ClearSpan PB01110R4N User manual

Instruction Manual
Poly Shelters
House Style Shelter
12' Wide x 10' High x 24' Long
SKU #PB01110R4N
© 2004 ClearSpanTM
All rights reserved. Reproduction prohibited without written permission.
Rev: 22 June 04

Introduction
Thank you for purchasing the ClearSpanTM Poly Shelter. We appreciate your patronage. We hope
you enjoy building and utilizing your shelter. Please read this entire instruction manual before
starting to assemble your shelter. If you require assistance during the construction process you may
call us at 1-888-603-4445.
A Word About Safety
Just as we want you to be pleased with your assembled shelter, we donʼt want you to get hurt in the
process of building it! Our suggestions include the following:
• Wear eye protection when drilling and power-screwing.
• Wear head protection when working with/under heavy parts including metal tubing.
• Wear gloves when handling metal tubing due to sharp or rough ends.
• Use a portable GFCI when working with corded power tools.
• Never erect a shelter directly under power lines.
• Be careful not to drive anchors into buried power cables.
• Do not climb on the shelter or its frame. It is not designed to support human weight.
• If the shelter is enclosed, provide proper and adequate ventilation.
• Do not store hazardous materials in the shelter without proper ventilation and precautions.
• If both ends are covered, provide proper ingress and egress to prevent entrapment.
• Do not occupy the shelter during very high winds, hurricanes, or tornadoes.
• If shelter is moved after construction, inspect shelter thoroughly before reuse.
• Use common sense at all times.
Required Tools
Before you start to build your shelter you should assemble the following tools:
• Tape Measure at least as long as your shelter
• Fine Point Marker to mark locations on tubing
• Electric Drill/Driver (cordless preferred)
• Adjustable Wrench (or wrench set)
• 1/4" Allen Wrench
• Scissors
• Step ladder tall enough to safely work at the height of your shelter
• Two 30-foot pieces of rope
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IMPORTANT - Read Anchoring Instructions
You must read the anchoring instructions packed with your kit prior to shelter assembly!
Selecting a Location
It is important to select a proper location for your poly shelter. While the location may have been
predetermined before you even ordered your shelter, you may want to “improve” the location before
starting the assembly process.
One of the most important considerations is that the location should be level. If it is not, the shelterʼs
frame will not assemble or sit properly. If your location is not level, you should consider grading it
before building on it. Another alternative is to provide footings which are level to support the shelter.
These could be pressure-treated posts, precast concrete blocks, or poured in place footings.
Drainage is another important consideration. Rain flowing off your shelter should have a natural path
to flow away from the shelter and not under or into it.
Section A - Unpack & Identify Parts
Step 1: Before you begin to assemble your shelter you should first unpack the contents of your
shipment. During this process you will learn what all of the various parts look like.
Tip: We recommend you start by laying out the contents of your shipment in an orderly fashion
as shown in the photograph below. Note that your parts may look different from those shown.
The contents of the Bill of Material for your shelter will depend on the size of the shelter ordered.
Please refer to the Bill of Material that came with your shelter.
Step 2: Carefully go through the bill of material that came with your shelter and verify that you have
all the required parts.
Tip: It is not necessary to open the plastic bags and count all of the fasteners at this time.
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Parts Identification
Note: Illustrations are not to scale.
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3
8
Purlin/Cover/End Conduit (only swaged is shown)
Strut
Brace Band
Fender
Washer
Swaged and Unswaged
Rafter Sections
(all pieces
not shown)
Tek Screw Carriage Bolt
& Hex Nut
Driver
Bit
Fabric Clip
Purlin End Clamp Purlin Cross Clamp
End Conduit Connector

Note: Illustrations are not to scale.
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Plain End Panel
Strap Ratchet
Zippered End Panel
Cover
Plain End Strap
D-Ring End Strap

Assembly Diagrams
Your assembled shelter will be similar to the illustration below:
First you will assemble the frame:
Note: Rafter count in illustration may differ from your shelter model
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Section B - Rafter Assembly
Step 1: Locate the 6 sections of pipe to make a rafter. This will include two “A” rafter lower side
sections, one “B” rafter top section, one “C” rafter top section, and two “X” rafter extensions.
Step 2: Fit the two top sections together, add the lower side sections, and then add the two rafter
extensions to form a house-shaped arch laying flat on the ground. It is essential that you
perform this step on level ground or the completed rafter assembly will be twisted.
Typical End Rafter Assembly
Step 3: Install the supplied 3/8" hex driver bit into the chuck of your drill/driver.
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Step 4: Secure each connection by inserting a Tek screw into the middle of the overlapped area on
the side of the rafter where it will not come into contact with the main cover or the end panel.
Tip: Tek screws are self-drilling and no pilot hole is usually required. If you have trouble
getting a Tek screw to “bite,” try another Tek screw (or you can drill a 3/16" pilot hole).
Step 5: Repeat the steps above to assemble all remaining rafters using the same procedures.
Two of your rafters will be used on the ends of your shelter, and these end rafters use special fittings
including Purlin End Clamps and Brace Bands. You will add these fittings now.
Step 6: Slide 2 sets of Purlin End Clamps onto each end of one of the rafters (4 clamp sets per end
rafter). These will be be used to secure the purlins to the end rafter. Turn them as required to
get past the Tek screws at the joints. Youʼll need a pair near the top of the rafter about a foot
down from the peak of the shelter and a pair just below the bend on the sides of the rafters.
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Step 7: Slide a Brace Band over each end of the rafter and up the rafter a few feet. These will be
used to secure the struts.
Step 8: Slide another set of Purlin End Clamps onto each end of the rafter. These will be be used
at the lower ends of the rafter and will “trap” the brace bands so they canʼt fall off. The clamp
should be about 2" away from the end of the rafter to leave room for the “T” connector which
will be added later. You should now have a total of 6 sets of end clamps on your rafter.
Lower Position (with purlin installed)
Step 9: Repeat the steps above to assemble the other end rafter exactly like the one you just made.
Step 10: On the inside rafters, install Purlin Cross Clamps at the same locations where you installed
end clamps on the end rafters. Leave the screws loose so you can slide in the purlins later on.
This model has 6 clamps per rafter.
Typical Cross Clamp Assembly
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Section C - Rafter Setup
Step 1: Stand up one of your end rafters (one of those with the brace bands attached). Secure it to
an existing structure if possible so that it is plumb. If you donʼt have an existing structure, you
can use some 2x4s as shown tied with rope:
Step 2: Insert purlins into the clamps at the bottoms of the end rafter and tighten the clamps.
The ends of the purlins should extend a half inch or less past the clamp, or the rough end of
the purlin could damage the cover when it is installed later. Note that the bolt side of the end
clamps must go toward the “inside” of the shelter” (the same side as the purlin) as shown.
Step 3: Slide an inside rafter (without brace bands) onto the two purlins. Position this 2nd rafter from
the end rafter using a rafter-to-rafter distance of 48". Have your partner hold the rafter in
position while you tighten the purlin clamps at the ends of this rafter.
Step 4: Slide a purlin through a clamp near the top of this rafter and also the clamp near the top of
the end rafter. Tighten the bolts with the end of the purlin a half inch past the clamp.
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Step 5: One at a time, slide purlins through the rest of the clamps and tighten the bolts with the
ends of the purlins a half inch past the edges of the clamps on the end rafter.
Step 6: After you have installed the first two rafters, slide a brace band onto each of the two bottom
purlins (before you go on to attach the third rafter).
Step 7: Using 1-1/2" carriage bolts and nuts, attach struts between the brace bands on the purlins
and the brace bands on the end rafter. Position the struts so that they form a triangle at roughly
a 45° angle when installed. Make sure the end rafter is plumb before you tighten the nuts.
Tip: If you forgot to slide a brace band into position on a rafter or purlin, you can wedge the
brace band onto the pipe by striking it with a mallet. Be careful, and wear eye protection!
You can then reclose the end of the brace band by pinching it with slip joint pliers if necessary.
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Step 8: Continue adding rafters (at 48" spacing) and purlins until all inside rafters are in place
between the two end rafters. Remember to use the other end rafter last.
Step 9: Using 1-1/2" carriage bolts and nuts, attach struts between the end rafter just installed and
bottom purlins as you did at the other end of the frame.
Step 10: With all rafters and purlins in place, position the shelter exactly where you want it located.
Step 11: Recheck the 48" rafter-to-rafter dimensions along all the purlins. Also check that every raf-
ter is standing up straight (plumb). Square the corners by measuring diagonally corner-to-cor-
ner, and line up all rafters using a straight line.
Step 12: Secure every joint between purlin sections with a Tek screw.
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Section D - Finish Rough Edges
Step 1: Check for any sharp edges on the frame and file them smooth so they will not cut the cover.
Step 2: Apply two layers of heavy duct tape on all pipe connections and clamps that may contact
the cover.
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Section E - Install End Panels
DO NOT INSTALL END PANELS ON A WINDY DAY AS DAMAGE TO THEM MAY RESULT!
Step 1: Locate the end panels, and end conduit sections, and end conduit connectors.
Step 2: Assemble a set of end conduit sections and add end conduit connectors at the ends. The
length should match the width of your shelter.
If the corners of your end panel have not been cut out, follow the procedure below to do so:
Step 3: Lay an end panel out on a clean flat surface.
Step 4: Place the end conduit assembly centered side-to-side on top of the hem as shown below.
Step 5: With scissors, trim the corner of the end panel on the dotted line shown below so the end
conduit connector will be exposed when it is placed inside the hem. Repeat at the other end of
this end panel and on both ends of the other end panel.
Step 6: Remove one end conduit connector and slide the end conduit assembly into the hem at the
bottom of the plain end panel. Replace the connector you removed.
Step 7: Place the end conduit in position and insert the bottom of the end rafter into the connector.
Tighten the allen screws to secure the connectors to the conduit.
Note: Cover is not shown in the photo so you can see the connector assembly.
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Step 8: While standing inside the shelter, start at the peak of the end rafter and pull the end panel
over the top of the rafter so the material edge is on the inside of the rafter.
Step 9: Secure the panel in place at the top center with a fabric clip.
Step 10: Move outward in both directions, placing one fabric clip every 24." Then, secure each clip
to rafter with a Tek screw (on side where it wonʼt contact cover).
Step 11: Your other end panel has 2 zippers which create 3 sections when the zippers are up. Insert
the conduit only through the side portions of this end panel and not through the middle door
section. Attach the end conduit to the bottom of the last rafter using the end conduit
connectors, and tighten the allen screws in the connectors.
Step 12: Secure this end panel up in place using fabric clips with Tek screws as you did on the plain
end panel.
Step 13: Your end panels may have been shipped as untrimmed rectangular pieces. If so, you may
use scissors to trim the excess end panel material inside the shelter to an inch or two past the
fabric clips as shown in the illustration above.
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Section F - Install Main Cover
Step 1: Fasten a ratchet to the end conduit with a Tek screw in the bottom hole of the ratchet. The
ratchet should be about 6" in from the end of the conduit. Repeat this step in all four corners.
Step 2: On one side of the shelter, identify the rafters where you will install side ratchets. These
locations are at the second, the next to the last, and every other rafter in between. On this
model, you will install ratchets at all even numbered rafters. If you numbered the rafters 1 to 7,
these locations are at rafters 2, 4, and 6.
Step 3: Fasten ratchets to the outside of these rafters using a Tek screw about 2" from the bottom of
the rafters. Note that ratchets are located on only one side of the shelter as this model uses
D-ring straps (installed later) on the opposite side.
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Step 4: Make up a pair of cover conduits each the length of your shelter. Start each with an
unswaged section and add swaged sections to arrive at the correct length.
Warning: DO NOT INSTALL COVER ON A WINDY DAY AS DAMAGE TO IT MAY RESULT!
Step 5: Unpack the main cover and unfold it completely with the inside surface facing up.
Step 6: Locate the ends with strapping and line them up with the front and back of the shelter.
Step 7: Slide cover conduits into hem openings as shown in the next illustration.
Step 8: To pull the cover over the frame, attach ropes to both ends of the cover conduit. Wrap the
rope around the conduit a few times as shown below to prevent it from slipping off accidentally.
Long shelters require additional ropes at every rafter where you installed a ratchet. If your cov-
erʼs hem was notched at the factory, you can attach additional ropes at these locations. If your
cover was not notched at the factory, you can cut a small slit in the hem just inside of the cover
conduit (see photos on next page), pass the rope through and tie a bowline knot.
Step 9: Throw the ropes up and over the frame and then pull the cover over the frame. You need
one person at each rope for this step.
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Step 10: Remove the ropes and position the cover evenly on all four sides.
Warning: Do not leave the cover unattended until it has been secured in all four corners.
Step 11: In the front and rear hems, locate the black straps. If either of your straps were shipped
with a D-ring attached, you must cut the D-ring off with scissors as it is not used on this model.
Step 12: Tighten both corner straps on each end by pulling on them manually. Have a partner help
you so you can pull on both straps for an end at the same time.
Step 13: Cut off the excess strap leaving about 12" in length, and feed the strap through the center
slot in the ratchet and tighten only slightly. Repeat in the other corners.
Step 14: On the side of the shelter opposite where you installed ratchets, lift the cover up from the
outside so you can see the conduit frame. You will install D-ring side straps on this side. You
will use the same rafters you installed ratchets to but on the opposite side.
Step 15: The hem containing the cover conduit needs to be slit or notched at each rafter where you
will install a side strap. If your cover was not notched at the factory, continue with this step. Cut
a 2" long slit in the hem just above the cover conduit. Repeat this step on the other side of the
hem so you can pass a 1" wide strap with D-rings over the conduit through the slits.
Side Strap Installation
Note: If you already made small slits in Step 8 above, you can simply elongate these slits
centered on the rafter as required.
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Step 16: Loop the black straps with D-rings over the cover conduit through the slits in the cover.
Secure the D-rings to the rafters with a fender washer and a Tek screw making sure the cover
is the same distance from the ground on both sides of the shelter.
Note: Frame is shown without cover material for clarity
Step 17: On the side of the shelter where you previously installed ratchets, lift the cover up from the
outside so you can see the conduit frame.
Step 18: As before, the hem containing the cover conduit needs to be slit above each ratchet. If
your cover was not notched at the factory, continue with this step. Cut a 2" long slit in the hem
just above the cover conduit as shown below. Repeat this step on the other side of the hem so
you can pass a 1" wide strap over the conduit through the slits.
Note: As before, if you already made small slits in Step 8 above, you can simply elongate
these slits centered on the rafter as required.
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Step 19: Locate the 3' long 1" wide straps. Feed a strap through the slits over the cover conduit.
Step 20: Feed both ends of each strap down through the slot in the ratchet and tighten slightly.
Step 21: Check that the cover is still centered evenly from front to back and side to side.
Step 22: Tighten the outer ratchets first and then the inner ratchets. If the ratchets need to be
released, open them completely and they will release. Excess strap can then be pulled through
the ratchets and re-tightened.
Section G - Shelter Maintenance
Thank you for purchasing this ClearSpanTM Poly Shelter. Following instructions for assembly and
proper care and maintenance of the shelter will ensure many years of exceptional performance.
The following notes include several items that need periodic checking.
• Cover must be kept taut; check and adjust tension periodically.
• Check connections and fasteners for tightness; replace and/or repair missing or damaged parts.
• Contact ClearSpan for assistance in identifying needed parts; call us toll-free at 1-888-603-4445.
• If shelter is moved after construction, inspect shelter thoroughly before reuse.
• Do not allow snow to accumulate on the cover.
• Use a means of snow removal that will not cut or damage the cover.
• Never attempt to climb on or stand on the shelter or its frame.
• To ensure longer zipper life, do not allow door to flap in the wind.
• When opening, roll up door and secure with built in ties.
• Close door frequently to ensure moisture does not accumulate in roll-up.
• Depending on contents stored in shelter, construction of shelter and shelter materials, and the
geographic location of shelter, the potential for condensation does exist. ClearSpanTM offers several
items that can be incorporated into the shelter to alleviate a condensation condition. If condensation
develops in your shelter, please call a ClearSpanTM representative for more information.
• Note that ClearSpanTM shelters (Truss Arch excepted) do not have any tested loading criteria.
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