ClearSpan Storage Master Solarguard User manual

Instruction Manual
Poly Shelters
© 2004 ClearSpanTM
All rights reserved. Reproduction prohibited without written permission.
Rev: 22 June 04
for Storage Master Solarguard (Round “Hut” Style)
SKU #PB00100R4N & #PB00100R3N 30' Wide x 15' High x 48' Long
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 Wrenches
• Step ladder tall enough to safely work at the height of your shelter
• Two (or more) 50-foot pieces of rope
Page 2

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.
Page 3

Parts Identification
Note: Illustrations are not to scale.
Page 4
3
8
Purlin/Cover Conduit (swaged shown)
Center Coupler
Pipe Strap
Rafter Top Section
Rafter Bottom Section
Tek Screw
Driver Bit
Foot
End Coupler
Purlin Cross Clamp
Carriage Bolt
& Hex Nut

Note: Illustrations are not to scale.
Page 5
Cover
Strap Ratchet
Plain End Strap
Fabric Clip
Band Clamp

Assembly Diagrams
Your assembled shelter will be similar to the illustration below:
First you will assemble the frame:
Note: All rafters are not shown in this illustration - Just the first 4 at the right end
Page 6

Section B - Rafter Assembly
Step 1: Select four pipes to build your first rafter. The two lower pieces have one smooth and one
notched end. The two upper pieces are notched at both ends. You will also need (3) 3-way
couplers and (2) base feet.The pipes are joined together using couplers to form an arch.
Step 2: First, slide one cross clamp onto each upper rafter pipe and two cross clamps onto each
lower rafter pipe. Then, connect each smooth end pipe to each base foot by guiding 3.5"
machine bolts through the pre-drilled holes and adding 3/8" nuts.
Page 7

Step 3: Assemble the notched ends of the pipe to the 3-way couplers. The notched pipe has
pre-drilled screw holes. Couplings have no holes.
Step 4: Install the supplied hex driver bit into the chuck of your drill/driver.
Step 5: Fasten the rafter sections to the coupling using 3/4" Tek screws. Go through the guide holes
in the rafter pipes into the coupling.
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).
Page 8

Step 6: Assemble the second and subsequent rafters by repeating the previous steps.
Note: Use (3) 4-way couplings instead of 3-way couplings. Donʼt put the cross clamps on the
rafters now as they will be easily added later.
Step 7: Assemble the last rafter exactly like the first one using 3-way couplings and cross clamps.
Section C - Connect Purlins
Step 1: Stand up your first rafter (one of those with the 3-way couplings). Secure it to an existing
structure if possible so that it is plumb (straight up and down). Make sure the third leg of the
couplings are facing in the direction where you have room to add more rafters.
Tip: If you donʼt have an existing structure, you can use some 2x4s as shown tied with rope.
Page 9

Step 2: With the second assembled rafter laying flat as shown, connect (3) 1" purlins onto the ends
of the 3-way couplers.
Important: Position the holes in the purlins so they face toward the inside of the arch.
Step 3: Secure these pipes with Tek screws through the predrilled holes into the couplers.
Step 4: Stand up the second rafter and connect the purlins to the couplers on the first rafter as
shown below.
Page 10

Step 5: Using a Tek screw from the bottom, fasten the top “ridge” purlin to the 3-way coupler at the
top of the first rafter as shown below.
Important: Purlins should be fastened to couplers on the underside or inside.
Screw heads should not be in position to come into contact with cover fabric.
Step 6: Check that the other purlins are securely connected onto the couplers.
Step 7: Check for straight alignment and correct if necessary.
Step 8: Finish this assembly by securing the connections at the other purlins with Tek screws.
Step 9: Connect purlins to the remaining unused rafters. Use Tek screws to secure the connections.
Step 10: Connect these rafter+purlin assemblies to the frame until it is complete. Be sure save the
other end rafter for last.
Step 11: To complete this operation, tape pipe connections and rafters.
Page 11

Section D - Adding Extra Purlins
Install six rows of extra 1.315" purlins midway between the existing 1" purlins and just above the feet
the using rows of conduit secured in place using cross clamps.
Extra Purlins (only one side shown)
Step 1: For the first extra 1.315" purlin, measure to the midway point along the rafters between the
top two 1" purlins and snap a straight line along the length of the shelter frame.
Step 2: Start with the first rafter. Insert a 1.315" purlin into the cross clamp from inside the shelter.
WIth the end of the purlin a quarter inch past the clamp, tighten the bolt. The purlin can not
extend more than a quarter inch past the clamp or itʼs rough end could damage the end cover.
Typical Cross Clamp Assembly
Page 12

Step 3: Add cross clamps at the other rafters, and continue to add sections of 1.315" pipe to reach
the other end. Tighten the cross clamp on the last rafter at the other end of the shelter.
Step 4: Add the next 1.315" purlin just above the feet, and add the last midway between the purlin
just installed and the 1" purlin above it. Refer to the illustration on the previous page.
Section E - Square Corners and Finish Sharp Edges
Step 1: With all rafters and purlins in place, position the shelter exactly where you want it located.
Step 2: Square the corners by measuring diagonally corner-to-corner, and line up all rafters using a
straight line.
Step 3: Adjust to a width of 30' 9".
Step 4: String lines from front to back and adjust the width of the remaining rafters.
Step 5: Check for any sharp edges on the frame and file them smooth so they will not cut the cover.
Step 6: Apply two layers of heavy duct tape on all pipe connections that may contact the cover.
Step 7: Apply two layers of heavy duct tape on all pipe ends where they protrude past the cross
clamps and may contact the cover.
Page 13

Section F - Installing Struts
After the frame is square and secure, and the rafters are plumb, install the diagonal struts. The
struts keep the frame stabilized by preventing it from rocking forward and backward. You will use
conduit pipe to construct the struts.
Step 1: Assemble four 14' struts using (2) 6' pieces of swaged conduit and a 2' plain piece each.
Secure the joints with a Tek screw.
Step 2: Attach one end of the strut to an end or outside rafter, approximately 7' above the ground,
using a pipe strap and 2 Tek screws. Make sure the end of the pipe is flush with the strap and
tighten the screws.
Step 3: Attach the other end of the strut to the fourth rafter directly above the lowest purlin with a
pipe strap and 2 Tek screws positioning the strap 1" in from the end of the strut (so the pipe
sticks out of the strap 1"). Do not tighten the Tek screws yet so the strut can slide if necessary.
Step 4: After the pipe is angled in place, apply pipe straps and Tek screws to the other two rafters in
between.
Tip: When angling each strut, have someone help hold it in place or use heavy tape. Also, a
slight bend will be required in the strut for proper alignment. This procedure is best done by
two people. Have one person apply the necessary pressure to hold the pipe against the rafter,
while another applies the strap and screws.
See the illustration below showing the struts installed:
Note: All rafters are not shown in this illustration - Just the first 4 at the right end
Page 14

Step 5: Tighten the screws on the strap at the lower end (the ones you left loose).
Step 6: Finish each connection by securing all the straps to the pipe with a third Tek screw through
the center of each strap into to pipe as shown below.
Section G - Install End Panels and Door Kit
You must now refer to the separate instructions that came with your end panel
kit SKU #103956 to install the end panels and door.
Page 15

Section H - Install Main Cover
Step 1: Using a Tek screw, fasten a ratchet to the front of the end conduit about 10" in from the end
of the rafter. Fasten ratchets to the remaining 3 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 2" ratchets to the outside of these rafters on both sides of the shelter. Remove the
machine bolt, place ratchet, then reinstall bolt through ratchet, rafter and foot and tighten.
Ratchets are located on the same rafters on both sides of the shelter. Repeat so you have
ratchets on both sides of the shelter opposite each other.
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.
Page 16

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.
Page 17

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 3"
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 2" 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.
Step 13: Locate the yellow 5' straps and loop them over the conduit where the hem is cut out.
Step 14: Feed both ends of the straps through the slot in the ratchets and tighten slightly.
Page 18

Note: Frame is shown without cover material for clarity
Section I - 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.
• 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.
Page 19