ClearSpan Storage Master Solarguard User manual

Instruction Manual

Poly Shelters

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

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

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