ClearSpan PB00566R3 User manual

Instruction Manual
Poly Shelters
for Freestanding “Hut” Style Model
14' Wide x 14' High x 36' Long
SKU# PB00566R3 and PB00566R4
© 2004 ClearSpanTM
All rights reserved. Reproduction prohibited without written permission.
Rev: 24 Sept 04
Note: Photo may be of a different but similar model

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.
Page 4
3
8
Purlin/Cover/End Conduit (only swaged is shown)
Strut
Band Clamp
Fender
Washer
Swaged and Unswaged
Rafter Sections
(all pieces
may not
be shown)
Tek Screw Carriage Bolt
& Hex Nut
Driver
Bit
Purlin End Clamp Purlin Cross Clamp

Note: Illustrations are not to scale.
Page 5
Cover
Strap Ratchet
Plain End Strap

Assembly Diagrams
Your assembled shelter will be similar to the illustration below:
First you will assemble the frame:
END
RAFTER
INSIDE
RAFTER
PURLINS CROSS
CLAMPS
END
CLAMPS
STRUT BAND
CLAMP
RATCHET
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 swaged sections labeled
“1” which are straight at one end and curved at the other, two sections labeled “2” and “3”
which are curved throughout but “2” is swaged and “3” is not, and two extensions labeled “X.”
Step 2: Fit the sections together starting with section “1” then “2” then “3” and then another “1” to
form an arch laying flat on the ground. Then, add a straight extension “X” to each end. It is
essential to perform this step on level ground or the completed rafter assembly will be twisted.
Typical End Rafter
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 side of the arch.
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 Band Clamps. You will add these fittings now.
Step 6: Slide 3 sets of Purlin End Clamps onto one of the rafters. 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 one at the top of the rafter and one on each side of the rafter at the joint.
Tip: On the sides of the rafter, position the top strap of the end clamp so it rests on the Tek
screw. This will help prevent the clamp from slipping if the purlin has to support any weight.
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Step 7: Slide a 1.66" band clamp 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 band clamps 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 5 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 all 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 5 clamps per rafter.
Typical Cross Clamp Assembly
Tip: On the sides of the rafter, position the top strap of the cross clamp assembly so it rests on
the Tek screw. This will help prevent the clamp from slipping if the purlin supports any weight.
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Section C - Rafter Setup
Step 1: Stand up one of your end rafters (one of those with the band clamps 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 band clamps) onto the two purlins. Position this 2nd rafter
from the end rafter using a rafter-to-rafter distance of 36" for R3 models and 48" for R4 models.
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 the clamp at the top of this rafter and also the clamp at 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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