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.
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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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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 1.315" band clamp 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 band clamps on the purlins
and the band clamps on the end rafter. Position the struts so that they form a triangle at rough-
ly a 45° angle when installed. Make sure the end rafter is plumb before you tighten the nuts.
Tip: If you forgot to slide a band clamp into position on a rafter or purlin, you can wedge the
band clamp onto the pipe by striking it with a mallet. Be careful, and wear eye protection!
You can then reclose the end of the band clamp by pinching it with slip joint pliers if necessary.
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Step 8: Continue adding rafters (at the proper spacing) and purlins until the 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 rafter-to-rafter dimensions along all five purlins. Also check that every rafter is
standing up straight (plumb). Square the corners by measuring diagonally corner-to-corner, and
line up all rafters using a straight line.
Step 15: Secure every joint between 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 Main Cover
Step 1: Fasten a ratchet to the end rafter with a Tek screw in the bottom hole of the ratchet. The
ratchet should be as low as possible and still operable. Repeat this step in all four corners.
Step 2: On the 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.
Step 3: Fasten ratchets to the outsides of these rafters using a Tek screw about 2" from the bottom
of the rafters. Ratchets are located on the same rafters on both sides of the shelter. Repeat the
previous steps so you have ratchets on both sides of the shelter opposite each other.
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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. Feed the strap through the center slot
in the ratchets and tighten down all four corners slightly. Do not tighten completely at this time.
Step 12: The hem containing the cover conduit needs to be slit or notched at each rafter where you
installed a 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: If you already made small slits in Step 8 above, you can simply elongate these slits
centered on the rafter as required.
Side Ratchet Strap Installation
Step 13: Locate the 3' straps and loop them over the conduit where the hem is slit.
Step 14: Feed both ends of each strap through the slot in the ratchet and tighten slightly.
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Side Ratchet Strap Installed and Tightened
Step 15: Check that the cover is still centered evenly from front to back and side to side.
Step 16: 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 F - 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.
• 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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