ClearSpan 4040SS User manual

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CLEARSPAN™SUNBLOCKER SYSTEM
Visit www.ClearSpan.com for additional products and customer assistance.
Revision date: 10.09.07
©2007 ClearSpan™
All Rights Reserved. Reproduction
is prohibited without permission.
ClearSpan™
Add-A-Bay Shade System
Photo may show a different but similar model.
STK# DIMENSIONS
4040SS 40' W x 40' L x 10' H
4060SS 40' W x 60' L x 10' H
4080SS 40' W x 80' L x 10' H

CLEARSPAN™SUNBLOCKER SYSTEM
2Visit www.ClearSpan.com for additional products and customer assistance. Revision date: 10.09.07
YOU MUST READ THIS DOCUMENT BEFORE YOU
BEGIN TO ASSEMBLE THE SHELTER.
Thank you for purchasing this ClearSpan™ SunBlocker™
shelter. 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
shelter. 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.
• Wear gloves when handling metal tubes.
• 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.
ANCHORING INSTRUCTIONS
Prior to assembling this shelter, please read the MUST
READ document included with the shipment.
WARNING: The anchor assembly is an integral part
of the shelter construction. Improper anchoring may
cause shelter instability and failure of the structure to
preform as designed.
Failing to anchor the shelter properly will void the
manufacturer’s warranty and may cause serious injury
and damage.
LOCATION
Choosing the proper location is an important step before
you begin to assemble the structure.
The following suggestions and precautions will help you
determine whether your selected location is the best
location.
• Never erect the structure under power lines.
• Identify whether underground cables and pipes are
present before preparing the site or anchoring the
structure.
• Location should be away from structures that could
cause snow to drift on or around the building.
• Do not position the shelter where large loads such as
snow and ice, large tree branches, or other overhead
obstacles could fall.
SITE
After choosing a location, proper preparation of the site is
essential. Follow the information below.
• A level site is required. The site must be level to
properly and safely erect and anchor the structure.
• For sites that are not concrete or gravel, placing wood
blocks or other suitable supports under each rafter leg
or the perimeter base frame helps prevent the pipes
from sinking or working into the site. Does not apply to
shelters with ground posts.
• Drainage: Water draining off the structure and from
areas surrounding the site should drain away from the
site to prevent damage to the site, the structure, and
contents of the structure.
WARNING: The individuals assembling this structure
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.

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CLEARSPAN™SUNBLOCKER SYSTEM
Visit www.ClearSpan.com for additional products and customer assistance.
Revision date: 10.09.07
ASSEMBLY PROCEDURE
Following the instructions as presented will help ensure
the proper assembly of your shelter. Failing to follow these
steps may result in an improperly assembled and anchored
shelter and will void all warranty and protection the owner is
entitled to.
The steps outlining the assembly process are as follows:
1. Verify that all parts are included in the shipment. Notify
Customer Service for questions or concerns.
2. Read these instructions, the Must Read document, and
all additional documentation included with the shipment
before you begin assembling the shelter.
3. Gather the tools, bracing, ladders (and lifts), and
assistance needed to assemble the shelter.
4. Check the weather before you install the roof cover
and any panels (if equipped). Do not install covers or
panels on a windy or stormy day.
5. Re-evaluate the location and site based on the
information and precautions presented in the
documentation included with the shipment.
6. Prepare the site (if applicable).
7. Assemble the frame components in the order they are
presented in these instructions.
8. Assemble the frame including the struts (if equipped).
9. Consult the MUST READ document and properly
anchor the assembled frame.
10. Install, tighten, and secure the end panel and main
cover (if equipped). This applies to fabric covers that
stretch over the frame assembly. Your shelter may
include roof panels or side panels or both.
11. Read the care and maintenance information at the end
of these instructions.
12. Complete and return all warranty documentation as
instructed.
LIST OF WORDS AND PHRASES
Before you begin, it is important to become familiar with the
words and phrases used in this instruction manual.
These words and phrases are common to most
ClearSpan™ shelters and identify the different parts of
the shelter. (Some are used in this document. Others may
not apply to this particular shelter.) These terms describe
the shipped parts and can also be found on the materials
list/spec sheets included with the shipment. To aid in the
assembly, read through the following definitions before you
begin to assemble your shelter.
• Conduit: An assembly of pipes used to secure the
main cover and end panels (if equipped). Purlins and
some strut assemblies also consist of connected pipes
to form a conduit. Each pipe joint of a conduit assembly
is secured with a self-tapping Tek screw.
• Coupler or Fitting: A part of the frame assembly
where legs, purlins and rafter pipes are inserted and
secured. In most instances, 3-way and 4-way couplers
are used. In some larger applications, couplers are
used to secure the joints of the different rafter sections
during the assembly of the rafters. Some shelters do
not use couplers.
• Foot or Rafter Foot: The part attached to and found
at the base of the rafter or leg of the shelter.
Depending on the shelter, the foot is an optional
purchase. Some shelters do not offer an optional foot.
Some use 1-way connectors; others use ground posts.
• Must Read Document: This document includes
building and shelter anchoring instructions, steps for
end wall reinforcement, safety precautions, and notices
and warnings. The Must Read document is sent with all
shelters and buildings. If you did not receive a Must
Read document, contact Customer Service to request
one.
• On-Center: Term used to describe a measurement
taken from the vertical center of the rafter or frame
member to the vertical center of another.
• Purlin: The pipe assembly that runs perpendicular to
the rafters or framework that supports the main cover.
Purlins are found on the sides and roof areas of the
assembled frame, are evenly spaced, and typically run
from the front to the back of the shelter.
• Plain or Straight Pipe: A term used to describe a pipe
that has the same diameter or width throughout its
entire length.
• Strut: A strut is usually a length of pipe with two
flattened ends and is used for diagonal bracing of the
shelter frame. A strut is typically secured to the frame
work by special brackets and bolts.
• Swaged End or Swaged Pipe: The term “swaged''
refers to the tapered end of the pipe or tube. Swaged
ends of a pipe can be inserted into couplers and the
straight ends of other pipes.
• Tek Screw: A self-tapping fastener used to secure pipe
joints and to fasten brackets to rafters.

CLEARSPAN™SUNBLOCKER SYSTEM
4Visit www.ClearSpan.com for additional products and customer assistance. Revision date: 10.09.07
Space below is reserved for customer notes.
REQUIRED TOOLS
The following list identifies the main tools needed to
assemble the shelter. Additional tools and supports may be
needed depending on the structure, location, and
application.
• Tape measure or measuring device
• Variable speed drill and impact driver (cordless with
extra batteries works best)
• Wrench set, or ratchet and socket set (recommended)
• Hammers, gloves and eye protection
• Metal file and metal-cutting saw
• Ladders, work platforms, and other machinery for lifting
designed to work safely at the height of the shelter
UNPACK AND IDENTIFY PARTS
The following steps will ensure that you have all the
necessary parts before you begin to assemble the shelter.
Unpack the contents of the shipment and place 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/Spec
Sheets are present. If anything is missing or you have
questions, consult the Pictorial Parts Guide 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 or
washers.
QUICK START GUIDE
For an overview of this shelter and to see the main
connection details, consult the diagrams in the Quick Start
Guide located at the back of these instructions.

5
CLEARSPAN™SUNBLOCKER SYSTEM
Visit www.ClearSpan.com for additional products and customer assistance.
Revision date: 10.09.07
QUICK START GUIDE
The following graphics and photos will help you identify
the different parts and show you how they are used.
(Not all parts are shown.)
103856
Band Clamp
103838
Strut
CC4595
Ball Tie Down
103837
Straight Coupler
2375P120 Plain Pipe
2375P120D Drilled Pipe
103839
5-Way Coupler
Cross Port
Cross Port
Through Port