ClearSpan 30' Wide Pony Wall Building · helpful hints and important information needed to safely assemble and properly maintain the shelter. Please read ... snow and ice, large tree

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CLEARSPAN™ POLY BUILDINGS

Revision date: 12.08.15

©2015 ClearSpan™All Rights Reserved. Reproduction is prohibited without permission.

STK# DIMENSIONS

PB00812R4W 30' W x 19' H x 48' LPB00813R4W 30' W x 19' H x 60' LPB00814R4W 30' W x 19' H x 72' L

ClearSpan™ 30' Wide Pony Wall Building

Photo may show a model of a different length and design.

*Height shown includes 4' pony wall.


2 Revision date: 12.08.15

READ THIS DOCUMENT BEFORE ASSEMBLY BEGINS

Thank you for purchasing this ClearSpan™ shelter. When properly assembled and maintained, this product will provide years of reliable service. These instructions include helpful hints and important information needed to safely assemble and properly maintain the shelter. Please read these instructions before beginning.

For answer to questions during assembly, contact Customer Service for assistance.

SAFETY PRECAUTIONS

• Wear eye protection.

• Wear head protection.

• Wear gloves when handling metal tubes.

• Use a portable GFCI (Ground Fault Circuit Interrupter) when working with power tools and cords.

• Do not climb on shelter or framing during or after construction.

• Do not occupy shelter during high winds, tornadoes, or hurricanes.

• Provide adequate ventilation if structure is enclosed.

• Do not store hazardous materials in shelter.

• Provide proper ingress and egress to prevent entrapment.

ANCHORING INSTRUCTIONS

Prior to assembling this shelter, please read anchoring precautions and instructions included in the MUST READ document. You must anchor the building after frame is assembled and before cover installation.

WARNING: The anchor assembly is an integral part of shelter construction. Improper anchoring may cause shelter instability and structure failure. Failing to anchor shelter properly will void the manufacturer’s warranty and may cause serious injury and damage.

LOCATION

Choosing the proper location is an important step before assembly.

The following suggestions and precautions help determine whether the selected location is the best location.

• Never erect structure under power lines.

• Identify whether underground cables and pipes are present before preparing site or anchoring structure.

• Location should be away from structures that could cause snow to drift on or around building.

• Do not position shelter 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 help ensure integrity of the structure.

• A level site is required to properly and safely erect and anchor the frame.

• Drainage: Water draining off structure and from areas surrounding the site should drain away from site to prevent site and structure damage, and to better protect contents of the structure.

WARNING: 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.

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ASSEMBLY PROCEDURE

Following the instructions as presented will help ensure proper assembly. Failing to follow these steps may result in an improperly assembled and anchored shelter and will void all warranty and protection owner is entitled to.

The steps outlining the assembly process are as follows:

1. Verify all parts are included in shipment. Notify Customer Service for questions or concerns.

2. Read these instructions, the Must Read document, and all additional documentation included with shipment before shelter assembly begins.

3. Gather tools, bracing, ladders (and lifts), and assistants needed to assemble shelter.

4. Check the weather before cover and panels (if equipped) installation. Do not install covers or panels on a windy or stormy day.

5. Re-evaluate location and site based on information and precautions presented in documentation included with shipment.

6. Lay out site (if this has not been completed).

7. Assemble frame components in the order presented.

8. Assemble frame including bracing (if equipped).

9. Consult Must Read document for anchoring comments and instructions.

10. Install, tighten, and secure end panel (if equipped) and main cover. This applies to fabric covers that stretch over the frame.

11. Read care and maintenance information.

12. Complete and return all warranty information as instructed.

LIST OF WORDS AND PHRASES

To begin, it is important to become familiar with the words and phrases used in this instruction manual.

These words and phrases are common to most ClearSpan™ shelters and identify the different shelter parts. (Some are used in this document. Others may not apply to this particular shelter.) These terms describe shipped parts and can also be found on the materials list/spec sheets included with shipment. To aid in assembly, read through the following definitions.

• Conduit: An assembly of pipes used to secure main cover and end panels (if equipped). Purlins and some strut assemblies also consist of connected pipes to form a conduit. Each pipe joint of a conduit assembly is secured with a self-tapping Tek screw.

• Coupler or Fitting: A part of the frame assembly where legs, purlins and rafter pipes are inserted and secured. In most instances, 3-way and 4-way couplers are used. In some larger applications, couplers are used to secure joints of different rafter sections during rafter assembly. Some shelters do not use couplers.

• Foot, Rafter Foot, or Base Plate: The part attached to and found at the rafter or leg base. Depending on the shelter, the foot is an optional purchase. Some shelters do not offer an optional foot. Some use 1-way connectors; others use ground posts.

• Must Read Document: This document includes building and shelter anchoring instructions, steps for end wall reinforcement, safety precautions, and notices and warnings. The Must Read document is sent with all shelters and buildings. If you did not receive a Must Read document, contact Customer Service to request one.

• On-Center: Term used to describe a measurement taken from the vertical center of the rafter or frame member to the vertical center of another.

• Purlin or Angled (or Lateral) Bracing: The pipe assemblies that run perpendicular to rafters or framework supporting the main cover. These assemblies are found on sides and roof areas of the assembled frame, are evenly spaced, and typically run from the front to the back of the shelter.

• Plain or Straight Pipe: A term used to describe a pipe that has the same diameter or width throughout its entire length.

• Strut: A strut is usually a length of pipe with two flattened ends and is used for diagonal bracing of the shelter frame. A strut is typically secured to the frame using special brackets, bolts, and/or clamps.

• Swaged End or Swaged Pipe: The term "swaged'' refers to the tapered tube or pipe end. Swaged ends of a pipe can be inserted into couplers and straight ends of other pipes of the same diameter.

• Tek Screw: A self-tapping fastener used to secure pipe joints and to fasten brackets to rafters.



REQUIRED TOOLS

The following list identifies the main tools needed to assemble shelter. Additional tools and supports may be needed depending on the structure, location, and application.

• Tape measure or measuring device.

• Marker.

• Variable speed drill and impact driver (cordless with extra batteries works best).

• Wrenches or ratchet and socket set (recommended).

• Scissors or utility knife to cut cover material and strap.

• Tool to cut cable to required length.

• Hammers, gloves, and eye protection.

• Ladders, work platforms, and other machinery for lifting designed to work safely at shelter height.

• Rope (or straps) for cover installation.

• Customer-supplied PVC glue (for buildings longer than 48').

UNPACK AND IDENTIFY PARTS

The following steps will ensure all necessary parts are present.

1. Unpack shipment contents and place where an inventory of parts can occur. Refer to the Bill of Materials/Spec Sheets.

2. Verify all parts listed on Bill of Materials/Spec Sheets are present. If anything is missing or you have questions, consult the Pictorial Parts Guide and all shelter diagrams throughout these instructions for clarification, or contact Customer Service. NOTE: At this time, do not open the plastic bags containing fasteners.

QUICK START GUIDE

For a quick overview of this shelter and its components, consult Quick Start Guide near back of these instructions.

Pages of Quick Start Guide show exploded views of all critical connections. Use the diagrams to assemble frame. Consult remainder of these instructions for additional important assembly details.

SHELTER CARE AND MAINTENANCE

Proper care and maintenance is important. Check these items periodically for proper maintenance:

• Regularly check cover and panels (if equipped) to see these remain tight and in proper repair.

• Check connections and all fasteners to verify they remain tight.

• Do not climb or stand on shelter at anytime.

• Remove debris and objects that may accumulate on shelter. Use tools that will not damage cover when removing debris.

• Remove snow to prevent excess accumulation. Use tools that will not damage cover when removing snow. NEVER ALLOW SNOW TO ACCUMULATE ON COVER!

• Check contents of shelter to verify nothing is touching cover or side panels that could cause damage.

• Check anchoring system to ensure all components are tight and in good repair.

• Check pony wall periodically to ensure it is in good repair and that all rafter mounts are secure.

• Replace all worn or damaged parts promptly.

• If shelter is moved, inspect all parts and connections before reassembling.

• For replacement or missing parts, call 1.800.245.9881 for assistance.

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The following graphics and photos will help identify the different building parts. Consult Quick Start Guide for additional details and diagrams. (Some parts are not shown.)

FA4482BTek Screw

QH1061 1" Ratchet

100441Nut Setter

Swaged

Plain

Swaged and Plain Rafter Sections

QH10652" Ratchet

AS10033/16" Cable Clamp

AS10833/16" Cable Thimble

104189 Turnbuckle

102546Cross Connector

QH1070Pipe Strap

103856Band Clamp

FAH325B & FALB32BCarriage Bolt & Nut

104302Pipe Fitting w/Plate



Interior RafterEnd Rafter

Cable Assemblies

Purlin

Inside View

30' on-center

ATTENTION: Frame shown may differ from actual frame.

ClearSpan™Pony Wall Building

OVERVIEW

This section describes assembling pony wall building. For details of each assembly procedure, consult Quick Start Guide and the individual sections of these instructions. See illustration below to identify main parts of shelter.

1. Layout site and identify required parts for each procedure.

2. Assemble all rafters.

3. Assemble and anchor frame.

4. Cut, assemble, and install all cables.

5. Prepare and install main cover.

Instructions that follow describe assembling all rafters and then constructing the frame. Depending on the number of individuals assisting with construction, it may be best and more efficient to have someone assemble rafters and others assemble the frame as rafters are completed.

Other factors to consider during assembly, especially for buildings longer than 60', include:

• Amount of working area

• Available lifts and work platforms

• Number of assistants

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LAY OUT BUILDING SITE

Review the previous Location and Site information before beginning pony wall construction.

Customer/contractor are responsible for providing a pony wall suitable for shelter, soil conditions, and weather (including but not limited to wind, rain, snow, frost, and ice, etc.). Depending on location, climate and weather, timbers or other posts may need to be cemented into the ground at least 4' to prevent movement caused by frost and other weather related loads. Consult local and regional building codes before beginning. Consult a qualified contractor as needed.

ATTENTION: To install and secure cover properly, rafters must be positioned to the outside edge of the pony wall. This allows main cover to drape evenly down the side of the pony wall where it is secured to ratchets. Read the following:

• Width: Recommended width of pony wall for a 30' wide building is 30' 6" to 31' (outside-to-outside). Wall must accommodate 30' on-center rafter width without being too wide to interfere with cover installation. See pony wall thickness comment below.

• Length: Pony wall length should be shelter length (48', 60', or 72') plus an additional 6"-12" to accommodate mounting plate dimensions, which extend beyond end rafters.

• Top of pony wall must be level. Building frame will not assemble properly if wall top is uneven.

• Pony wall thickness: Thickness of pony wall must provide a surface for entire mounting base of each rafter foot. See diagram to the right. REMEMBER: Building cover is attached to outside of pony wall. Position rafters as close to outside edge of pony wall as possible without compromising fastener requirements.

• Pony wall must support load created by shelter plus additional loads imposed by wind and other elements. Concrete, large pre-cast concrete blocks, or 8" x 8" (or larger) timbers (to accommodate the rafter mounting feet) are all acceptable materials when constructing pony wall.

• Standard and approved building techniques are required. Observe and adhere to all local and national building codes and requirements. Consult a professional contractor when in doubt.

104302Rafter Foot

5 1/2"4"

ATTENTION: Procedures that follow describe assembling each rafter, attaching rafter feet to pony wall or support posts, and then setting rafters in place to assemble frame.

Review all diagrams before beginning. Customer is responsible for supplying the appropriate fasteners to secure rafter feet to pony wall structure.

Consult a contractor for additional fastener and construction information.



ATTACHING RAFTER FEET TO CONCRETE WALLAdditional materials required to secure rafter feet to concrete are not included and must be purchased by customer. Materials and rafter foot shown in the following diagrams differs from that included with building. Use the following information to determine anchor bolt that best applies.

1. See next pages to properly position mounting plate. Using plate as a template, drill holes into the concrete pony wall or pier according to anchor bolt size.

IMPORTANT: DO NOT over-drill hole. Wedge anchor bolt will not work properly if hole is too deep. Mounting plate shown differs from actual plate. Installation is same.

2. Insert anchor bolt into one drilled hole. Firmly tap with a hammer to secure wedge anchor into concrete.

NOTE: Depending on wedge anchor bolt, verify the washer and nut are attached before driving anchor bolt. Striking bolt may cause thread damage and prevent nut installation after bolt is set.

3. Tighten nut.

4. Repeat for each anchor bolt until mounting plate is adequately secured to concrete base.

5. Repeat steps to secure remaining plates.

Length of Anchor Bolt equals (=):Thickness of material to be fastened+plus minimum embedment (see manufacturer recommendation)+plus 1" for nut and washer application.

Sample wedge anchor bolt

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Complete these steps:

1. Remove pipe insert from each 104302 mounting foot assembly.

2. Reattach connecting bolts to mounting plates so they are not lost. Set pipe inserts aside for rafter assembly.

3. Use diagrams below to set and secure mounting plates to support posts or pony wall. ATTENTION: To ensure rafter alignment, position all mounting plates so flanges face toward the same end of building. Customer is responsible for providing fasteners to secure mounting feet.

BUILDING MOUNTED ON SUPPORT POSTS

Support Posts

30' Width center of plate to center of plate

4'center of plate to center of plate

TOP VIEW

SIDE VIEW

48" center of plate to center of plate

48" Support Posts

Flange

Step 1 & 2

Pipe Insert

Connecting Bolt Flange

ATTACH MOUNTING FEET TO SUPPORT POSTS OR PONY WALL



BUILDING MOUNTED ON PONY WALL

Pony Wall

4'center of plate to center of plate

30' Width center of plate to center of plate

TOP VIEW

48" center of plate to center of plate

48" Pony Wall

Pony Wall

SIDE VIEW — MOUNTING PLATE ONLY Flange

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ATTENTION: After assembling end rafters, set them aside in an accessible area. One rafter is positioned at each end of frame during assembly.

Do not bury end rafters under other assembled interior rafters (next procedure).

Assemble End Rafters

1. Connect pipes as shown below. Each rafter assembly consists of four (4) pipes: 2 (30R23S1D), 1 (30R23S1), and 1 (30R23P2). Each 30R23S1D pipe includes one drilled hole near bottom used to connect rafter mounting foot.

2. With rafter pipes assembled on the ground, secure each pipe joint using two (2) self-tapping Tek screws (FA4482). Position screws so they will not interfere with or contact cover once it is installed. Tape over screws using duct tape. See photos below.

3. Attach all upper (QH1070) brackets using two (2) Tek screws for each. Attach brackets to underside of rafter in locations shown below and on Front Profile diagram in Quick Start section near back of this guide. QH1070 straps should remain loose; do not fully tighten at this time. Evenly space brackets the same for each end rafter.

4. Slide one (1) 103856 band clamp onto the end of each rafter leg. Tape clamp to rafter pipe if needed.

5. Measure 10" from rafter end and mark a line on the inside surface of rafter. Position bottom of QH1070 bracket on line and secure it to rafter using two (2) Tek screws. Pipe strap should remain loose.

6. Repeat Step 5 to attach a QH1070 strap to other rafter end.

7. Take two (2) mounting foot pipe inserts (removed from mounting plates–earlier procedure) and attach one to each rafter end using an FAG363B 3/8" x 3" bolt and FALB04B 3/8" nut. Install bolt so nut is toward inside of rafter.

8. Repeat steps to assemble the second end rafter.

30R23S1D30R23S1D

30R23S1 30R23P2

QH1070Tek screwStep 3

Step 2

10"

Band Clamp

Step 7

ASSEMBLE BUILDING COMPONENTS

NOTE: Assistance is required to assemble the shelter.

END RAFTER ASSEMBLY (2)

Gather parts:

• Rafter pipes: 30R23S1D, 30R23S1, & 30R23P2

• Pipe straps: QH1070 & band clamps 103856

• Tek screws (FA4482B) and FAG363B 3/8" x 3" bolts, and FALB04B 3/8" nuts



Assemble Interior Rafters

1. Connect pipes as shown below. Each rafter assembly consists of four (4) pipes: 2 (30R23S1D), 1 (30R23S1), and 1 (30R23P2). Each 30R23S1D pipe includes one drilled hole near bottom used to connect rafter mounting foot.

2. With rafter pipes assembled on the ground, secure each pipe joint using two (2) self-tapping Tek screws (FA4482). Position screws so they will not interfere with or contact cover once it is installed. Tape over screws using duct tape.

3. Take two (2) mounting foot pipe inserts (removed from mounting plates–earlier procedure) and attach one to each rafter end using an FAG363B 3/8" x 3" bolt and FALB04B 3/8" nut. Install bolt so nut is toward inside of rafter.

4. Stack all interior rafters in the same accessible location.

5. Continue with frame assembly. The 102546 cross connectors are installed during frame assembly.

ATTENTION: After assembling interior rafters, set them aside in an accessible area.

Do not mix end rafters with these interior rafters.

30R23S1

30R23S1D 30R23S1D

30R23P2

Diagram shows position of cross connector. Cross connectors are installed during frame assembly.

102546 Cross Connector

Step 3

INTERIOR RAFTER ASSEMBLIES

Gather parts:

• Rafter pipe: 30R23S1D

• Rafter pipes: 30R23S1 & 30R23P2

• Tek screws (FA4482B) and FAG363B 3/8" x 3" bolts, and FALB04B 3/8" nuts

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FRAME ASSEMBLY

Gather parts:

• All rafter assemblies

• Purlin pipes: 1.315" x 75" swaged (131S075) & 1.315" x XX" plain (131P0XX)

NOTE: The XX" represents length required to reach end of shelter after connecting the 75" pipes. Consult spec sheet and Side Profile diagrams (Quick Start) for pipe identification and quantities.

Frame Assembly Steps

1. Using a lift, stand first end rafter and secure it to the end set of mounting plates attached to pony wall. (End rafter includes the QH1070 pipe straps attached earlier.) Tighten mounting bolts.

2. Use rope, cable, or some other form of temporary bracing to hold rafter in position. Plumb the end rafter. NOTE: Plumbing end rafter at this stage assists in setting remaining rafters.

3. With first end rafter secured, set first interior rafter in place and attach it to the mounting feet. Tighten bolts.

ATTENTION: Set all rafters on side of mounting plate flange that aligns rafter with center of mounting plate.

4' on-center

Actual components may differ from this example.

ATTENTION: Keep rafter attached to lift until purlins are installed. See next step.

Step 1

104302

QH1070

pony wall

A

A



FRAME ASSEMBLY (CONTINUED)4. Place a cross connector (102546) at top of inside rafter, align it with the QH1070 pipe strap attached to underside

of end rafter at the top.

5. Insert plain end of purlin pipe (131S075) through cross connector and through pipe strap at the top of end rafter.

6. Verify both rafters are plumb and properly spaced (center-to-center) over the top. Verify purlin does not extend beyond end rafter and tighten cross connector at top of interior rafter.

7. Return to and tighten the QH1070 pipe strap at top of end rafter to secure purlin. To prevent cover damage, do not allow purlin to extend beyond outer edge of end rafter. See dashed line—diagram A above.

8. Secure purlin to QH1070 strap by driving a Tek screw through strap and into purlin pipe. See arrow in diagram A.

Cross Connector to Rafter Tek Screw

Purlin to Cross Connector Tek Screw

Rafter

Purlin

NOTE: To prevent cover damage, do not allow purlin to extend beyond edge of end rafter.

NOTE: Align cross connector with pipe strap attached to end rafter.

End Rafter

A

Interior Rafter

Purlin

B

Attach top, center purlin first.A

B

Tek ScrewStep 8

Step 9

9. Return to each purlin and cross connector and secure cross connector to rafter and the purlin to cross connector. See example in diagram above. Position Tek screws so they will not contact cover once it is installed.

10. With first section of top, center purlin in position, move to next purlin position from the top, verify on-center rafter spacing, and install first section of purlin pipe at this location.

11. Working down the frame, move to other side of the rafter and repeat Step 10.

12. Install first pipe section of remaining purlins. Consult diagrams in Quick Start section as needed. ATTENTION: To prevent cover damage, DO NOT allow purlin pipes to extend beyond end rafter. Verify purlins run parallel with each other before securing pipes to rafter and connectors.

Step 11

Step 10

Work down to pony wall.

Frame shown may differ from actual frame, illustration purposes only. All cross-connectors will align with the QH1070 pipe straps attached to end rafters when properly installed.

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FRAME ASSEMBLY (CONTINUED)

13. Repeat previous steps to set and secure all remaining interior rafters.

14. As purlin pipes are added, secure each pipe splice using a Tek screw.

15. Finally, set remaining end rafter, which includes QH1070 pipe straps, and finish each purlin run using a XX" pipe (131P0XX). Position plain finish pipe between last interior rafter and final end rafter to complete the assembly. Consult the spec sheet and Side Profile diagrams (Quick Start) for "XX" pipe identification.

NOTE: Cables shown in the diagram above are installed in the next procedure. Ratchets are shown attached to side of pony wall. These are installed during cover installation steps.

16. With frame assembled, continue with cable assembly and installation.

ATTENTION: If last pipe extends beyond end rafter after end rafter is straight/plumb, cut pipe as needed. Do not allow it to extend beyond end rafter.



CABLE ASSEMBLY

Cable assemblies provide diagonal bracing. Each cable assembly includes the following items:

• Cable (2 cables cut to length)

• Turnbuckle (1)

• Cable thimbles (4)

• Cable clamps (4)

NOTE: For each cable assembly, four (4) additional cable clamps are used to attach cable assembly to frame. In addition, Cable C assemblies require an additional cable thimble at each lower end to complete the connection to band clamp attached to end rafter leg. See Side Profile Diagrams. Consult Cable Diagram on following page and Side Profile diagram in Quick Start section for clarification and cable locations.

Cable Assembly Procedure

1. Using the Side Profile Diagram in Quick Start section as a guide, measure distance needed on frame and cut cable to the proper length for each assembly. Remember to account for the turnbuckle and the cable length needed to attach thimbles at each end. (Extra cable has been sent for cabling.) Make a single assembly before making them all. This allows a check to be sure the correct length has been cut. Make the necessary length adjustments as needed before making additional assemblies. To prevent running out of cable, always measure before cutting. ATTENTION: One (1) turnbuckle and two (2) cables are used for each cable assembly type. For best results and to reduce cable waste, use the diagram on the next page and measure the distance required for a specific cable type. Additional cable length is needed to anchor cable to frame and to attach cable sections to turnbuckle. Measure and cut the follow assemblies as needed:

2. Place one cable thimble approximately twelve inches (12") from end of a cable section and wrap cable around thimble as shown in the figure to the right.

3. Grasp both sections of the cable near the thimble and position one cable clamp one inch away from thimble as shown above. NOTE: Position clamp on cable with its U-bolt portion over the short/"dead" cable section.

4. With the saddle portion of the cable clamp in position on the "live" cable section, thread nuts onto U-bolt section of clamp and tighten slightly to maintain clamp position.

Thimble

Cable

• Cable Assembly A: 16 cable lengths; 8 turnbuckles

• Cable Assembly B: 16 cable lengths; 8 turnbuckles

• Cable Assembly C: 16 cable lengths; 8 turnbuckles

ATTENTION: Consult the diagram on the next page to identify cable assemblies and cable locations.

Cable Clamps Thimble

"Live" Cable Section

Turnbuckle Turnbuckle Jaw

ThimbleTurnbuckle Jaw

Cable Clamps

Typical Turnbuckle Assembly

"Dead" Cable Section

17



CABLE ASSEMBLY (CONTINUED)

5. Install a second cable clamp six to eight (6"-8") inches from first clamp and tighten both clamps.

6. Remove bolt from turnbuckle jaw and position cable end with thimble into turnbuckle jaw.

7. Insert bolt through turnbuckle jaw and cable thimble, thread nut onto bolt, and tighten to secure.

8. Repeat Steps 2-7 for remaining length of cable for this assembly.

9. Open turnbuckle to its longest position and set assembly aside.

10. Repeat the above procedure for all remaining assemblies. Length of upper cables may differ from side cables. Always measure length on frame before cutting cables.

11. With all cables assembled, move to top of the sixth (6th) rafter (4' spacing) and drill a 5/16" hole down through rafter and top, center purlin. This is the rafter-purlin connection where the ends of upper cables are wrapped and secured. See the insert in the diagram below for Steps 11 and 12.

12. Insert 5/16" x 5" carriage bolt (FAH325B) down through 5/16" hole, add a 5/16" nut, and tighten.

13. Repeat Steps 11 and 12 for remaining rafter-purlin position at the other end of frame.

14. Attach cables to assembled frame. See diagrams below and in Quick Start section of these instructions for details and cable locations. Cable assembly length and positions are the same for other side and end of frame. Verify that turnbuckles are fully extended before attaching cables to frame.

Cable A

Cable B

Cable C

5" Carriage Bolt

Steps 11-12

Band Clamp Locations: Band clamps for end rafters were installed on each end rafter during end rafter assembly.

Pony Wall

CONSULT SIDE PROFILE DIAGRAM FOR SPECIFIC SHELTER LENGTH FOR CABLE LOCATIONS.

ATTENTION: Lower end of Cable Assembly C is connected to frame using a 103856 band clamp. Install band clamp by spreading clamp and placing it around leg of rafter in the locations shown in this diagram and on the Side Profile diagrams in Quick Start section. Squeeze clamp into shape using adjustable pliers.



CABLE PLACEMENT

Diagram and inserts below identify placement and proper way to attach cable assemblies.

Do not tighten cables until frame is properly and securely anchored as described in the Must Read document.

Carriage Bolt

NOTE: Cable assembly positions are identical for opposite side and remaining end of building. Consult Side Profile diagram in Quick Start section for rafter spacing and cable locations.

View is from inside the shelter.

Apply duct tape over cables on end rafters to protect the main cover.

Carriage bolt runs through rafter and top center purlin on 6th rafter (depending on spacing) at each end.

Attach band clamp (103856) above lowest pipe strap (QH1070) on end rafters only. Once cable is attached and clamp is tightened, secure clamp to the rafter using a Tek screw.

View is from inside the shelter.

103856

QH1070

ATTENTION: Install a carriage bolt in this location at both ends of the shelter. Drill through rafter and purlin to install bolt.

IMPORTANT! Tape over cables to protect cover.

Top, Center Purlin

Top, Center Purlin

19



TIGHTEN CABLES

Complete these steps:

1. After attaching all cable assemblies, verify each band clamp is tight and secured to rafter leg using a Tek screw.

2. Return to first set of turnbuckles and tighten. NOTE: Tighten cables in each section evenly so that frame remains plumb.

3. After one set of cables is tightened, move to another set and repeat steps to tighten those cables.

4. Repeat this process until all cables are tight.

5. Continue by installing all ratchets.

ANCHOR THE SHELTER

After installing all cable assemblies, anchor the frame. Once frame is anchored properly, continue with these instructions.

WARNING: Securing rafter mounting feet to baseboards set on the site is not a substitute for properly anchoring shelter. You must anchor shelter as described in the MUST READ document.

FAILING TO PROPERLY ANCHOR THE SHELTERWILL RESULT IN DAMAGE TO THE SHELTER ANDMAY CAUSE PERSONAL INJURY.

READ THE MUST READ DOCUMENT TO PROPERLY ANCHOR THE SHELTER.

INSTALL MAIN COVER RATCHETS

Attach all ratchets to the outside of pony wall or support posts. Gather parts:

• Ratchets (QH1061)

• Ratchets (QH1065)

• Customer-supplied fasteners for pony wall or support post materials. Due to the different materials used to construct pony walls, customer is responsible for supplying the required fasteners. Consult the advice of a qualified professional contractor if needed.

Complete the following steps to secure ratchets to pony wall or support posts.

1. Locate four (4) ratchets (QH1061) and attach these to outside ends of pony wall as shown in diagram below. Attach each ratchet using customer-supplied fasteners. (Fasteners for pony walls constructed of material such as concrete, stone, or wood are not included and must be purchased separately. Consult a contractor if needed.) ATTENTION: If attaching ratchets to concrete, read Attaching Ratchets to Concrete section and apply that procedure when needed. See next page.

2. Locate the QH1065 ratchets and divide quantity in half. Use half for each side of shelter.

3. Evenly space QH1065 ratchets along the outside of pony wall. ATTENTION: Consult Side Profile diagram in Quick Start Section for ratchet locations for specific building length.

Distance shown by arrow above is approximately 6" to 8" from center of end rafter to center of ratchet.

Inside of Shelter

End (front or back) of pony wall.

6"-8"

Consult a construction professional to determine the best fasteners for pony wall or support posts.



FINAL FRAME CHECK

1. Return to frame connections and verify bolts are tight.

2. Verify each purlin splice is secured with a Tek screw.

3. Verify each purlin is secured to pipe strap and cross connector and that each cross connector and pipe strap is secured to rafter. See diagram below.

4. Inspect frame for sharp areas that could damage cover. If found, file smooth and cover with layers of duct tape to protect cover.

5. Verify all bolts are positioned with heads to the outside of frame. Tape bolts, rafter joints, and cables before installing cover.

6. Verify cables wrapped around rafters at top of frame are covered with layers of duct tape or material to protect cover when installed.

Cross Connector to Rafter Tek Screw

Purlin to Cross Connector Tek Screw

Rafter

Purlin

ATTENTION: Position Tek screws so they will not touch cover once it is installed.

Space ratchets as evenly as possible and opposite one another below the same rafter to best stretch and secure main cover.

5. After installing all side ratchets and a final check of frame is complete, continue with cover installation.

24"

Photo shows straps and cover already installed, these items are installed later in the instructions.

Additional materials required to secure ratchets to concrete are not included and must be purchased by customer. Materials and frame shown in the following diagrams may differ from actual items. Consult the Attaching Rafter Feet to Concrete section on page 8 to determine anchor bolt size that best applies.

1. Determine where to attach first ratchet and drill mounting hole according to anchor bolt size.

NOTE: Hole needs to be deep enough so anchor bolt will not interfere with ratchet operation.

2. With ratchet in open position, insert anchor bolt through ratchet hole and into mounting hole. Firmly tap with a hammer to secure wedge anchor into concrete.

NOTE: Depending on wedge anchor bolt, verify that washer and nut are attached before driving anchor bolt. Striking bolt may cause thread damage and prevent the nut installation.

3. Tighten nut and test ratchet operation. Cut excess if needed.

4. Repeat for each ratchet.

ATTACHING RATCHETS TO CONCRETE PONY WALL4. Measure approximately 24" down from top of pony wall or support posts and attach ratchet. Install ratchets immediately across from each other below the same rafter.

21



PREPARE MAIN COVER

Gather parts:

• Pipe 1.66" x 99" swaged

• Pipe 1.66" x XX" plain: The XX refers to the length of plain pipe needed to reach frame end and to complete conduit. Consult Side Profile diagram in Quick Start section of these instructions to identify this pipe length.

• Main cover and Tek screws

Assembly Procedure NOTE: When handling main cover and setting it in position, do not pull on end straps. They will pull out of cover bonnet pocket. Do not insert any cover conduit into a cover pocket that includes a pre-installed strap.

WARNING: To prevent damage to cover and to prevent serious personal injury, DO NOT attempt to install main cover on windy days or when such conditions are expected.

1. Assemble two main cover conduits. Start each cover conduit assembly with one plain pipe and add swaged pipes to arrive at the frame length. Conduits are used to tighten and secure the main cover. Consult the Side Profile diagram in Quick Start section for pipe identification.

2. After assembling cover conduits, locate main cover and unfold it on a clean, smooth surface near frame. Unfold cover with inside surface facing up and straps positioned at front and back of frame.

3. Align cover ends with front and back of shelter and insert one cover conduit into each side pocket of cover.

a. Locate all sections of pipe needed to assemble the cover conduit.

b. Insert swaged end of each pipe into plain end of another pipe until conduit is assembled.

c. Secure each pipe joint with a Tek screw.

d. Use duct tape to tape over each Tek screw.

NOTE: Shelter shown above may be of a different style or length than actual shelter.

4. Continue by pulling cover up and onto frame.

Cover Conduits

Cover Ends w/Strapping

Stretch Hem Pockets

(See note above.)

Side Pocket

Side Pocket

NOTE: Stretch hem pockets are found on covers for buildings longer than 48'.

Rope or straps to pull cover over frame.



ATTACH MAIN COVER

Gather parts:

• Main cover (with conduits inserted)

• Ropes (provided by customer) or strap long enough to reach over frame

• Box cutter or utility knife

WARNING: To prevent damage and injury, do not leave cover unattended if it has not been properly secured. Ropes can be used to temporarily keep cover from blowing off frame.

Assembly Procedure

1. To pull cover over frame, attach ropes or straps to both ends of cover conduit positioned farthest from frame. Wrap rope around conduit a few times to prevent it from slipping off. See diagram on previous page.

NOTE: Depending on cover length it may be necessary to attach additional ropes to conduit between end ropes. Cut small openings in cover pocket and tie rope around conduit. DO NOT cut through main cover. Cut through conduit pocket only.

2. With all ropes attached conduit, toss ropes over frame, and pull cover into position. Position one person at each rope. Verify the cover stretch pockets (if equipped) are to the inside. This will be the underside of cover when it is pulled into position.

3. Once cover is pulled into position, center it on frame (end-to-end and side-to-side). WARNING: To prevent damage and injury, do not leave cover unattended if it has not been properly secured.

4. Locate straps at front and rear hems. Feed through center slot in each end ratchet. Operate ratchet to wrap strap onto center hub just enough to keep secure.

NOTE: Use lifts and additional assistants (if needed) to help pull cover up and over frame.

Shelter shown may be a different style or length.

Cover Conduit

Ropes

NOTE: Do not tighten completely at this time. This helps to temporarily secure cover.

5. Tie ropes (or straps)—used to pull cover—to frame to help hold cover.

6. Move to other side conduit and temporarily secure that side to frame. NOTE: Tie short pieces of rope to ends of side conduit and directly across from ropes or straps tied to other side conduit to temporarily secure cover. Once side straps are installed and slightly tightened, remove temporary ropes.

7. Continue with installation of side straps.

Inside of Shelter

End (front or back) of the pony wall.

23



INSTALL MAIN COVER SIDE STRAPS

Side straps wrap around conduit in side pocket. Ends of each strap are then fed into each side ratchet attached to pony wall or support posts and slightly tightened to keep cover in position.

Required parts and tools:

• 2" Strap (CC5391) (Some strap may ship in a bulk roll. Measure and cut as needed.)

• Tool to cut slits in cover conduit pockets

Complete these steps to install the side straps:

1. Move to one side ratchet attached to pony wall and cut an opening in conduit pocket as shown. Photos show using a utility knife. Cover design differs from actual shelter. Procedure is the same.

NOTE: When cutting pocket for strap, do not cut through main cover. Cut only the pocket material. Cutting access to cover conduit as shown allows water to flow over pocket opening and not into pocket.

2. Select one tie down strap (CC5391) and insert one end through pocket and around cover conduit (A). NOTE: For bulk strap, use ratchet position to determine required length and cut strap as needed.

3. Feed both strap ends through slot in ratchet and slightly tighten strap (B). Do not tighten completely at this time.

Conduit in cover pocket.

Conduit in cover pocket.

A B

Conduit Conduit



5. After all side straps are in place and slightly tightened and cover is centered evenly on frame, complete the following steps to install the PVC cover conduit. NOTE: The following procedure applies to shelters longer than 48'. If building is 48' long or shorter, skip the next section and continue by tightening side ratchets as described on Page 27.

4. Repeat previous steps to install and slightly tighten remaining straps. Photos below show examples of pony wall shelters and how to attach ratchets to secure main cover.

INSTALL MAIN COVER SIDE STRAPS–continued

Conduit

25



INSTALL PVC CONDUIT FOR MAIN COVER ENDS Complete this section if building is longer than 48'. The PVC conduit is inserted into a pocket at each end of the cover. Strapping is then threaded around the conduit and end rafters. Finally, strapping is tightened to stretch main cover end-to-end.

Required parts and tools:

• LJ2842 (3/4" PVC conduit) and 103620 (1" strap)

• Duct tape, Tek screws, and driver for Tek screws

• Tool to cut strap, a lift or ladders to reach top of frame, and assistants to install and tighten strap

Photo shows stretch pocket and conduit and strapping as installed for a similar cover. View shows cover as seen when standing inside the building looking up at end rafter.

Main Cover

PVC Conduit

Strap

End Rafter

Notched Stretch Hem Pocket

Install PVC conduits near main cover ends to provide an additional tie-down position. Complete these steps to install conduit and strapping for main cover stretch pockets.

1. Take first section of PVC conduit and feed into stretch pocket from bottom at one end of cover. Insert plain end of conduit into pocket so next section can be joined to the first.

2. Once the bell end reaches the pocket, take another section of PVC conduit, insert the plain end into the bell end of the previous section and secure the joint using customer-supplied PVC glue.

NOTE: Wrap joint using duct tape. Photo shows conduit inside stretch pocket on inside surface of cover.

Apply PVC glue to belled end of conduit.



3. Repeat steps and continue to assemble and feed PVC conduit into pocket.

4. Once conduit is fully assembled, secured at all joints, and inserted into pocket, repeat steps to install conduit at other end of cover.

5. Return to one end and cut access notches in stretch hem pockets for strap installation.

INSTALL PVC CONDUIT (CONTINUED)

6. Verify cover is centered on frame (side-to-side and end-to-end) and move to one end rafter.

8. Move to cover end opposite the temporary straps and cut notches in stretch pocket as prevously described.

9. Next, take one end of the bulk roll of 1" strapping and weave it around end rafter and PVC conduit as shown.

Photo shows how to weave strap between end rafter and PVC conduit. (Cover and rafter shown differs from actual cover.) Maintain an even distance between conduit the pocket and end rafter as strap is installed.

10. Continue weaving strap around end rafter and PVC conduit working up and over rafter and down to other end of PVC conduit. NOTE: Keep strapping snug during this step, but do not over tighten. Also, maintain a even distance between the top of the end rafter and the PVC conduit.

11. After weaving strapping, cut strap and tie it to frame to temporarily secure it.

12. Take remainder of bulk strap roll, move to other end of the frame, and repeat steps to weave strap between the PVC conduit and top of end rafter. NOTE: The temporary rope or straps at this end can be removed once main strapping is in place.

13. After strap is completely installed at this end, cut strap to length and tie it to frame.

Space notches 18" to 24" apart on-center.

Dashed line shows position of conduit in stretch pocket.

End Rafter

PVC conduit in notched pocket

Temporary strap or rope

Main Cover Bonnet

18"- 24"

7. Take rope or strap and cut a few sections long enough to tie PVC conduit to end rafter in evenly spaced locations. See photo above.

End Rafter

27



INSTALL PVC CONDUIT (CONTINUED)

Shelter shown above may be a different model and length. Photo used for illustration purposes only.

NOTE: During this procedure, maintain an even distance between end rafter and PVC conduit as strap is tightened. Also check that bonnet portion of cover overlaps end rafters evenly at both ends before stretching cover. Check this periodically as cover is stretched. If side straps are too tight and prevent cover from stretching end-to-end, loosen but do not remove the straps as needed and continue.

15. Once strap is tight at one end, cut it to length (if needed) and tie it to end rafter.

16. At each end of the stretch hem strap, drive a Tek screw through the strap and into the back side of rafter to secure strap to rafter.

17. Return to the other end of frame and tighten that strapping to complete stretching main cover from end-to-end.

18. Secure strap using a Tek screw at each end (Step 16).

19. Tighten side ratchets by completing next procedure.

14. Beginning at either end, tighten strap. Strapping will pull against strapping installed at the other end.

TIGHTEN SIDE RATCHETS

Verify that cover is in the desired position and centered on the frame. (Loosen and reposition if needed.) Continue with these steps to tighten side ratchets.

1. Move to side ratchets attached to the outside of pony wall or support posts. Begin with the pair of ratchets closest to center of pony wall and opposite each other.

2. With someone on each side of the shelter, tighten the first pair of ratchets opposite each other until cover is snug. Do not over-tighten. ATTENTION: Tightening ratchets opposite each other simultaneously helps keep cover centered and results in a more uniform appearance.

3. Move to the next pair of ratchets and repeat the steps to tighten them. NOTE: If strap builds up in ratchet, loosen ratchet, remove some strap, and tighten.

4. Repeat steps until all side ratchets are snug.

5. Return to all ratchet pairs and repeat the steps to tighten.

6. After all side ratchets are tight, move to the end of the pony wall where cover bonnet straps are located. Tighten these end ratchets to secure cover bonnet.

7. Move to other end and secure cover bonnet.

8. Recheck all ratchets and read care and maintenance information presented near the beginning of this guide.

Diagram shows ratchet attached to pony wall. This ratchet is used to secure cover bonnet.

Main Cover Bonnet

NOTE: Cover shown may differ from actual cover.



QUICK START GUIDE

30' Wide Pony Wall Building

Frame shown may differ in length from actual frame. See Side Profile diagram for specific building length to determine cable patterns and locations.

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Documents

ClearSpan 30' Wide Pony Wall Building · helpful hints and important information needed to safely assemble and properly maintain the shelter. Please read ... snow and ice, large tree