Curved Eave

Curved Eave
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
User Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cross Country Curved Lean To Series Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly of the Aluminum Frame
A.
B.
C.
Back Gable-End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Front Gable-End Assembly with Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Taping Poly Bar with Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Aluminum Frame Installation
1.
2.
3.
4.
4A.
5.
6.
7.
8.
9.
10.
11.
Side Base / Sill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Side Base / Sill To Front Gable-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Side Base / Sill to Back Gable-End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Ridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Truss Assembly Installation (If Necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . .See Appendix A
Poly Bar With Sliders (#1 or #2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Vent Frame Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Side / Roof Poly Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Roof Purlin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Taping Poly Bars with Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fastening & Sealing Greenhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Side Vents, Intake Shutter and
Exhaust Fan Installation (if necessary). . . . . . . . . . . . . . . . . . . .See Appendices B through G
Polycarbonate and Cap Installation
12.
13.
14.
General Information About Handling Polycarbonate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Roof Polycarbonate Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Back/Front Gable-Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Sealing The Greenhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Door And Vent Installation
15.
16.
17.
Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Vent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Appendices: Optional Installations
Truss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix A
Vent Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix B
Intake Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix C
Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix D
Side Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix E
Glass Louvre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix F
–1–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Foreword
Your Cross Country greenhouse is designed and constructed to the highest engineering standards
and provides structural strength and maintenance-free service for year-round gardening pleasure.
The Cross Country greenhouse must be built upon a firm, level surface. The greenhouse
foundation or sill can be made from pre-treated timbers, concrete or bricks. Whatever your choice
of material, the base must be square and level.
When selecting a site for your greenhouse, keep in mind that a flat, level site is essential so that the
greenhouse can be easily installed and the complete structure is stable and secure. If possible,
choose a site with proper water drainage.
Locating the greenhouse in a north-south position is most suitable for raising summer and autumn
crops since the sun’s rays will be on the greenhouse from daybreak until sunset. An east-west
position is ideal for early spring and winter crops since the winter months, with shorter daylight
hours, still allow six hours of light exposure to the greenhouse.
Try to locate your greenhouse for easy access, especially to the necessary power and water that is
required for greenhouse gardening.
Please watch the enclosed video and follow the steps in this manual for your greenhouse
installation. Remember, if all else fails, read the instructions.
Seal
Sealing the polycarbonate sheets to the aluminum “ ”
and base is optional, however we highly recommend it.
Eliminating any water from entering the inside of the
aluminum, will prevent excessive moisture inside the
panels.
Seal
Base
Base
Seal
Aluminum H
The Cross Country greenhouse structure has been
designed to withstand extreme weather conditions such
as high winds and accumulated snowfall. Hanging
baskets and sidewall shelving can also be attached to its
sturdy frame. The greenhouse design also makes it
possible to add extra sections at a later date.
Seal
Aluminum H
User Notes
PLEASE NOTE: These Illustrations may not
be specific to your greenhouse, however the
detail of aluminum shapes are all consistent.
The user notes are a generic instruction for
all Cross Country Greenhouses – assembly
instructions are common, only the number
of pieces and sizes vary.
Once a year the greenhouse needs to be completely
washed inside and out. You should do this task when
your greenhouse contains the least number of plants, generally just before the garden plants are
brought in for wintering over. A recommended cleaning solution is a mixture of soap and water,
this will not damage your polycarbonate sheets. Any benches, shelving, plastic trays, pots and
baskets should also be cleaned thoroughly. Prevention is the best known method for controlling pests
and diseases in the greenhouse.
NOTE: DO NOT STORE POLYCARBONATE SHEETS IN THE SUN.
–2–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
List of Drawings
Cross Country Curved Lean To Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Foundation Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Back Gable End Line Drawing Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Back Gable End Detail Drawing – Details 1 – 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front Gable End (With Door) Line Drawing Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front Gable End (With Door) Detail Drawing – Details 5 – 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly Outline: Aluminum Frame Steps 1 – 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 - 19
Polycarbonate Installation Steps 12 – 14 . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 22
Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Vent Assembly - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Truss Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix A
Vent Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix B
Intake Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix C
Exhaust Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix D
Side Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix E
Glass Louvre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix F
–3–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Cross Country Component List
Ridge & Ridge Slider
Poly Cap & Poly Bar
Poly End Bar
Ventframe Bottom
Side Base/Sill
Bracing Angle
Aluminum H
Vent Frame Sides
Purlin
Bolts / Nuts
#8 Screws
Front & Back Base/Sill
Door Frame
Tools
#2 Square head
screw driver (#8 Screw)
Measuring tape
Level to check foundation
3/16” concrete bit
(concrete foundation)
9/64” aluminum bit
Optionals
7/16” wrench
Razor blade cutter
Caulking gun
Ladder
Hammer
Automatic Opener
Circulating Fan
Max/Min thermometer
Benches
Eyebolts
Motorized Intake Shutter
Exhaust Fan
Thermostat
Heater
Side Vent
–4–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Foundations
Check your local building codes for foundation requirements in your area.
CONCRETE FOUNDATIONS
When you prepare the concrete foundation, the size should be 1” longer and wider than the
greenhouse’s outside dimensions. One option is to fasten a treated 4” x 4” wooden sill on top of
the foundation. This sill is the exact outside dimensions of the greenhouse.
PRE-TREATED WOOD FOUNDATIONS
A greenhouse that is approximately 100 sq. ft. (9.3 m2) can be fastened to a 4” x 4” pre-treated
wood timber foundation. For larger greenhouses, a 6” x 6” wood timber foundation is
recommended. These timbers are placed on a 4” (10 cm) deep and 8” (20 cm) wide gravel bed.
Wood timbers can be stacked to increase the height of the greenhouse. One advantage of the wood
foundation is that it is not classified as a permanent structure. Therefore, if you move, the greenhouse can be
dismantled and moved to another location.
A SQUARE AND LEVEL FOUNDATION
Check the width and length of the foundation’s outside dimensions. Then, square the foundation
by measuring diagonally from opposite corners in the form of an “X”. Next, use a long carpenter’s
level to check and adjust the foundation until it is level. Finally, measure where the door will be
placed (in most cases it is 341/2” wide). Mark these measurements on your foundation.
Foundation Styles
Steel Truss on
Models over
13’ Long
Steel Truss on
Models over
13’ Long
Flashing by
Others
Steel Truss on
Models over
13’ Long
Steel Truss on
Models over
13’ Long
Flashing by
Others
Pressure
Treated
Wood
NOTE:
8” Concrete
Wall on Gable
Ends, models
over 16’ wide
(see detail)
Pressure
Treated
Wood
Pre-cast
Concrete Pier
Block
Gravel
Pressure Treated
Wood
4x4, 4x6, 6x6
Concrete Wall or
Concrete Block
with Pressure
Treated Wood
Plate
Concrete Wall
with
Footing
Concrete Wall
with
Footing and
Brick Facing
PRE-TREATED WOOD FOUNDATION
–5–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Assembly of Aluminum Frame
A.
BACK GABLE-END ASSEMBLY
Lay out the back pieces into the shape of the end wall. Refer to the line/detail drawing.
1.
For the curved Poly End Bars, the flat surface should lie on the ground
(See the example to the right. Use the curved end bars with angle sliders attached to it
and 1-straight one on the side, see sketch 1A ).
GROUND
2.
Bolt the Poly Bars on the top first (See Detail #1 & 1A, Page 7).
3.
Bolt the base/sill to the bottom of the Poly Bars (See Detail #2, Page 7).
4.
The angle brace is bolted approximately 56” from the base. The slider brackets that have
already been fastened to the poly end bar curve will determine the height (See Detail #3, Page
7). When bolting the horizontal cross brace onto the back wall, measure the back wall so that
it does not sag (See Detail #4, Page 7).
Back Gable-End Line Drawing Assembly Procedure
1
2
1A
Curved Poly End Bars
Poly Bars
3
4
Cross
Brace
1" x 2" Angle Base
–6–
ACF Greenhouses
3
Back Gable-End
Detail Drawing –
Details 1 – 4
1
2
4
1A
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
–7–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
B.
FRONT GABLE END ASSEMBLY WITH DOOR
1.
Lay out the front pieces of the greenhouse into the shape of an end wall. The door frame and
all the Poly Bars have a track for the bolt. The track must face up when you assemble the gable
ends. Slide the bolts into the track of the bars or use the notches that have already been
punched out in the bars. (Refer to the line/detail drawing on the following page. The order
of assembly is represented by dark lines. Detailed pictures are on page 10.) When you are
assembling the greenhouse, you view the sketches and drawings from the inside the
greenhouse. Bolt the bottom plates (4 holes) to the base/sill and the door frame sides using
1/4” x 1/2” stainless steel bolts (see Detail #5). Before tightening the bolts, be sure that it is
square (If you ordered a greenhouse with a door drop, measure from the bottom of the door
frame to the underside of the base according to the specified distance).
2.
At the top of the door frame, put on the door frame header (which looks the same as the side
pieces). Put the header between the two side pieces and bolt on the plates (6 holes). (See
Detail #6). The plates should stick up 1” above the door frame. Note how the plates are put
on (See Detail #7). Before tightening the bolts, be sure to square up the sill to the door frame.
3.
Take all the Poly Bars and bolt them to the base/sill. The angle cut should match the roof
slope (See Detail #8).
4.
The 1” x 2” angle above the door (50” long) can now be bolted on. The 1/4” round holes
should be lined up with the holes in the plates. Each end of the 1” x 2” angle has a slot
punched out to accommodate the bolt. This slot lines up with the bolt track in the back side
of the Poly Bars. Slide a bolt in the top of the Poly Bar and fasten the angle to it (See Detail #6
& 9).
5.
Curved Roof Poly End Bar. Each curved Poly End Bar has at least two small aluminum
brackets attached to it with a 1/4” hole drilled in it. These pieces line up with the upright Poly
Bar(s) (See Detail #8 & #9)
6.
When the upright Poly Bars are fastened to the aluminum bracket that is attached to the poly
end bar, bolt on the short Poly Bar above the door to the 1” x 2” angle.
7.
The diagonal bracing can now be bolted on. Remove the bottom nut in the top plate and insert
the brace. Then put the nut back on (See Detail #4). Bolt the other end to the 1/4” hole in the
base using a 1/4” x 1/2” bolt (See Detail #10).
NOTE: You may want to fasten a temporary brace across the bottom of the door frame to keep them together.
This can be a piece of wood, make sure that the opening is the same as on the top of the door frame.
–8–
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Front Gable-End (with door) Line Drawing Assembly Procedure
1
2
Door Frame Top
Plates
Door
Frame
Sides
Plate
3
1" x 2" Angle
4
Poly Bar
5
6
Poly Bar
Curved
Poly
End Bar
7
Diagonal
Angle Brace
–9–
ACF Greenhouses
Front Gable-End (with door)
Detail Drawings
Details 5 – 10
9
7
8
– 10 –
Curved
Glass End
Bar
Diagnol
Brace
Door
Frame
10
5
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
6
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
C.
TAPING POLY BARS WITH FOAM
Tape all the aluminum poly bars with a 1/8” foam gasket. Tape the poly end bars on one side only
(See Detail 14 ). Tape all the other poly bars on both sides. Take a roll and, starting at one end,
press on the bar. Make sure that the aluminum is dry. (You should move all the pieces into a shed or
undercover if it is raining). Slowly roll down the tape toward the outer edge and press it down at
the same time (See Details 14A & 14B ). Be careful because sometimes the edge of the paper is quite
sharp. Do not remove the paper until later. Do not tape where the poly bar is notched out (See
Detail 15 ).
NOTES: Taping can also be done either before (as shown in pictures to the right) or after the
greenhouse is assembled.
13
14A
14
14B
Do NOT put foam
tape along
the End Bars.
The polycarbonate
slides under the lip
and needs to be
sealed when the
greenhouse is
finished
15
– 11 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Aluminum Frame Installation
Check that the foundation is level and square. If your
foundation is larger than the greenhouse, mark a line on it
with a pencil or with a chalk line. Take a caulking gun and
put in a tube of caulking. Cut 1/4” off the top at a 25-degree
angle. Then put a bead of caulking on your foundation
approximately 1” in from the outside of the foundation or
the marked line. DO NOT CAULK THE DOOR OPENING.
Measure your door opening in the front.
1.
SIDE BASE/SILL
Lay down the aluminum side base/sill flush with your base or on the line you have marked
out. Push down on it so that the caulking squeezes out.
(See Step 1 Detail, page 14)
2.
FRONT GABLE-END
Stand up the door end, flush with your base or marked line. Slide up one bolt in the bottom
of curved glass end bar (front). Take the end bar and push it into the side base where it is
notched. The back of the bar lines up with the first slot in the side base/sill. Slide the bolt
down and fasten it. When you are lined up and in the right place, screw down the front
base/sill using the screw holes that are already there. Then put one screw in the side base to
hold it in place. When you have fastened down the front, it should stand by itself. (If it is
windy, you will need another person to hold up the front, or you can use a stepladder so that
the front can lean against it.) (NOTE: after the greenhouse frame is up, double check for square
and plumb. Seal behind the poly bar, against the wall and the ridge, then put in all the screws.) (See
Step 2 Detail, page 14)
3.
BACK GABLE-END
Follow the same procedure for the back gable-end as you did for the front. When you have
bolted it to the side base and it lines up flush with your base/sill or marked line, then you can
proceed. Fasten the base/sill down to your foundation with the screws that are provided.
When fastening the side/base sill to the foundation, be sure that the base is straight.
(See Step 3 Detail, page 14)
4.
RIDGE
Before you slide in the ridge, put one bolt in the top of each curved poly end bar. Take the ridge
(one person at each end) and slide it between the end bars on the top. You will notice the
punched-out slots in the bottom flange of the ridge. The slots on the end line up with the
bottom side of the poly end bar. Now slide in the ridge and slide the bolt into the ridge slot.
Make sure that the curved poly end bar is tight against the ridge – use a 7/16 flat wrench (at this
time you can temporarily fasten the ridge to keep it from moving around). (See Step 4 Detail, page 15)
4A. SEE APPENDIX A FOR TRUSS ASSEMBLY INSTALLATION FOR
GREENHOUSES LONGER THAN 16 FEET.
5.
CURVED POLY BARS WITH SLIDERS (1, 2, 3 etc.)
Each Poly Bar (with a vent frame slider) is marked with a number (1, 2, 3 . . .) to correspond
with the number on the ridge. Slide the bolt into the top of the Poly Bar and line it up with
the slot in the ridge. Move up the bolt and fasten it. Do the same for the bottom of the
polybar. Slide in the bolt, lift up the end, and push it into the side base/sill as far as you can.
Then bolt it on. Do this for all the Poly Bars with sliders and numbers. The end of the bar
(See Step 5 Detail, page 16)
should be tight to the base.
– 12 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
6.
VENTFRAME ANGLE
The ventframe angle is 50” long with the ends cut out to fit between the two Poly Bars with
sliders. The ventframe is the same shape as your base/sill. Put the head of the bolt into the punch
out in the back of the poly bar (24” from the top), slide the bolt up and fasten it to the
ventframe on the bar. Make sure that the angle flanges are facing toward the sidewall (down)
and that it is pushed up against the side sliders (already on the Poly Bar). Do this for all of
them.
(See Step 6 Detail, page 17)
7.
SIDE/ROOF POLY BARS
Bolt on all the remaining Poly Bars. Make sure that the top is tight against the ridge.
(See Step 7 Detail, page 18)
8.
ROOF PURLIN (CHANNEL)
When installing the roof purlin, mark it out by measuring from the ridge. The roof purlin
should be located approximately the center of the roof. Always face the open end of the
purlin up towards the ridge so that it can be used for hanging baskets. Every Poly Bar has
notches punched out so that the head of the bolts can be inserted and can slide up or down
on the bar.
(See Step 9 Detail, page 20)
9.
TAPE ALL POLY BARS
Complete all taping with the 1/8” foam tape if it was not done before.
(See photographs, page 11)
1O. FASTENING / SEALING THE GREENHOUSE TO THE WALL
Before you seal behind the ridge and end poly bars, square your greenhouse using the 3/4/5
method (see sketch). Sometimes the foundation is
1
level but your wall is not plumb. You may have
to decide to pull the greenhouse away from the
wall or make your foundation off-level. When
your greenhouse is squared up, mark the edge
of the ridge on your wall and pull your
greenhouse away from the wall and seal behind
it. Push the greenhouse back to the wall and fasten it with
screws. NOTE: Sealing can also be done after greenhouse is finished and before the vents are
installed.
11. SIDE VENTS, INTAKE SHUTTER AND EXHAUST FANS INSTALLATION
(IF NECESSARY) SEE APPENDIXES B THRU E. THEN RETURN TO THE
NEXT PAGE AND CONTINUE
– 13 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Assembly Outline
Fro
nt
Step 1: Side Sill & Base
Step 2:
Front
Gable-End
Step 3:
Back
Gable-End
– 14 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Step 4: Ridge
Inside View
1
1
Inside View
4
4
Outside View
Outside View
– 15 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Step 5: Poly Bar with
Vent Frame Sliders
3
3
2
2
– 16 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Step 6: Vent Frame Bottom
Inside
View
– 17 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Step 7: Install All Remaining Poly Bars
– 18 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Step 8: Roof Purlin
3" Purlin on larger greenhouses
3" Purlin
3" Purlin
– 19 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Polycarbonate Panels & Cap Installation
GENERAL INFORMATION ABOUT HANDLING POLYCARBONATE
All polycarbonate sheets are covered with a thin sheet of plastic on both sides to prevent the sheets
from becoming dirty and scratching during handling. One side is a clear plastic while the other side
is blue or some other colour, depending on the manufacturer. This latter side should be installed so
that it faces out. (The sheet is marked to indicate which side should face out.)
Before you begin installing, lay out the sheets lengthwise so that it is easier to take the one you
want to install. Do the same with the capping.
Remove all the paper on the foam strip on the greenhouse before you begin installing the panels.
If the weather is warm and sunny, the foam strips will be sticky. Take a trigger spray bottle and fill it
with soap and water. Just before you install the panels, spray the foam lightly so that the panels can
be moved around.
(Do not store polycarbonate bundles outside in the sun. Instead, store them
in a cool dark place, such as a garage, until you are ready to use them.)
12. SIDE WALLS
Start with the first long panel and peel off the plastic. Remember to
mark in the corner which side is out. Stand the sheet up into the
bottom track of the side base/sill. Push the panel against the foam. If
the polybars do not line up with the panel, move the greenhouse ridge
toward the front or back until the bars line up.
Take the cap, hold it against the panel and position it in the center of
the polybar.
Note: Use #8 x 1/2" screws and fasten the cap to the bar (approx 3 to 4
screws to the curve)
Continue to the next panel and follow the same procedure.
When you have completed the side, make sure that the length of the
panels are correct. The panels should be approximately 20” shorter at
the place where the vents go.
Now go back to the first panel, and at this point you need an assistant.
He/she should take a ladder and set it below the vent opening. As you push the sheet down
on the polybar, your assistant needs to guide the top end of the sheet into the vent frame
slider track. At this point, if the greenhouse is not square, remove the screws in the ridge and
move the ridge to the front or back to square it. After the sheet is in place, your assistant
should hold it down while you take the cap and bend it over the curved bar.
Fasten the ridge and the upright bars to the wall.
Note: When bending the cap around the curved part of he polybar, do it slowly and put in
the screws as you go along. If you push too fast, the cap may buckle. Keep it in the center put
in the screws as far as you can reach. Then your assistant can take over. Do this with all the
sheets. (If it is windy while installing the panels, you may need to finish off each panel as you move
along.) (See page 23.) (See page 21 for pictures.)
– 20 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
– 21 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
13. BACK/FRONT GABLE-ENDS
2
Poly en
d bar
3
e
Door fram
1
Start with the round panels and peel off the plastic. Remember which side is the outside of
the sheet. Put on the bottom of the panel an aluminum “ ” (page 22, picture 1 ). Stand up
the sheet and push it sideways into the end poly bar track (page 22, picture 3 ). Start with the
bottom and move upward. You will have to twist the panel to get it in. Another way to
accomplish this is to remove the poly bar beside the sheet, push the panel into the end tract
and then rebolt the poly bar back into place.
For the next panel, put an aluminum “ ” on the bottom. Stand it up in place, bend the
center of the panel toward you and pop the top of the panel into the track. (You can also slide
the panel in the top track first and then push the bottom in place.)
Put the cap on the bar and screw on with #8 x 1/2"
screws. Do all other pieces the same way. The panels
beside the door are usually narrow pieces and have an
aluminum “ ” on the top and the bottom (The
aluminum “ ” does not slide into the door frame track).
Also, make sure that the second track (in the door frame) is
used; otherwise, the panel will sit on an angle (page 22,
picture 2 ). Finish off the door
end.
– 22 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
14. SEALING THE GREENHOUSE
When all the polycarbonate sheets are installed, take a tube of clear silicone sealant and seal all
the panels that fit into the aluminum tracks on the top, the bottom, the inside and the outside.
In this way, you can keep out most of the moisture from the end of the panels. If this sealing
process is not done, water will sit in the bottom, fill the inside of the panels and grow algae.
1. Unscrew the plastic nozzle on the tube of silicone sealant.
2. Cut the top of the tube.
3. Screw on the plastic
nozzle again.
4. Cut approximately
1/8” off the end of
the plastic nozzle at
a 30-degree angle.
5. Put the tube into
the caulking gun.
When using the
gun, squeeze the
handle slowly.
Inside view
6. Wherever the polycarbonate sheets are sitting in a
track or aluminum “ ”, seal the edge, including
the end poly bars. Also seal the inside of the
sidewalls because greenhouse humidity runs
along the walls and into the bottom track.
7. Seal the vents before you slide them into place.
Seal the places where the panels fit into the door
frame bar and the “ ” under the above door
angle.
Outside View
CAULKING
• Seal the door frame bar where the base/sill
meets the door frame.
• Seal the inside of the base/sill along the
perimeter of the foundation.
– 23 –
Roof
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
15. DOOR INSTALLATION
(Refer to the drawing.) Take the door and set it inside the door frame. Lift it up as high as
possible on the hinge side and put the screws through the existing holes in the door frame.
Now the door will hang by itself.
Remove the black clip from the “Z” bar and put one screw into the door frame to hold the “Z”
bar. Open the door, take off the clips and put back the screws. Close the door and check that it is
square. If the frame and the door are square, then fasten the “Z” bar to the frame. If not, move
the “Z” bar up or down to square it. If this
1
is not enough, loosen the bolts in the top
plates and move the frame to make it
square. When it is in place, tighten all the
bolts.
Next install the door handle (see the
instructions inside the box). To install
the door catch angle, slide in two bolts
into the back of the door frame. Bolt on a
small angle (provided with the door
Door Catch Angle
handle). Face the angle towards the door,
line it up with the center of the door handle, and then tighten the two bolts (see picture to the
right). Take the door catch out of the door handle box and screw it on. Close the door and
adjust the door sweep at the bottom of the door to eliminate potential gaps.
NOTE: There are two types of manufactured doors. The door catch angle on the white door may have to be
turned the opposite way as shown on picture 1 .
Run a bead of silicone under the angle above the door and against the door frame. Also
silicone the “ ” on the polycarbonate beside the door to ensure an airtight seal.
Z Bar
Z Bar
– 24 –
ACF Greenhouses
Door Installation
Z-Bar
1/2"
Door
Screws
– 25 –
Z-Bar
Vertical Jamb
Base
Plan View
Base
Plate @ Base
Vertical Jamb
Door
INSIDE
GREENHOUSE
Base
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
#10 x
OUTSIDE
GREENHOUSE
Z-Bar
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
16. VENT ASSEMBLY (SEE DRAWING & PICTURES PAGES 27 – 30)
1.
Lay down the gutter with the punches facing up towards you.
2.
Poly bars with sliders on are for the end. Lay them down with the bolt slot facing up.
3.
Hinge with punches facing up towards you.
4.
Slide the bolts into both ends of the end bar. Take the gutter and line up the bolt with the 1st
punch, slide the bolt down and tighten it. Do the same with the hinge, other side and center
bar. Make sure that the poly bars are tightly fitted to the gutter and hinge after vent
assembled.
5.
Turn it over and square it up.
6.
Put 1/8” foam on the poly bars.
7.
Take polycarbonate panel, remove the film (clear inside) and slide it into the hinge track.
Before you do this; remove the paper and lightly spray the foam so that it doesn’t stick. Lay it
on the foam and slide it into the hinge (top) section and then down into the gutter track. Do
the same with the next piece.
8.
Take the caps and lay them on the bars, center them, fasten with 1/2" screws.
9.
Take the silicone gun and seal where the sheets slide into the track. Inside and out.
17. VENT INSTALLATION
Take the vent and slide it in the end of the ridge. You will have to remove a rectangular screw
in the ridge. Then push it into place and put the screw back in. Now attach manual opener
(picture A).
A
– 26 –
ACF Greenhouses
Vent Assembly - Exploded View
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
– 27 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Greenhouse Roof Vent Details
1
3
4
7
8
2
5
6
9
10
11
12
– 28 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
1
Appendix A – Truss
1.
TRUSS ASSEMBLY
(This section is to be used only for greenhouses that are over 14’ long.)
Trusses are usually installed after the sides, base, front, back and
ridge are bolted together. Make sure that the greenhouse is
temporarily braced (see 4A on Aluminum Frame Assembly).
2
A. Lay the truss piece in the shape of an end wall.
B. Slide the center pieces into the top of the truss and bolt them
together. 1 , 2 and 3 (lean to models do not have a center
piece – see next page).
3
C. Slide the truss feet into the bottom of the truss and bolt them
together. 4 and 5 .
D. Bolt on the cross brace (if required) 6 .
4
2.
TRUSS ASSEMBLY & INSTALLATION (IF REQUIRED)
The next step takes two people, one on each side. Carry the
truss to the center of the greenhouse and put the feet on your
foundation between the side base/sill 7 . Lift the top of the truss
towards the ridge and bolt it on 8 . Use the notch on either side
of the center. There are three notches in the ridge because if the
glassbars have already been installed with the truss bracket facing
one way, you can bolt the truss to either notch without having to
turn the truss bracket around. Sometimes the installers put in all
the glassbars first and slide the truss bracket in beforehand.
5
Remove the truss bracket from the truss. (It may also be in a plastic
bag.) Unbolt the bar from the base. Slide the truss bracket into the
bottom of the glassbar (long bar) 9 & 10 and slide it to the place
where there is a 9/64” hole drilled into the truss. Fasten it with a
screw. If the hole does not line up, you may have to drill a new
hole in the truss bracket 11 . Do this after all the glass bars have
been bolted together. To fasten the truss to the foundation, use
1/4" x 2" leg bolts.
6
7
8
9
10
11
– 29 –
ACF Greenhouses
Ridge
Detail
Poly Bar
Steel Truss
Truss Ridge Piece
Optional #8 Screw
(Drill 3/32" hole)
Poly Bar
– 30 –
Steel Truss
1/4" x 2" S.S. Bolts
(2) 1/4" x 2" S.S. Bolts
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Cross Section of
Cleat Connection
1/4" x 1/2" S.S. Bolts
1/4" x 1/2" S.S. Bolts
Appendix A
Slide Poly
Bar on
Cleat
TRUSS SKETCH
1/4" x 4" S.S. Bolts
Truss Foot Piece
Drill 5/32" Hole & Fasten
with #8 Teck Screw
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Appendix B – Vent Opener
INSTALLING THE BAYLISS AUTOMATIC VENT OPENERS
Detailed instructions are included in the box with the control (there are a few extra parts).
Use #8 stainless steel screws to fasten the Bayliss and the vent sill 1 and the vent 2 . All holes are
already drilled.
After the Bayliss is fastened in place, install the threaded adjuster into the swivel block. This is
made easier by lifting the vent with one hand until the piston rod only projects 1/2” through the
swivel block.
2
Vent
Bottom Rail T Bracket
Power Tube
Vent Gutter
Closing Spring
Sill T
Bracket
1
Arm
Vent Frame Bottom Angle
Piston Rod
Swivel Block
Threaded Adjuster
– 31 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Appendix C – Motorized Intake Shutter
INTAKE SHUTTER ASSEMBLY
Inside View
Vertical
Glazing/
Poly Bar
Inside
Electric
Power
255/8"
Louvre Motor
Louvre Motor
26"
Rip Flush
2" x 1" x 1/8" Aluminum Angle
Vertical Glazing / Poly Bar
241/2"
1/4" x 1/2" S.S. Bolt
Louvre Motor
Inside
Outside View
Vertical Glazing / Poly Bar
– 32 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Appendix D – Exhaust Fans
INTAKE SHUTTER ASSEMBLY
Inside
Fan
Motor
Fan Motor
Fan
Cage
2" x 1" x 1/8" Aluminum Angle
Vertical
Glazing /
Poly Bar
Vertical Glazing /Poly Bar
241/2"
1/4" x 1/2" S.S. Bolt
Inside
Fan Cage
– 33 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Appendix E – Side Vent
GLASS OR POLYCARBONATE SIDE VENT ASSEMBLY
Vertical
Glazing /
Poly
Bar
Inside
GLASS / POLYCARBONATE
GLASS / POLYCARBONATE
Locking
Handle
2" x 1" x 1/8 Aluminum Angle
Vertical Glazing / Poly Bar
241/2"
Locking
Handle
GLASS / POLYCARBONATE
Inside
GLASS / POLYCARBONATE
1. Slide slider on inside foam track of
Side Vent
glass / poly bar where
Frame
side vent is going to be located.
Slider
2. Install glass / polycarbonate below side vent.
3. Bolt on 1 x 2 angle sill in place making sure sliders are above sill.
4. Bolt top header in place on top of side sliders.
5. Slide vent into place.
1/4" x 1/2" S.S. Bolt
6. Install automatic or manual opener.
– 34 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Appendix E – Side Vent CONTINUED
– 35 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
Appendix F – Glass Louvre
GLASS OR POLYCARBONATE GLASS LOUVRE ASSEMBLY
– 36 –
ACF Greenhouses
CROSS COUNTRY SERIES CURVED LEAN TO MODEL • GREENHOUSE INSTRUCTIONS
At this point, stand back and enjoy your workmanship.
Your Cross Country Curved Lean To Greenhouse
should now be closed in and ready for use.
Congratulations!
ACF Greenhouses
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