ClearSpan R030B00008 User manual

1
Revision date: 06.04.10
©2010 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
Diagram shows a sample end panel kit for a frame. Actual panel positions and sizes for your end panel package may
differ from what is shown. Photo is used as an example only. Consult the diagrams in the Quick Start section of this
guide for your building to see the panel sizes and layout.
ClearSpan™
Twin-Wall Polycarbonate End Panel Kit
30' Wide & 35' Wide
STK#
R030B00008 (30' Wide)
R035B00008 (35' Wide)

2Revision date: 06.04.10
Table of Contents
Important Information ..............................................3
End Panel Installation ..............................................5
Shelter Care and Maintenance ................................9
Quick Start Guide .....................................................10
Polycarbonate Panels - 30' Wide ......................11
Polycarbonate Panels - 35' Wide ......................12
Notes..........................................................................13
TWIN-WALL PC PACKAGE: READ THIS BEFORE YOU
BEGIN
The twin-wall PC package is designed to attach to either
the R030B00001 end frame for the 30' wide roll-form,
or the R035B00001 end frame for the 35' wide roll-form
building after the end frame is assembled.
Choose one of the following options to continue:
If you purchased but have not assembled the end•
frame, stop here, return to the end frame instruction
guide, and continue with those instructions.
If you did not purchase an end frame for a roll-•
form building but plan to construct an end frame
using customer-supplied materials, review these
instructions before constructing the end frame 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 panels.
ATTENTION: If you purchased an optional door kit,
consult those instructions and proceed as instructed.
In most instances, the end 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 panels based on the end frame and
the position of the installed door or doors. Consult the
services of a qualified contractor to install the panels if
needed.
IMPORTANT: Some diagrams throughout this manual
show the outside edges of the end panels installed
aligned with the outside edge of the end rafter legs or
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 to create a finished corner.
See the diagrams in the Quick Start section for sidewall
examples.
FRAMING: None of the frame members (rafter, ground
posts, etc.) supporting the end panels are included
in the end panel kit. Only the panels and 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.

3
Revision date: 06.04.10
Important Information
YOU MUST READ THIS DOCUMENT BEFORE YOU
INSTALL THE END PANEL POLYCARBONATE KIT.
Thank you for purchasing this ClearSpan™ Twin-Wall
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 end panel kit. Please read these
instructions before you begin.
If you have any questions during the assembly, contact
Customer Service for assistance.
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 installing the 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 frame and•
panels
Variable speed drill and impact driver (cordless with•
extra batteries works best)
Metal file and metal-cutting saw•
Scissors or utility knife and tool to cut 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 or the installation
of comparable polycarbonate panels.
NOTE: Many ClearSpan™ shelters and greenhouses can
be designed to meet the snow and wind load requirements
in your area. Contact your account manager for additional
information if needed.
ATTACHING THE PANELS
When setting the panels in position, remember to install
each panel with the UV-protected surface facing toward
the outside. Read the information printed on each panel.
The diagrams in the Quick Start section show frames
with installed sidewall panels. View these before
attaching the panels to determine the best way to align
the end panels with the sidewall panels if your building
is equipped with sidewall panels.

4Revision date: 06.04.10
Important Information
ASSEMBLY PROCEDURE
Following the instructions as presented will help ensure
the proper installation of the polycarbonate 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 and all additional2.
documentation included with the shipment before
you begin.
Gather the tools, bracing, ladders (and lifts), and3.
assistants needed to assemble the end frame.
Check the weather4. before you install the end wall
panels. Do not install panels on a windy or stormy
day or when such conditions are expected.
Install the polycarbonate panels.5.
Read the care and maintenance information at the6.
end of these instructions.
Complete and return all warranty information as7.
instructed (if included).
PARTS IDENTIFICATION
The following graphics and photos will help you identify
the different hardware used for the installation of the end
panel. (Some parts are not shown.)
UNPACK AND IDENTIFY PARTS
The following steps will ensure that you have all the
necessary parts before you begin to install the end
panels.
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.
102921B & FA4484B
Tek Screws and neo-
bonded washers
104212
Aluminum
H-Channel
104774
Vent Tape
100441
Nut Setter
104213
Aluminum
U-Channel Profile
ATTACHING THE PANELS
When setting the panels in position, remember to install
each panel with the UV-protected surface facing toward
the outside. Read the information printed on each panel.
QUICK START GUIDE
For a quick overview of the end panel kit and its
components, consult the Quick Start Guide located at the
back of these instructions. Diagrams in the Quick Start
section show frames with sidewall panels installed.

5
Revision date: 06.04.10
End Panel Installation
Mark UV Side X
If a door was purchased, review those instructions
and position panels as needed to accommodate the
door position and installation.
END PANEL INSTALLATION
The steps that follow describe one way to complete the
polycarbonate panel installation. The materials and parts
needed to install the polycarbonate panels include:
Polycarbonate panels and vent tape (104774)•
Aluminum H-channel (#104212) and aluminum•
U-channel profile (#104213)
Tek screws (#FA4484B) and neo-bonded, galvanized•
washers (#102921B)
Read the following information before starting:
U-channel (104213) is used to finish the two (2)•
outside polycarbonate panel edges.
H-channel (104212) is used to join polycarbonate•
panels at the seams between panels.
Tek screws and neo-bonded washers are used to•
secure aluminum channel and panels to end wall
frame.
Install the polycarbonate panels with the UV-protected•
side to the outside. Mark this side with a piece of tape
if needed after removing the protective film.
ATTENTION: Remove the protective film from the
polycarbonate panels. Do not stack panels in direct
sunlight. Allowing the film to remain intact and in direct
sunlight will make the film difficult if not impossible to
remove.
During preparation, rest the edges of the panels on•
cardboard or other material to protect them from dirt
and damage.
Do not install panels on a windy or stormy day or•
when such conditions are expected.
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: Position panels as shown on the panel
diagrams. Using a panel in the incorrect place can affect
the placement of subsequent panels. In addition, the
amount of aluminum profile used between panels may not
be adequate if additional seams are created.
Install all accessories (fans, vents, heaters, etc.) after
installing all polycarbonate sheets.
Install panel cells vertically to allow condensation to drain
from the cells. Consult the polycarbonate panels diagrams
located in the Quick Start section for panel locations and
details for the 30' and 35' wide end walls. Complete the
following steps to install the end panels.
Working1. from the center of the end wall, take one
panel, remove the protective film, and mark the UV-
protected side as a reminder to install this side toward
the sun. Check diagrams in the Quick Start section.
Always remove the protective film, mark the surface
with a piece of tape, and install the UV-protected side
to the outside of the greenhouse.
Using the 104774 vent tape, tape the open cells2.
as described below. Cut panels to length before
taping as instructed on the following pages.
Take H-channel and attach to the outer edges of the3.
panel and flush with the top and bottom of panel.
Vent Tape
Panel
Apply tape to the lower end
of all lower panels and to
the upper end of all upper
panels to seal the cell
openings.
The two outer panels that
span from ground level to
the end rafter are taped at
the top and bottom.
Vent Tape
104212
H-Channel
104212
H-Channel
Lower Panel:
Consult the
diagrams in
the Quick
Start section
for panel
identification.

6Revision date: 06.04.10
End Panel Installation
END PANEL INSTALLATION (continued)
Locate and mark the center of the end wall and set4.
the first prepared panel, with the UV-protected side
facing to the outside, in position. Align the center of the
H-channel with the center of the end frame.
ATTENTION: Consult the diagram in the Quick Start
section for your end wall. For the 30' wide frame, trace
the end cap profile location on the panel, remove the
panel, and cut to fit. See lower-right diagram below.
Verify that the panel is square on the frame in the5.
desired position with the UV-protected surface toward
the outside. Attach it to the end frame using Tek screws
and washers (see photo to the right). Install the Tek
screws through the panel and into the brace every
12" on-center. Do not overtighten screws!
NOTE: Install Tek screws in the channel of the
aluminum H-channel. Do not use washers.
With the panel attached to the end frame, repeat the6.
steps to install the next panel. See diagrams on this
page.
For the 30' wide frame, install all remaining panels
and continue with Step 16. For the 35' wide frame,
continue with Step 7.
Diagram below shows the 35' wide end wall.
Actual end frame and panels may differ from frame
shown. The installation of doors also will affect
panel installation and position. Consult the panel
diagrams located in the Quick Start section for the
end kit ordered. ATTENTION: Installation of doors
and other accessories in the end wall may result in
leftover panel material and fasteners.
Brace
35' Wide End Wall
G
R
OU
ND
L
EVEL
A
6' x 8'
Panel
6' x 8'
Panel
Tek screws
and washers Tek screw
only
Brace
Use assistants when setting and securing the
panels to the end frame.
A
30' Wide End Wall
Trim H-channel
as needed to fit
under the lip of the
end cap attached
to the end rafter.
G
R
OU
ND LEVEL
4' x 8'
Panel
4' x 8'
Panel
4' x 8'
Panel
4' x 8'
Panel
104212
H-Channel
Trace & trim
panels,
then tape
the top edge
with vent
tape.
After trimming end panel to length, tape
the top edge and slide panel under the
lip of the end cap before securing to
frame.
Rafter
End Cap
Tape

7
Revision date: 06.04.10
End Panel Installation
END PANEL INSTALLATION (continued)
Measure between the side H-channel sections of the center7.
panel (or panels) and cut H-channel to length. See diagrams
for panel size.
Install H-channel along the top of the installed lower panel (or8.
panels). Upper panels slide into this H-channel (diagram B).
Set the first upper panel in place into the H-channel of the9.
lower panel and align the edges with the lower panel. Do not
attach at this time. Have an assistant hold the panel against
the end frame. Do not install panels on windy or stormy days.
Using the end rafter end cap as a guide, trace along the end10.
cap to mark the panel height. Set the panel on a protected
surface and cut the panel to the correct size. Cut the panel
approximately 1/8" shorter to allow for easier installation.
Tape the cells at the upper end using vent tape.
Measure the distance along the vertical edges of the panel11.
sides and cut H-channel to the measured length. H-channel,
when installed properly, is positioned under the end cap with
the panel. Use the end cap as a guide to properly cut the
upper end of the H-channel.
Set the panel back in place,12. with the UV-protected side facing
to the outside, against the end wall and install the H-channel
along the edges. Top end of the side H-channel fits under the
lip of the end cap and slides onto the polycarbonate panel.
Verify that the panel is square and in the desired position,13.
and attach the panel to the end frame using Tek screws and
washers.
H-Channel
B
Upper
Panel
Lower
Panel
G
R
OU
ND
L
EVEL
6' x 8'
Panel
6' x 8'
Panel
Measure here
for Step 7.
6' x 8'
Panel
6' x 8'
Panel
Brace
Brace
C
B
Trim
excess panel
Trim
excess panel
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.
35' Wide End Wall
Install Tek screws and
washers through the
panel and into the end
wall braces. Evenly
space the screws at 12".
Trim H-channel
as needed to fit
under the lip of the
end cap attached
to the end rafter.
End Rafter
End Cap
Panel C

8Revision date: 06.04.10
End Panel Installation
END PANEL INSTALLATION (continued)
Repeat steps to install the next panel. Work from the center14.
outward to install the remaining panels.
35' wide: The center, upper panels include H-channel
installed on both sides and along the bottom edge. The
bottom H-channel is common between upper and lower
panels and connects the two panels.
Finish the end wall using two (2) 6' x 10' panels on the15.
outer position of the end wall. Measure, cut, and install
panels as previously described. Cut the outer 6' x 10'
panels so each is flush with the side wall hat channel and
installed side panels (if equipped) of the main building.
NOTE: The edges of the two outer end panels must not
extend beyond the edge of the side wall hat channel and
installed sidewall panels. When installed, the panels of the
end wall and sidewall meet to form a finished edge at each
corner of the building.
Measure and cut a section of 104213 profile and install it16.
along the outside edge of each outer panel to complete
installation (see drawing C).
Install a Tek screw to secure the H-channel to the frame in17.
each place where H-channel crosses the end wall brace.
See letter D in the diagram below for an example.
Continue by reading the care and maintenance section.18.
G
R
OU
ND
L
EVEL
6' x 12'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 12'
Panel
Trim
excess panel
Trim
excess panel
Trim
excess panel
Trim
excess panel
Trim
excess panel
Trim
excess panel
104213
C
DD
DD
DD
Panel pattern may vary. Refer to the panel
diagrams located in the Quick Start section
for the layout of panels for your end wall.
Outer PanelOuter Panel
35' Wide End Wall
104213
Sidewall Hat
Channel
104213
End
Panel
C
104213
Outer End Wall
Panel

9
Revision date: 06.04.10
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 panels:
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.
Check the contents of the shelter to verify that nothing•
is touching the polycarbonate panels that could cause
damage.
Inspect the end wall frequently and regularly to ensure•
that it remains secure and in good repair.
Replace broken or missing components immediately.•
If the shelter is moved, inspect all parts and•
connections before it is reassembled.
For replacement or missing parts, call your sales•
associate for assistance.

10 Revision date: 06.04.10
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 outside edge of the
end rafter legs or ground posts (no sidewall panels).
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. Diagrams in this section include sidewalls.
G
R
OU
N
D
LEVE
L
Install Tek screws
and washers through
the panel and into
the end wall brace.
Evenly space the
screws at 12".
6' x 8'
Panel
(102530)
4' x 8'
Panel
(102908)
4' x 8'
Panel
4' x 8'
Panel
4' x 8'
Panel
6' x 8'
Panel
6' x 12'
Panel
(102531)
6' x 8'
Panel
6' x 8'
Panel
6' x 12'
Panel
Panel Kit for 30'
Wide Frame
R030B00008
Sidewall
Panel
Sidewall
Panel
G
R
OU
ND
L
EVEL
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 8'
Panel
6' x 12'
Panel
Panel Kit for 35'
Wide Frame
R035B00008
Sidewall
Panel
Sidewall
Panel
6' x 12'
Panel
(102531)
6' x 8'
Panel
(102530)