ClearSpan PB03100R4 User manual

ClearSpan™ 42' Wide Free-Standing
Shelter shown above may be shorter than your shelter.
Use these instructions for the following building: PB03100R4 (42' W x 17' 3" H x 48' L)
PB03102R4 (42' W x 17' 3" H x 60' L)
PB03104R4 (42' W x 17' 3" H x 72' L)
PB03106R4 (42' W x 17' 3" H x 96' L)
©2006 ClearSpan™
All rights reserved. Reproduction prohibited without written permission.
Revised: February 2006g

Introduction
Thank you for purchasing this ClearSpan™ structure. When properly assembled, the ClearSpan™
structure will provide years of reliable service. This instruction manual includes helpful hints and
important information needed to safely assemble the structure. Please read this instruction manual
before you begin. If you need assistance during construction, call us at 1-888-603-4445.
Safety Precautions
• Wear eye protection.
• Wear head protection.
• Wear gloves when handling metal tubes and cables.
• Use a portable GFCI 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 without proper ventilation.
• Provide proper ingress and egress to prevent entrapment.
Required Tools
The following list identifies the tools needed to assemble the building. Additional tools and supports
may be needed depending on the structure, location, and application.
• Tape measure or measuring device
• Marker to mark locations
• Electric drill and driver (Battery-powered drivers work best.)
• Metal-cutting saw or tool to cut cable to the required length
• Wrench set to tighten bolts
• Utility knife or scissors
• Ladders, work platform, and other machinery designed to work safely at the height of the
building
• Rope or cable
• Adjustable pliers
• Lifts to set and hold rafters in place
Anchoring Instructions
Prior to assembling the structure, you must read the anchoring precautions and instructions included
with the kit. Anchoring instructions are included in the MUST READ document. You must anchor the
building after the frame is assembled and before the cover is installed.
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Location
Choosing the proper location is an important step before you assemble the structure. The following
suggestions and precautions will help 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 building in a place 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. The following site characteristics
will help ensure the integrity of the structure.
• The site must be level to properly and safely erect and anchor the structure.
• If the site is not level, use footings to provide a secure base for the structure. Pre-cast concrete
blocks, pressure-treated wood posts, or poured footings are all acceptable when properly
used.
• Drainage: Water draining off the structure and from areas surrounding the site must drain away
from the site to prevent damage to the site, the structure, and contents of the structure.
ATTENTION: 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.
Unpack and Identify the Parts
The following steps will ensure that you have all the necessary parts before you assemble the
structure.
1. Unpack the contents of the box and place them where you can easily inventory the shipment.
Refer to the Bill of Material.
2. Verify that all parts listed on the Bill of Material are present. If anything is missing, contact
customer service.
NOTE: At this time, you do not need to open the plastic bags containing the fasteners.
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166P0XX
1.66” XX” PIPE
PLAIN
QH1061
1” x 4000-LB. RATCHET
QH1065
2” RATCHET
FALB08B
1/2”-13 NUT - ZINC
FALB04B
3/8”-16 NUT - ZINC
FA4482
#14 x 1” TEK SCREW
PART IDENTIFICATION
(All parts are not shown)
166S099
1.66” 99” PIPE
SWAGED
42R3501D
PIPE 3.50” DRILLED
RAFTER POSITION 1
42R3502
PIPE 3.50”
RAFTER POSITION 3
42R3501
PIPE 3.50”
RAFTER POSITION 2
105118
4’ STRUT
105242
3.50” PIPE FITTING W/BASE
(See diagram on next page.)
105350
PURLIN
CONNECTION
BRACKET
105353
3’ STRUT
(3' rafter spacing only.)
105350 Bracket
X's represent length
needed to reach the end
of the building.
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100441
3/8” NUT SETTER
104189
TURNBUCKLE ½” X 6”JAW/JAW
GALVANIZED
AR1050
GALVANIZED
CABLE 3/16”
AS1003
3/16” CABLE CLAMP
AS1083
3/16” CABLE THIMBLE
The rafter foot for each rafter leg must be assembled before it can be attached to the rafter. Use the following
diagram and information when assembling each rafter foot.
FAG355
HEX CAP 3/8”X 1”
104188
1/2” x 5 1/2” HEX CAP
BOLT
105370
1/2” x 4 1/2” HEX CAP
BOLT
LJ7510
DUCT TAPE
Rafter Foot Assembly
105092
Pipe
105371
Carriage
Bolt
105241
Base
FAMA40
Lock
Washer
FALB08B
Nut
ATTENTION: Assemble as
shown, but do not tighten the
mounting bolt at this time.
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Frame Assembly Diagram
(Frame shown may be shorter than actual frame.)
End Rafter: Rafter A
End Rafter: Rafter A
Purlin
Purlin
Customer-Supplied
Baseboard
Interior Rafters: Rafter B Cable Assemblies
Customer-Supplied
Baseboard
Frame End View:
Purlin Locations
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Side View of Rafter Assembly
Diagram above shows the 4' on-center rafter spacing.
4' Center-to-Center
Rafter Width: 42' Center-to-Center
Purlin
Custom-Supplied
Baseboard
End View of Rafter
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Layout the Building Site
After the site is prepared, marking the ground where the building will be situated and identifying
where the corners of the building will be placed helps square the frame after it has been assembled.
Taking these steps before assembling the building saves time and ensures that the structure is
positioned as desired. The following procedure is a suggested method. Its use depends on the size of
the building, its application, the footings, and the method used to anchor the building.
Square the Site
1. Identify a corner where a building rafter will be positioned, drive in a stake, and string a line the
exact width of the building and stake in place. (Width of the rafter is measured from center-to-
center of the rafter legs.)
2. String a line at least as long as the building from the first stake at 90°.
NOTE: A transit can be used to ensure an accurate 90°angle, or the 3-4-5 rule can be used. See
the diagram below. Using multiples of 3-4-5 such as 6-8-10 or 12-16-20 helps to maintain an
accurate 90°angle.
3. After squaring the position of the building and placing a stake at all corners, string a line between
the stakes to outline the base of the building.
4. Next, paint a line on the ground using the strings between the stakes as guides.
NOTE: There is no need to mark the rafter spacing. The purlins, when installed correctly, will
maintain even rafter spacing throughout the length of the shelter.
5. After marking the outline of the building, remove the strings and continue with the rafter and
framework assembly instructions for the building.
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Rafter Introduction
All rafters consist of the following five (5) pipes: 2 (42R3501D), 2 (42R3501), and 1 (42R3502). The
two 42R3501D pipes include two drilled holes near the bottom to connect the rafter foot.
Assemble Rafter A (There are two (2) end rafters.)
1. Connect the pipes as shown in Diagram A below.
2. Assemble rafter on the ground; slide swaged section into plain section until 9/16” holes line up
(Figure 1). Secure each pipe joint with one ½" x 5½" bolt and a single Purlin Connection Bracket
(Figure 2).
3. Insert one rafter foot (105242) into the bottom of the rafter and secure with (1) one ½" x 5½" bolt
and a single Purlin Connection Bracket in hole furthest from foot base. In hole closest to foot
base, secure foot to rafter using ½" x 4½" bolt (Figure 3).
4. Repeat Step 3 for the remaining rafter foot.
5. Repeat the above steps to assemble a second Rafter A.
ATTENTION: Install all brackets and bolts so they do not interfere with the installation of the main cover. To protect the
cover, tape all rafter joints with duct tape.
Diagram A
Figure 2
Figure 1
Figure 3
42R3501D
42R3501
42R3502
Arrow points
to the inside
of the shelter.
Position
p
urlin bracket to the inside of the shelter.
Duct Tape here
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Assemble Rafter B (Interior rafters)
NOTE: The length of the shelter and the on-center spacing of the rafters determine the number of
interior rafters. Locate the All Frame Diagrams near the end of these instructions to view the frame of
your shelter.
1. Connect the rafter pipes as shown in Diagram B below.
2. Assemble rafter on the ground; slide swaged section into plain section until the 9/16” holes line up
(Figure 4). Secure each pipe joint with one ½" x 5½" bolt and two (2) Purlin Connection Brackets
(Figure 5).
3. Insert one rafter foot (105242) into the bottom of the rafter and secure with (1) one ½" x 5½" bolt
and two purlin connection brackets in the hole furthest from foot base. In hole closest to foot
base, secure foot to rafter using ½" x 4 ½" bolt (Figure 6).
4. Repeat Step 3 for the remaining rafter foot.
5. Complete this entire procedure to assemble remaining interior rafters (Rafter B).
ATTENTION: Install all brackets and bolts so they do not interfere with the installation of the main cover. To protect the
cover, tape all rafter joints with duct tape.
42R3501D
42R3501
42R3502
Diagram B
Figure 4
Figure 6
Figure 5
NOTE: For longer shelters, assemble and place
the interior rafters in an accessible position that
will not interfere with the frame assembly.
105350
Duct ta
p
e here
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Frame Assembly: Standing the End Rafters
After all rafters are constructed and placed in an orderly fashion for frame assembly, proceed with
standing the first end rafter. Forklifts and personnel booms are recommended for lifting and setting
the rafters. Consult a construction professional if you are not familiar with construction techniques and
erecting similar structures.
Stand and Secure the First End Rafter
ATTENTION: Use the proper lifts. Rafter assemblies are heavy and awkward to handle.
1. Stand the first end rafter (Rafter A) and secure it using rope, cable, or some other form of bracing
to hold the rafter in position. Use a level (or other leveling device) to plumb the end rafter.
NOTE: Plumbing the end rafter at this stage assists in placing the remaining rafters.
2. Secure the rafter feet to the site (or customer-supplied baseboards) to prevent the rafter from
shifting.
NOTE: The use of a baseboard beneath the feet of the rafters is strongly recommended. The feet
then can be secured to the baseboard using the supplied lag screws. Baseboard can be treated or
plastic lumber. Contact Customer Service at 1-800-245-9881 for additional information.
Temporary bracing
used to secure the
end rafter in place.
Rope or Cable
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Frame Assembly (continued)
With the first end rafter standing, plumb, and properly secured, set the interior rafters in place.
Stand the Interior Rafters
1. Stand the second rafter (Rafter B) and secure the rafter feet as before.
2. While the lift or personnel are holding the rafter in position, start at the top-center of the arch and
install a purlin. Each purlin pipe is attached using 3/8" x 1" Hex Cap bolts provided. Use two (2)
bolts per connection point when attaching the purlins to the purlin clamps. (See insert below.)
3. With center purlin in position (arrow below), install the remaining purlins. There are six (6) purlins
between each rafter. Consult the Frame Diagram shown earlier in these instructions for purlin
location.
4. Repeat the process for the remaining interior rafters for the length of your building. (Align the rafter
feet with the lines previously marked on the site if that method was used.)
5. After all interior rafters are in place and secure, install the final end rafter (Rafter A).
6. With all rafters in place, read the MUST READ document to anchor the frame. You must anchor
the assembled frame before continuing.
7. After anchoring the frame, continue by installing the cabling for the structure.
ATTENTION: As the purlins are attached, it may be necessary to tap the purlin brackets with a hammer to align the
brackets with same brackets on the next rafter set in place. To protect the cover, tape all rafter joints with duct tape.
Purlins (105118) are
interchangeable.
View from the top looking down on
the rafter, purlin clamps, and purlins.
Attach this purlin first.
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Cable Assemblies
Cable assemblies provide diagonal bracing for the building. Each cable assembly includes the following items:
• 2 lengths of cable cut at 100"
• 1 turnbuckle
• 4 cable thimbles
• 4 cable clamps
Typical of all Turnbuckles for this Building
NOTE: For each cable assembly, two (2) additional thimbles and four (4) additional cable clamps are used to
attach the cable assembly to the purlin clamps. Consult the Cable Diagram on the following page and the All
Frame Diagram for clarification and cable locations.
Cable Assembly Instructions
Complete the following steps:
1. Cut the cable to the proper length for each assembly. More than an adequate amount has been sent for the
cabling application. (Cut two lengths at 100" and make a single assembly before proceeding to make all.
This will allow a check to be sure a suitable length has been cut.) Make the necessary length adjustment if
needed.
2. Place one cable thimble approximately 12" from the end of a cable section and wrap the cable around the
thimble as shown in the above figure.
3. Grasp both sections of the cable near the thimble and position one cable clamp one inch away from the
thimble as shown above.
NOTE: The clamp must be positioned on the cable with its U-bolt portion over the short section of the cable.
4. With the saddle portion of the cable clamp in position, thread the nuts onto the U-bolt section of the clamp
and tighten slightly to maintain the position of the clamp on the cable.
5. Install a second cable clamp on the cable six to eight inches from the first clamp.
6. Tighten both clamps.
7. Remove the bolt from the jaw of the turnbuckle and position the cable end with the thimble into the jaw of
the turnbuckle.
Turnbuckle Turnbuckle Jaw
Thimble
Cable
Cable Clamps Thimble
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8. Insert the bolt through the eye of the turnbuckle and the cable thimble, thread the nut onto the bolt, and
tighten.
9. Repeat Steps 2-8 for the remaining length of cable for this assembly.
10. Open the turnbuckle to its longest position.
11. Repeat the above procedure for all remaining cable assemblies.
Cable Placement
The diagram and figures below identify the placement and proper way to attach the cable assemblies to the
building.
Cable Placement Diagram
To protect the cables,
position thimbles as
shown in the diagrams.
View above is from inside the shelter.
Customer-Supplied
Baseboard
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Tighten the Cabling
The positions of the cable assemblies are identical for the opposite side and the remaining end of the building
that are not shown in the previous diagram. For cable locations for your building, consult the All Frame
Diagram.
1. After attaching all cable assemblies to the building frame, return to the first set of turnbuckles and tighten
the cables.
NOTE: Tighten the cables in each section evenly so that the frame remains plumb.
2. After one set of cables is tightened, move to another set and repeat the tightening steps.
3. Repeat this process until all cables are tight.
4. Continue with installing the ratchets for the main cover.
Install the Ratchets for the Main Cover
The ratchets are attached to the legs of select rafters on the outside of the rafter leg. Complete the following
steps to locate and secure the ratchets to the rafter legs.
1. Locate the four (4) QH1061 ratchets and attach these to the outside of the two end rafters as shown in the
diagrams that follow. All ratchets are attached using FA4482 Tek screws.
2. After attaching the four QH1061 ratchets, return to each leg of each end rafter and attach a QH1065
ratchet in the location shown above.
3. Select the remaining QH1065 ratchets and evenly space these along each side of the frame. The following
is an example of where to attach the remaining ratchets.
QH1061
QH1065
Attach the
ratchet above
the purlin
bracket
mounting bolt.
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NOTE: Depending on the length of your structure, you may not be able to install the ratchets on every other
rafter as shown above. The main point is to space the ratchets as evenly as possible so you can stretch and
secure the main cover. See the example below. Frame shown may be shorter than your frame.
4. After all ratchets are installed, continue with the main cover installation.
Location of QH1065 Ratchets
along one side of a frame
assembly.
Customer-supplied Baseboard
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Main Cover Installation
WARNING: To prevent personal injury and damage to the structure and main cover, do not attempt to install
the main cover on a windy or stormy day.
Assemble Cover Conduits
Cover conduits are pipe assemblies that are slid into pockets sewn into the bottom edge of the main cover.
These conduit assemblies consist of the following pipes:
1.66" Cover Conduit (Quantity 2): 99" (166S099) Swaged pipe
XX" (166P0xx) Plain pipe (Use this pipe last to end the run of pipe.)
The X's represent the length needed to reach the end of the cover. Locate the cover conduit pipes and
assemble them. The conduits can be assembled at once or in short sections. Secure each joint with a Tek
screw and use duct tape to tape the joint and screw to protect the cover.
Install the Main Cover
1. Unpack the main cover and unfold it with the inside surface facing up. (The pockets for the cover conduits
should be visible when the cover is unfolded.) See the example below.
2. Locate the ends of the main cover with the strapping and align the ends with the front and back of the
frame assembly.
Frame shown is to illustrate the location of the cover during installation.
3. Slide one of the 1.66" cover conduits into the hem opening and repeat this step using the other 1.66" cover
conduit and the remaining hem opening. Remember to secure the conduit joints with a Tek screw and to
tape the joint with duct tape.
4. Grasp each end of the cover conduit and carry the main cover toward the frame assembly and place on the
ground along the frame side.
ATTENTION: Do not use the black straps in the main cover to pull the cover into position. They will pull out
of the cover hem and must be rethreaded to properly secure the cover.
Cover Conduit
Pull cover from this
end toward the frame.
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5. With the cover in position near the edge of the frame, attach ropes to both ends of the cover conduit.
NOTE: For long shelters, attaching ropes at every rafter position where a ratchet is located is
recommended. If needed, a small slit can be made on the inside of the sleeve that holds the conduit, which
will allow the use of additional ropes. This slit can be used later when the straps for the ratchets are
installed. DO NOT cut through to the outside of the main cover. Cut only the sleeve in which the
conduit rests.
6. With all ropes tied securely to the conduit, toss the free ends over the frame assembly and pull the cover
over the assembly and into place.
NOTE: Use lifts and additional assistants (if needed) to help pull the cover up and over the frame.
7. Once in place, center the main cover on the frame. Center the cover side-to-side and end-to-end.
WARNING: To prevent damage and injury, do not leave the cover unattended if it has not been
properly secured. The ropes can be used to temporarily keep the cover from blowing off the frame.
8. Locate the black straps at the front and rear hems and feed the straps through the center slot in the
QH1061 ratchets located on the outside of the first and last rafters and slightly tighten all corners. Do not
tighten completely at this time. This helps to temporarily secure the cover.
9. Lift the main cover skirt, locate the QH1065 ratchets attached to the rafters, and make a slit in the cover
conduit sleeve at these locations.
NOTE: If ropes were used at these locations when the main cover was pulled in place, a slit may already
be present.
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10. Select one of the 5' tie down straps that shipped with the building and insert one end of the strap through
the sleeve opening, around the cover conduit, and back through the opening.
11. Feed both ends of the strap through the slot in the ratchet and tighten slightly.
NOTE: Do not fully tighten the strap at this time.
12. Repeat Steps 10 and 11 for the remaining straps.
13. After all side security straps are in place and slightly tightened and the cover is centered evenly on the
frame, complete the following steps to install the PVC cover conduit as described in the following
procedure.
Installing the Main Cover PVC Conduit
To better secure the main cover on longer buildings, PVC conduits are used near the ends of the cover to
provide an additional tie-down position. Complete these steps to assemble and install the PVC conduits.
1. With the main cover in position on the frame and the end straps loose in the ratchets, locate the pocket for
the PVC conduit near the end of the main cover and insert one length of the PVC pipe (smooth end first).
2. Select another piece of PVC, feed it into the pocket of the main cover and into the bell end of the first piece
of PVC. Use duct tape (or PVC glue–not provided) to secure each PVC joint.
Photo shows a different
shelter with a similar
ratchet and cover
design. The procedures
to secure the main
cover are identical
despite the differences
in the frame assembly.
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3. Continue feeding the PVC conduit into the cover pocket in this pattern until the PVC conduit is completely
assembled and inserted for one end of the shelter. Repeat these steps for the other end.
4. Once the conduits are assembled and installed, loosen the straps at the end of the main cover and peel the
cover back to expose the end rafter.
5. Using the 1" strapping provided, start at the base of the building and lace the strap around the PVC conduit
that shows through the open notches of the main cover and tie the strap end to the rafter.
6. From this point, lace the strap as shown below and work up and around the end rafter.
Frame shown differs from your shelter. The steps to secure the cover are similar however.
7. Repeat the steps to lace the strap for the remaining end of the main cover.
NOTE: When fully laced, the PVC conduit should be even and run parallel with the rafter at both ends of
the building.
End Rafter
PVC Condui
t
Main Cover
Conduit Pocket
Slide the
PVC Conduit
into the main
cover pocket.
Cover and
frame shown
differ from the
actual frame.
The installation
steps are the
same however.
Do not fully
tighten the end
strapping until
the straps for
both ends are
in place. View to the left
shows the main
cover as seen
from inside the
shelter.
Main Cover
Cover PVC
Conduit
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