ClearSpan 26' Wide Pony Wall Building

LAY OUT THE BUILDING SITE The pony wall must support the load created by theshelter plus the additional loads imposed by the windand other elements. Concrete, large pre-cast concreteblocks, or 8" x 8" (or larger) timbers (to accommodatethe rafter mounting feet) are all acceptable materialswhen constructing the pony wall. Standard and approved building techniques arerequired. You must observe and adhere to all local andnational building codes and requirements. Consult aprofessional contractor when in doubt. Due to the characteristics of the pipe (including bendradius) and the design of the shelter, there are oftenvariations in the width and height of the building.Covers and end panels purchased or supplied withthe shelter include sufficient material to accommodatethese variations.Review the previous Location and Site information beforeyou begin construction of the pony wall.You (and your contractor, if any) are responsible forproviding a pony wall suitable for the shelter, the soilconditions, 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 needto be cemented into the ground at least 4' to preventmovement caused by frost and other weather related loads.Consult the building codes (if any) for your area beforeyou construct the pony wall. Consult a qualified contractorbefore you begin construction of your pony wall.ATTENTION: To install and secure the cover properly, therafters must be positioned to the outside edge of the ponywall. This allows the main cover to drape evenly down theside of the pony wall where it is secured to ratchets.104302Rafter FootRead the following before you begin pony wall construction:Width: The recommended width of the pony wall for a 26'wide building is 26' 6" to 27' (outside-to-outside). Wall mustaccommodate the 26' on-center width of the rafters withoutbeing too wide to interfere with cover installation. See ponywall thickness comment below. Length: The length of the pony wall should be theshelter length (24', 36', or 48') plus an additional 6"12" (at least) to accommodate the dimensions of themounting feet, which extend beyond the end rafters.51/2" The top of the pony wall must be level. The buildingframe will not assemble properly if the top of the ponywall is uneven.Pony wall thickness: The thickness of the pony wallmust provide a surface for the entire mounting base ofeach rafter foot. See diagram to the right.REMEMBER: The cover of the building is attached tothe outside of the pony wall. Position rafters as close tothe outside edge of the pony wall as possible.4"ATTENTION: The procedures that follow describeassembling each rafter, attaching the rafter feet (seediagram above), and then setting the rafters in place toassemble the frame.Depending on the application, the pony wall, and personalpreference, the builder/owner may want to space andattach the rafter feet to the pony wall first and then secureeach rafter to each set of anchored rafter feet to assemblethe frame. Review all diagrams before you begin.In either case, the customer is responsible for supplying thefasteners to secure the rafter feet to the pony wall structure.7

CLEARSPAN POLY BUILDINGSASSEMBLING THE RAFTERSNOTE: Assistance is required to assemble the rafters.Gather the parts: Rafter pipe (#26R1902) Rafter pipe (#26R1901) & rafter pipe (#26R1901D) Purlin end clamps (#102857) Band clamps (#QH1404) Tek screws Magnetic nut setter (3/8'' x 2-9/16")3. With the main rafter pipes seated at each joint and therafter positioned on a flat surface, secure each jointusing a single self-tapping Tek screw. Position Tekscrew approximately 1'' from pipe joint.1 Tek screwRafter Assembly ProcedureEach rafter assembly consists of five (5) rafter sections:four (4) swaged sections, one (1) plain section.1. Select the five (5) pipes needed to assemble a rafterand arrange these on a flat surface as shown below forassembly.ATTENTION: Install the screws so they will not touchthe cover once it is installed. This is typically on thebackside of the rafter, which will be the surface visiblefrom the inside of the shelter once the frame isassembled.Install the screw so that it secures the outer pipe to theswaged end of the inside pipe at the joint.4. Assemble all rafters as described and continue with theadditional steps to assemble the two end rafters.(#26R1902)END RAFTER ASSEMBLY(#26R1901)In addition to the steps in the previous procedure, completethe following steps for the two end rafters only.(#26R1901D)1. Take one of the assembled rafters and place it on a flatsurface.2. Slide the swaged portion of each rafter pipe into theplain end of the pipe as shown.2. Slide six (6) end clamps and two (2) band clamps ontothe rafter in the locations noted below. (Do not securethe clamps to the rafter at this time. These clamps arerepositioned during the frame assembly when thepurlins are added.)View of the end rafter and clamps as shown is from theoutside when the frame is assembled.NOTE: Position all clamps as shown. Use a piece ofduct tape to keep the clamps from sliding when therafter is set in place if desired.8Revision date: 09.11.09

RAFTER ASSEMBLY (CONTINUED)View below shows how to position all end clamps toprepare for the frame assembly. Purlin pipe shown isinstalled during the frame assembly procedure.2. Repeat step to attach the remaining rafter foot.3. Repeat the above procedure for all rafter assemblies.4. Continue with the FRAME ASSEMBLY instructions thatfollow.#102857Space below is reserved for customer notes.PurlinEnd RafterToward the insideof the frame whenassembled.3. Repeat the same procedure for the final end rafter.4. Continue with the ATTACH RAFTER FEET instructionsthat follow.ATTACH RAFTER FEETAfter assembling the rafters, attach two (2) rafter feet toeach rafter.NOTE: Skip this section if you have first spaced andsecured the rafter feet to the pony wall. Continue with theframe assembly. Adapt those steps as needed to accountfor any changes resulting from first attaching the feet.1. Attach one rafter foot (104302) to a rafter using the 3/8"hex head bolt (FAG363) and nut (FALB04B).Bolt head to theoutside of theshelter.FAG363Bolt104302Rafter FootFALB04BNut9

CLEARSPAN POLY BUILDINGSFRAME ASSEMBLY3. Verify that the on-center rafter width is 26' and securethe rafter feet of the end rafter to the pony wall usingcustomer-supplied fasteners to prevent shifting.Gather the parts: All rafter assemblies Purlin pipe 1.315" x 75" swaged (131S075) Purlin pipe 1.315" x XX" plain pipe (#131P0XX) Band clamps (#QH1400) and cross connectors(#102547) Struts (#QH1308) and Tek screwsNOTE: The XX" represents the remaining length requiredto reach the end of the shelter. Consult the Spec Sheet andSide Profile diagrams (Quick Start) for pipe identification.If pony wall is concrete, consult the Attaching RafterFeet to Concrete section for suggested fasteningmethod.4. Brace the rafter in place and tighten the rafter basemounting bolts as shown below.CustomerSuppliedFastenerStep 4Frame Assembly Procedure1. Stand one end rafter. The end rafters include the endclamps. Be sure to position the bolt side of end clampto the inside of the frame when setting the end rafter inposition. See the diagram below.1/2''Step 4104302104302End Clamp BoltViews are shown from outside the shelter.PurlinEnd RafterToward the insideof the frame whenassembled.5. With the first end rafter set and the on-center width at26', set the first interior rafter in place.6. Using the on-center, rafter-to-rafter spacing, setthe interior rafter in position and repeat Steps 3-4.(Additional assistants are required to hold the rafterin position.) See Side Profile diagrams for the correctrafter spacing.Upper EndClampNOTE: Purlin pipe shown in the above diagram isinstalled during the frame assembly.Upper EndClampUpper CrossConnector2. Check that the rafter is standing straight (plumb) andbrace it in place.Step 7center-tocenterLower CrossConnectorPosition7. Install the upper two (2) cross connectors on theinterior rafter and insert a purlin pipe through eachconnector and through the upper end clamps near thetop of the end rafter. See circles above.Shelter shown may differ from actual frame in design.108. Verify that both rafters are plumb and properly spacedon-center and tighten the upper end clamps and crossconnectors.Revision date: 09.11.09

FRAME ASSEMBLY (CONTINUED)CAUTION: To prevent cover damage, the ends of thepurlins should extend no more than ½'' past the endclamp. See diagram that follows Step 14. Do not allowpurlin to extend beyond the edge of the end rafter.12. Install the remaining cross connectors and purlins.Verify that the rafter spacing is on-center for the shelterand tighten the end clamps and connectors.center-tocenter9. Move to the lower clamp positions and repeat Step 7to install the purlin pipes in those locations. See thediagram on the previous page following Step 6.QH1400center-tocenterLower EndClampLower CrossConnectorQH1400Band ClampStep 910. Slide a band clamp (#QH1400) on each of the twobottom purlins between the second and third rafters.Position the head of each band clamp bolt toward theoutside of the shelter.11. Move to the lower end of the rafters, verify that theposition of the purlin is approximately 6"- 8" above thetop of the pony wall, and tighten the lower end clampsand cross connectors.TightenClamps andConnectiorsTightenClamps andConnectiorsStep 1213. Continue adding rafters and purlins until the frame isnearly complete.NOTE: Remember to add band clamps to the lowerpurlins between the second and third rafter at theremaining end of the frame for the installation of thestruts. Review Step 1 to set the final end rafter.14. Finish each purlin with a plain pipe and use the finalend rafter to complete the assembly.NOTE: To prevent cover damage, DO NOT allow thepurlin to extend beyond the end rafter.If the last end rafter is plumb and the purlin run extendsbeyond the end of the rafter, cut the last section ofpurlin pipe to the required length.Typically purlin pipes do not require cutting. Verify thatthe finished purlin run has the correct plain pipe beforecutting any pipe. Consult the Side Profile diagrams inthe Quick Start section for pipe identification.1/2''End Rafter6"- 8"Inside ofshelterPurlinStep 11CAUTION: To prevent cover damage, the ends of thepurlins should extend no more than ½'' past the endclamp. Position the bolt side of the end clamps to theinside of the shelter as shown.11

CLEARSPAN POLY BUILDINGSFRAME ASSEMBLY (CONTINUED)ANCHOR THE SHELTERStrut Installation ProcedureAt this point, anchor the frame. Once the frame is anchoredproperly, continue with these instructions.1. After the rafter assembly is complete, verify that theband clamps are in the proper location. See diagrambelow.WARNING: You must anchor the shelter as describedin the MUST READ document.FAILING TO PROPERLY ANCHOR THE SHELTERWILL RESULT IN DAMAGE TO THE SHELTER ANDMAY CAUSE PERSONAL INJURY.End RafterFirst Inside RafterBand ClampREAD THE MUST READ DOCUMENT TO PROPERLYANCHOR THE SHELTER.Space below is reserved for customer notes.Lower PurlinPositions of band clamps depend on the rafter spacingand may differ slightly from what is shown.2. Remove the bolts and attach a strut between the bandclamp on the purlin and the band clamp on the endrafter. Position the strut so that it forms a triangle asshown below. Actual strut and position may vary.Strut90 NOTE: Verify that the bolt heads are to the outside ofthe shelter and tighten the nuts.3. Install the remaining struts and tighten all band clampbolts.4. Secure each band clamp to the purlin and rafter usinga Tek screw for each connection.5. Return to each purlin joint and secure using a Tekscrew.12Revision date: 09.11.09

INSTALL THE MAIN COVER RATCHETSAttach all QH1061 side ratchets on the outside of the ponywall.Gather the parts: Ratchets (#QH1061) Tek screws (#FA4482B): Tek screws may not be thecorrect fastener for some pony wall constructions. Seethe note in Step 1. Due to the different materials usedto construct pony walls, the customer is responsible forsupplying the required fasteners. Consult the advice ofa qualified professional contractor if needed.4. Measure approximately 12"-16" down from the top ofthe pony wall and attach as shown below.Install ratchets immediately across from each otherbelow the same rafter.12"-16"Complete the following steps to secure the ratchets to thepony wall.1. Locate four (4) ratchets (#QH1061) and attach theseto the outside ends of the pony wall as shown in thediagram below. Attach each ratchet using a Tek screw(FA4482B). (Fasteners for pony walls constructedof material such as concrete, stone, or wood are notincluded and must be purchased separately. Consult acontractor if needed.)ATTENTION: If attaching ratchets to concrete, read theAttaching Ratchets to Concrete section and apply thatprocedure to the following instructions.Photo shows straps and cover already installed, theseitems are installed later in the instructions.The main point is to space the ratchets as evenly aspossible and opposite one another below the samerafter to best stretch and secure the main cover.5. After installing all side ratchets and a final check ofthe frame is complete, continue with the main coverinstallation.FINAL FRAME CHECKInside of Shelter6"-8"End (front orback) of thepony wall.Consult aconstructionprofessional todetermine the bestfasteners for yourpony wall.Distance shown by the arrow above is approximately6" to 8" from center of the end rafter to the center ofthe ratchet.2. Locate the remaining ratchets and divide the quantity inhalf. Use half for each side of the shelter.3. Evenly space the remaining QH1061 ratchets along theoutside of the pony wall.ATTENTION: Consult the Side Profile Diagram in theQuick Start Section for ratchet locations.1. Return to the frame connections and verify that all boltsare tight.2. Verify that each purlin splice is secured with a Tekscrew.3. Verify that each purlin is secured to the end clamp andcross connector and that each cross connector andend clamp is secured to the rafter. See diagram below.ATTENTION:Position the Tekscrews so they willnot touch the coveronce it is installed.Cross Connectorto Rafter TekScrewRafterPurlinPurlin to CrossConnector Tek Screw4. Inspect the frame for sharp areas that could damagethe cover. If found, file smooth and cover with layers ofduct tape to protect the cover.5. Verify that all bolts are positioned with the heads to theoutside of the frame. Tape the bolts and rafter jointsbefore installing the cover.13

CLEARSPAN POLY BUILDINGSATTACHING RAFTER FEET TO CONCRETEATTACHING RATCHETS TO CONCRETEAdditional materials required to secure the rafter feet to theconcrete base are not included and must be purchased bycustomer. Materials and rafter foot shown in the followingdiagrams may differ from actual purchases.Additional materials required to secure ratchets to aconcrete base are not included and must be purchasedby customer. Materials and frame shown in the followingdiagrams may differ from actual purchases.Use the following information to determine the size of theanchor bolt that best applies to your purchase.Consult the boxed information to the left to determine thesize of the anchor bolt that best applies to your purchase.Length of Anchor Bolt equals ( ):Thickness of material to be fastened plus minimum embedment (see manufacturer recommendation) plus 1" for nut and washer application.1. Determine where the first ratchet will be attached anddrill the mounting hole according to the anchor boltsize.1. Verify rafter foot is in the correct position. Using thefastener holes as a guide, drill holes into the concretebase according to the anchor bolt size.NOTE: Rafter footshown may differfrom actual rafterfoot. Installation is thesame.IMPORTANT: DONOT over-drill hole.Wedge anchor boltwill not work properlyif hole is too deep.NOTE: Hole needs to be deep enough that the anchorbolt will not interfere with ratchet operation.2. With ratchet in the open position, insert anchor boltthrough ratchet hole and into mounting hole. Firmly tapwith a hammer to secure wedge anchor into concrete.2. Insert anchor bolt into one drilled hole. Firmly tap with ahammer to secure wedge anchor into concrete.Samplewedgeanchor boltNOTE: Depending on wedge anchor bolt, verify that thewasher and securing nut are attached before drivingthe anchor bolt into concrete. Striking bolt may causethread damage and prevent the nut installation.3. Tighten the nut.NOTE: Depending on wedge anchor bolt, verify that thewasher and securing nut are attached before drivingthe anchor bolt into concrete. Striking bolt may causethread damage and prevent the nut installation.4. Repeat for each anchor bolt until rafter foot isadequately secured to the concrete base.5. Repeat for each rafter foot.143. Tighten the nut.4. Test ratchet operation. Cut excess if needed.5. Repeat for each ratchet.Revision date: 09.11.09

PREPARE MAIN COVERGather the parts: Pipe 1.315" x 75" swaged Pipe 1.315" x 73.5" plain Main cover Tek screwsWARNING: To prevent damage to the cover and to preventserious personal injury, DO NOT attempt to install the maincover on windy days.Assembly ProcedureNOTE: When handling the main cover and setting it in position, do not pull on the end straps. They will pull out of thecover. Do not insert any cover conduit into a cover pocket that includes a pre-installed strap.WARNING: To prevent damage to the cover and to prevent serious personal injury, DO NOT attempt to install themain cover on windy days.1. Assemble two main cover conduits. Start each cover conduit assembly with one plain pipe and add swaged pipes toarrive at the length of the frame. Once assembled, the cover conduits are inserted into the side pockets of the maincover. The conduits are used to tighten and secure the main cover to the frame. Consult the Side Profile Diagram inthe Quick Start section for pipe identification.a. Locate all sections of pipe needed to assemblethe cover conduit.b. Insert the swaged end of each pipe into theplain end of another pipe until the conduit isassembled.c.Secure each pipe joint with a Tek screw.d. Use duct tape to tape over each Tek screw.2. After assembling the cover conduits, locate the main cover and unfold it on a clean, smooth surface against the ponywall. Unfold the main cover with the inside surface facing up and the straps positioned at the front and back of thepony wall.CoverEnds w/StrappingSide PocketCover ConduitstSide Pocke3. Align the cover ends with the front and back of the shelter and insert one cover conduit into each side pocket of themain cover.NOTE: Shelter shown above may be of a different style or length than actual shelter.4. Continue by pulling the cover up and onto the frame.15

CLEARSPAN POLY BUILDINGSATTACH MAIN COVER3. Once the main cover is pulled into position, center thecover on the frame (end-to-end and side-to-side).Gather the parts: Main cover (with conduits inserted) Ropes (provided by customer) or strap long enough toreach over the frame Box cutter or utility knifeWARNING: To prevent damage and injury, do notleave the cover unattended if it has not been properlysecured. The ropes can be used to temporarily keepthe cover from blowing off the frame.WARNING: To prevent damage and injury, do notleave the cover unattended if it has not been properlysecured.4. Locate the straps at the front and rear hems and feedthe straps through the center slot in each end ratchet.Operate the ratchet to wrap the strap onto the centerhub just enough to keep the strap secure.Inside of ShelterAssembly Procedure1. To pull the cover over the frame, attach ropes or strapsto both ends of the cover conduit positioned farthestfrom the frame. Wrap the rope around the conduit a fewtimes to prevent it from slipping off.NOTE: Depending on the length of the cover it maybe necessary to attach additional ropes to the coverconduit between the end ropes by cu

End Clamp 102547 Cross Connector QH1061 Ratchet 103620b Plain End Strap Swaged Plain Swaged and Plain Rafter Sections QH1400 Band Clamp 104302 Rafter Foot QH1404. . Pony wall thickness: The thickness of the pony wall Rafter Foot ATTENTION: .