correct position
and trace a line along the end
rafter. Remove panel and cut
to fit.
Adjust panels as needed to
create a finished corner joint
where end panels meet sidewall
panels. See arrows to the left.
50" x 12' 2"
Panel
Trace along the end rafter to mark where the panel2.
needs to be cut to fit into the end cap.
Remove panel, cut along traced line, and set panel3.
back into position by tucking the top edge under the
end cap. Do not damage panel section cut from main
panels; these may be used in another position.
Verify that the panel is flush with the ground and that4.
the outer edge is aligned so that it creates a finished
corner with the sidewall panels (if equipped) when
these are installed. Attach panel to the end frame.
End Cap
Position top of
end panels here
Typical End
Rafter Position

6Revision date: 04.13.09
End Panel Installation
END PANEL INSTALLATION (continued)
Secure the panel to the end frame girt using Tek5.
screws and neo-bonded washers inserted every 6" or
so (see drawing A).
Do not install Tek screw into the valley where the next
panel overlaps the first. See diagram B.
Select another 50" x 12' 2"6. panel and brace it in place,
overlapping the first panel by one (1) rib as shown in
drawing B. Do not attach at this time.
Holding the panel in place, repeat steps 2 through 57.
to mark, trim, and attach panel to the end frame. DO
NOT attach the panel to the top girt at this time. See
diagram below.
NOTE: Leave the innermost valley open for the
installation of the next panel; panels overlap by one
(1) rib. See diagram below for girt positions.
Continue attaching 50" x 12' 2" panels in this fashion8.
until the bottom row of end panels is complete. Cut
the final panel to fit as needed.
Remember to account for the installation of the
sidewall panels if equipped. Position and cut final
panel as needed.
Valley
Corrugated Panel
Girt
TOP VIEW
A
Ground Level
50" x 12' 2"
panel
50" x 12' 2"
panel
Girt
A
B
Trim
excess panels
Trim
excess panels
Actual end frame and panels may differ from frame
shown. Consult the panel diagrams located in the
Quick Start section for the end kit ordered.
Do not attach panels to the top girt. Tek
screws are installed after the top panels
are set into place. Top panels overlap
lower panels. Typical overlap is 6".
Rib
Corrugated Panel
No Tek screw in
this valley. No Tek screw in
this valley.
Girt
TOP VIEW
B

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Revision date: 04.13.09
Sample End Wall Complete
End Panel Installation
END PANEL INSTALLATION (continued)
With the bottom row of panels installed, measure from9.
the top of the end rafter to the bottom of the top girt.
Use this measurement to cut the first section of a10.
50" x 12' 2" panel. Typical overlap is 6".
Holding the pre-cut panel in place, trace along the end11.
rafter to mark where the panel needs to be cut to fit
under the end cap.
Remove panel, cut along traced line, and set panel12.
back into position by tucking the top edge under the
end cap. The top panel overlaps the lower panel.
Verify the bottom edge of the panel aligns with the top13.
girt and attach the top panel to the end frame using
Tek screws and washers.
Continue measuring, cutting and installing the14.
remaining sections of the 50" x 12' 2" panel until the
top row is complete.
Continue by reading the care and maintenance15.
section that follows.
Secure panel by installing Tek screws through both the
top and bottom panels and into the girt.
x
Measure from the top
of the end rafter to the
bottom of the top girt.
Trim excess panel
Tek screws
and washers
Ground Level

8Revision date: 04.13.09
Space below is reserved for customer notes.
Shelter Care and Maintenance
SHELTER CARE AND MAINTENANCE
Proper care and maintenance of the end panels is
important. Check the following items periodically to
properly maintain the end wall:
Regularly check the polycarbonate panels to see•
that these are secure and in good condition. Replace
damaged panels if needed.
Check connections and all fasteners to verify that they•
remain tight.
Do not climb or stand on the shelter at anytime.•
Inspect the anchoring system to verify that all•
components remain tight and in good condition.
Remove debris and objects that can accumulate on•
the shelter. Use tools that will not damage the panels
when removing debris.
Do not allow snow to pile up against the end wall•
and panels. Use tools that will not damage the
polycarbonate panels when removing snow.
Check the contents of the shelter to verify that nothing•
is touching the polycarbonate panels that could cause
damage.
If the shelter is moved, inspect all parts and•
connections before it is reassembled.
Depending on the contents, construction of the shelter,•
shelter materials, and shelter location, the potential for
condensation exists. ClearSpan™ offers several items
that can be used to alleviate a condensation condition.
Please contact a ClearSpan™ representative for
additional information.
For replacement or missing parts, call 1-800-245-9881•
for assistance.
NOTE: With the exception of Truss Arch buildings or as
otherwise noted, ClearSpan™ shelters and greenhouses
do not have any tested loading criteria.

9
Revision date: 04.13.09
QUICK START GUIDE
30' and 35' Wide End Panels
Quick Start Guide
IMPORTANT: Diagrams throughout this manual show the
end panels installed in line with the centers of the end
rafter leg/ground posts.
For buildings that include sidewall polycarbonate panels,
shift the position of the end panels as needed so these
panels meet the sidewall panels and create a finished
corner.
30' Wide Sample Panel overlap
seams.
Ground Level
Top edge of the
lower panels.
35' Wide Sample
Ground Level

10 Revision date: 04.13.09
Polycarbonate Panels - 30' Wide
4'-2"
12'-2"
2"
Rib
Corrugated
Panel
Corrugated
Panel
Girt
TOP VIEW
Each panel overlaps the previously installed panel by one (1) rib.
Create all top panels from one (1) 50" x 12' 2" panel.
Panel diagram is shown without end framing for clarity.
Ground Level
If a door was purchased, position panels as needed to accommodate the door installation. Install door or doors before end panels. Diagram below shows the installed sidewall hat channel used for the installation of the sidewall polycarbonate panels of the main building.
(approximate
width)
Sidewall Hat Channel

11
Revision date: 04.13.09
Polycarbonate Panels - 35' Wide
4'-2"
2"
12'-2"
Rib
Corrugated
Panel
Corrugated
Panel
Girt
TOP VIEW
Each panel overlaps the previously installed panel by one (1) rib.
Panel diagram is shown without end framing for clarity.
Ground Level
Create all top panels from two (2) 50" x 12' 2" panels.
(approximate
width)
If a door was purchased, position panels as needed to accommodate the door installation. Install door or doors before end panels. Diagram below shows the installed sidewall hat channel used for the installation of the sidewall polycarbonate panels of the main building.
Sidewall Hat Channel