Moo-Tel Calf Hutch Photo may show a different but similar model. 2008 ClearSpan All Rights Reserved. Reproduction is prohibited without permission. STK# DIMENSIONS 102852 14 W x 12 L 102853 14 W x 18 L 102854 14 W x 24 L 1
YOU MUST READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLE THE SHELTER. 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 you begin. If you have any questions during the 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 the shelter or framing during or after construction. Do not occupy the shelter during high winds, tornadoes, or hurricanes. Provide adequate ventilation if the structure is enclosed. Do not store hazardous materials in the shelter. Provide proper ingress and egress to prevent entrapment. ANCHORING INSTRUCTIONS Prior to assembling this shelter, please read the MUST READ document included with the shipment. LOCATION Choosing the proper location is an important step before you begin to assemble the structure. The following suggestions and precautions will help you determine whether your selected location is the best location. Never erect the structure under power lines. Identify whether underground cables and pipes are present before preparing the site or anchoring the structure. Location should be away from structures that could cause snow to drift on or around the shelter. Do not position the 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. Follow the information below helps to ensure the integrity of the structure. A level site is required. The site must be level to properly and safely erect and anchor the structure. For sites that are not concrete or gravel, placing wood blocks or other suitable supports under each rafter leg helps prevent the pipes from sinking or working into the site. Does not apply to shelters with ground posts. Drainage: Water draining off the structure and from areas surrounding the site should drain away from the site to prevent damage to the site, the structure, and 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. WARNING: The anchor assembly is an integral part of the shelter construction. Improper anchoring may cause shelter instability and failure of the structure to perform as designed. Failing to anchor the shelter properly will void the manufacturer s warranty and may cause serious injury and damage. 2
ASSEMBLY PROCEDURE Following the instructions as presented will help ensure the proper assembly of your shelter. Failing to follow these steps may result in an improperly assembled and anchored shelter and will void all warranty and protection the owner is entitled. The steps outlining the assembly process are as follows: 1. Verify that all parts are included in the shipment. Notify Customer Service for questions or concerns. 2. 3. Read these instructions, the Must Read document, and all additional documentation included with the shipment before you begin assembling the shelter. Gather the tools, bracing, ladders (and lifts), and assistance needed to assemble the shelter. 4. Check the weather before you install the roof cover and any panels (if equipped). Do not install covers or panels on a windy or stormy day. 5. 6. 7. 8. Re-evaluate the location and site based on the information and precautions presented in the documentation included with the shipment. Lay out the site (if this has not been completed). This may not apply to smaller shelters such as awnings that are attached to buildings. Assemble the frame components in the order they are presented in these instructions. Assemble the frame including the struts (if equipped). 9. Consult the Must Read document and properly anchor the assembled frame. 10. Install, tighten, and secure the main cover and panels (if equipped). This applies to fabric covers that stretch over the frame assembly. Your shelter may include roof panels or side panels or both. 11. Read the care and maintenance information at the end of these instructions. 12. Complete and return all warranty information as instructed. LIST OF WORDS AND PHRASES Before you 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 parts of the shelter. (Some are used in this document. Others may not apply to this particular shelter.) These terms describe the shipped parts and can also be found on the materials list/spec sheets included with the shipment. To aid in the assembly, read through the following definitions before you begin to assemble your shelter. Conduit: An assembly of pipes used to secure the 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 the joints of the different rafter sections during the assembly of the rafters. Some shelters do not use couplers. Foot or Rafter Foot: The part attached to and found at the base of the rafter or leg of the shelter. 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: The pipe assembly that runs perpendicular to the rafters or framework that supports the main cover. Purlins are found on the 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 work by special brackets and bolts. Swaged End or Swaged Pipe: The term swaged refers to the tapered end of the pipe or tube. Swaged ends of a pipe can be inserted into couplers and the straight ends of other pipes. Tek screw: A self-tapping fastener used to secure pipe joints and to fasten brackets to rafters. 3
REQUIRED TOOLS The following list identifies the main tools needed to assemble the shelter. Additional tools and supports may be needed depending on the structure, location, and application. Tape measure or measuring device Marker to mark locations on the pipes Variable speed drill and impact driver (cordless with extra batteries works best) Metal-cutting tool for pipe Wrenches or ratchet and socket set (recommended) Hammers and gloves Adjustable pliers Plumb Line Utility knife, scissors (or similar cutting tool) Ladders, work platforms, and other machinery for lifting designed to work safely at the height of the shelter Lay Out the Building Site After the site is prepared, identify the location of the shelter corners helps to square the frame after it is assembled. Taking these steps before assembling the shelter saves time and ensures that the structure is positioned as desired. The following procedure is a suggested method. Its use depends on the size of the shelter, shelter application, the footings, and the method used to anchor the shelter Square the Site 1. 2. Identify a corner where a building rafter will be positioned, drive in a stake, and string a line the exact width of the building and stake in place. String a line at least as long as the building from the first stake at 90. UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin to assemble the shelter. 1. Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets. 2. Verify that all parts listed on the Bill of Materials/Spec Sheets are present. If anything is missing or you have questions, consult the Pictorial Parts Guide and all shelter diagrams for clarification, or contact Customer Service. NOTE: At this time, you do not need to open the plastic bags containing smaller parts such as fasteners or washers. QUICK START DIAGRAMS For a quick overview of the shelter and its components, consult the Quick Start diagrams at the back of these instructions. Continue with procedures that follow. 3. NOTE: A transit can be used to ensure an accurate 90 angle, or the 3-4-5 rule can be used. Refer to diagram. Using multiples of 3-4-5 such as 6-8-10 or 12-16-20 helps to maintain an accurate 90 angle. After squaring the position of the building and placing a stake at all corners, string a line between the stakes to mark the base of the building. ATTENTION: The use of the above method depends on the shelter design and shelter length. Squaring the site helps position the frame during assembly for shelters exceeding 10' in length. 4
The following graphics and photos will help you identify the different parts. (Some parts are not shown.) FA4470B Tek screws CC6212 & CC6213 Fabric Clips QH1061 Ratchet 100442 Nut Setter Plain Swaged 103395 Spin Handle 103396 Universal Joint Swaged and Plain Rafter Sections 102194 4-Way Coupler 102193 3-Way Coupler *Panel design may differ from actual panel. Zippered End Panel* 5
Additional Parts Identification Notes In some instances, there can be differences between the parts that are shown and referenced in the instructions and the parts that are shipped with the shelter. These differences do not affect the integrity of the shelter, but can change the assembly procedures. The information that follows identifies possible changes in the assembly procedure found in this instruction document. Please implement these changes during the assembly of the shelter. 3-Way Coupler (no lock bolt) 3-Way Coupler (includes lock bolt) 4-Way Coupler (no lock bolt) 4-Way Coupler (includes lock bolt) There can be two types of couplers used during the assembly of the shelter: those that include an installed locking eyebolt and those that do not. See above. If the couplers included with your shelter do not have an installed lock bolt, use a self-tapping Tek screw to secure the different pipes to the couplers during the assembly process. The self-tapping Tek screws are included with the shipment. ATTENTION: Tek screws are sent with all shelters of this type. For couplers with locking eyebolts, install the Tek screws at each pipe connection for additional security if desired. WARNING: To prevent personal injury and damage to the shelter, fasten and tighten a Tek screw at each pipe and coupler joint. To prevent cover damage, install the Tek screw so that it does not touch the main cover or any optional side or end panels once these are installed. 6
Moo-Tel Calf Hutch ASSEMBLE THE MAIN ROOF FRAME This section describes assembling the roof frame. See illustration below to identify main parts of the assembly. 1. 2. Locate the required couplers and pipes and assemble the roof frame as shown below. Secure each pipe in the coupler using the locking eyebolt. If the couplers are not equipped with locking eyebolts, secure each pipe in the coupler using a Tek screw. ALTERNATIVE ASSEMBLY INFORMATION These instructions describe assembling the entire roof section of the shelter first. The frame is then lifted and the legs added. For long shelters or when limited assistance is available, constructing the frame and legs in sections suitable for lifting and moving and working from one end to the other is an alternative assembly method. (This method is not shown.) To assembly the frame in sections, read these instructions first and adapt the steps as needed. Consult all diagrams and the Quick Start section of this manual to better understand how the frame is assembled before you begin. Install the main cover as a single unit after the frame is assembled and anchored. ATTENTION: If used, position Tek screws so they will not touch the main covers or side panels when these are installed. Purlin Rafter Pipe Identification Location Pipe Length Rafter 166P096 96" Purlin 166P034 34" NOTE: Frame length shown may differ from actual frame. 7
INSTALL MAIN FRAME LEGS Required Parts Pipes #166P048 1. Locate the required plain pipes (#166P048) for the legs and insert them into the 3-way and 4-way couplers of the main frame. BASEBOARDS (RECOMMENDED) To prevent the rafter legs from sinking into the ground, baseboards (or other suitable supports) can be placed along each side and end under each leg pipe. The baseboard is not included with the shipment and is supplied by the customer. Treated or recycled plastic lumber works well for a baseboard. The baseboard, when installed properly, helps prevent the leg pipes from sinking into the ground when anchored. Customer-Supplied Baseboard Plain Pipe (#166P048) Frame length shown may differ from actual frame. Frame length shown may differ from actual frame. HELPFUL HINT: Install the legs along one side of the main frame and then install them on the remaining side. A lift may be required for long frames or when limited assistance is available. 2. 3. Secure each pipe in a 3-way and 4-way coupler using the locking eyebolt. If the couplers are not equipped with locking eyebolts, secure each pipe in the coupler using a Tek screw. Position Tek screws so they will not touch the main cover or end panels when these are installed. After all legs are installed, verify that all eyebolts are tight, install baseboards (recommended), and square the frame. 8
SQUARE THE ASSEMBLED FRAME 1. With the frame assembled and in position, perform a final square of the frame by measuring diagonally (corner-to-corner) at the bottom of the legs and verify that the two measurements are equal. Adjust if needed. ANCHOR THE FRAME At this point in the assembly process, anchor the assembled frame. Once the frame assembly is anchored properly, continue with these instructions. WARNING: Securing the legs to concrete blocks or wood boards set on the site is not a substitute for properly anchoring the shelter. You must anchor the shelter to the site. FAILING TO PROPERLY ANCHOR THE SHELTER WILL RESULT IN DAMAGE TO THE SHELTER AND MAY CAUSE PERSONAL INJURY. Turnbuckles and ground anchors are suitable to anchor this type of shelter. Consult a reliable construction professional if you need assistance when anchoring the assembled frame. CONSULT THE MUST READ DOCUMENT FOR ANCHORING INSTRUCTIONS. Frame length shown may differ from actual frame. Contact Customer Service at 1-800-245-9881 to purchase additional parts to anchor the shelter. 2. 3. 4. Adjust width. Measure width from center of rafter leg to center of other rafter leg of the same rafter assembly. Adjust if needed. Examine the frame and remove any sharp edges from the frame or reposition screws so they do not come in contact with the roof cover. Verify that the screws used to secure the purlin pipe joints are tight and positioned so they do not touch the cover. NOTE: These purlin joints and Tek screws can be taped to protect the cover if desired. 5. After the frame is squared, read or reread the MUST READ document and continue with the anchoring of the shelter. 9
END PANEL INSTALLATION The end panels for the end walls include zippered, roll-up panels. Each zippered panel includes a conduit pocket along the bottom. ATTENTION: If you are installing wire mesh, do so before you attach the end panels. If possible, install all wire mesh on the inside of the frame. This prevents potential conflicts with the panels and roll-up cover. END PANEL INSTALLATION (continued) 3. With the panel in the desired position (level against the ground), stretch the end panel up and over the end rafter. (Additional assistants are needed to keep the panel evenly stretched.) The following steps describe one way to install the panels. Required parts include: Zippered end panels (#QE102852WZ2) Tek screws (#FA4470B) CC6213 fabric clips (Use 16 for each end panel.) 1. DO NOT ATTEMPT TO PULL THE END PANELS INTO POSITION ON WINDY OR STORMY DAYS! Unfold and position the zippered end panel with its bottom pocket toward the end wall, and center the panel between the rafter legs of the end wall. 4. View from inside the frame. NOTE: Zippers should not have excess tension on them. Do not stretch the panel too tight. Actual frame may differ from frame shown. Attach the fabric clips to secure the end panel to the rafter. Evenly space the fabric clips at 24" intervals. Secure each fabric clip with a Tek screw. Keep the panel evenly stretched as you work along the rafter and down to the ground. NOTE: Install all end panel fabric clips on the backside of the rafter to prevent damage to the main cover when it is installed. 2. NOTE: Position the panel so that the zippers are accessible from the outside after the panel is pulled into position. Verify that the long black straps are on the inside, and the D-rings are on the outside. Panel shown may differ from the actual panel. With the proper lift (or ladders) positioned inside the frame and with assistance, pull the end panel up and over the top of the end rafter. Square the end panel on the end frame and verify that the bottom edge is in the desired position. 5. 6. 7. Test the zippers in the roll-up door. Loosen the fabric clips and adjust the material if needed. Re-install Tek screws in the fabric clips. After the panel is attached, locate a 131S075 swaged pipe (75") and a 131P0735 plain pipe (73.5"). Insert the swaged end of the 75" pipe into the plain end of the 73.5" pipe and secure connection using a Tek screw. Apply duct tape (customer supplied) over the Tek screw to protect the end panel and insert the assembled conduit into the end panel zippered door pocket. Roll-Up Conduit 10
END PANEL INSTALLATION (continued) 8. With the roll-up conduit positioned in the end panel pocket, secure the conduit in place using five (5) CC6212 fabric clips (for 1.315 pipe) and Tek screws. RATCHET INSTALLATION The main cover is secured to the shelter using ratchets and straps. Ratchets are attached to the outside of an end rafter 36" above ground level as shown. End Panel Fabric Clip Install a ratchet at each corner of the assembled frame. One end ratchet per corner. End Rafter Roll-Up Conduit 9. NOTE: Evenly space the clips along the conduit for best results. The remaining number of CC6212 fabric clips is divided in half and used for the roll-up side panel conduits installed later. The CC6212 fabric clips are the smaller of the two types of fabric clips for this shelter. Move to the inside of the frame and trim the excess panel material (if desired) from the inside edge of the panel. 10. Repeat steps for the remaining end panel. NOTE: To secure the roll-up doors in an open position, roll the door up and secure the black straps on the inside to the D-rings on the outside as shown below. 1. 2. 3. 36" Secure the ratchet to the end rafter using a Tek screw through the bottom hole in the ratchet. Repeat to install ratchets at the remaining three corners of the frame. Install the main cover. Actual frame may differ from frame shown. End panel material not shown for clarity. Roll door panel up and locate black straps in the back. MAIN COVER INSTALLATION The main cover is secured to the frame using ratchets and straps. The straps are contained within a pocket at each end of the cover. WARNING: To prevent damage to the cover and to prevent serious personal injury, DO NOT attempt to install the main cover on windy days. Wrap straps around to the front. The following steps describe one way to assemble the cover conduits and to install the main cover. 1. Locate the round 1.315" pipes for the cover conduits and assemble the two (2) cover conduits for the main cover. Each cover conduit assembly consist of following swaged and plain pipes: Attach straps to D-rings as shown. Shelter Swaged Pipe Plain Pipe #102852 #131S075 (1) #131P0735 (1) #102853 #131S075 (2) #131P0735 (1) #102854 #131S075 (3) #131P0735 (1) 11
MAIN COVER INSTALLATION (CONTINUED) 2. After assembling the two (2) cover conduits of equal length, secure the pipe joints with a Tek screw and tape over the screw head with duct tape. 7. Toss the ropes over the frame and pull the cover into position. One person is required at each rope. 3. These cover conduits are inserted into the pockets sealed into the main cover. The conduits are used to roll-up the sides of the main cover. Locate the main cover and spread it out on the ground (with its underside facing up) along the side of the assembled and anchored frame. See diagram below. End Straps Frame length shown may differ from actual frame. Ropes NOTE: Do not use the straps in the bonnet pocket of the main cover to pull the cover into place. These straps will pull out. Flaps 8. 9. With the cover on the frame, center the cover end-toend and side-to-side as needed. Beginning at one end of the main cover, determine the height of the roll-up side and remove the hem area. Slide cover conduit out of the way if needed. 4. 5. Cover Conduits NOTE: The black straps in the main cover are positioned at the front and back of the assembled frame. Do not install conduit into strap pocket. Insert the cover conduits into the pockets along the sides of the main cover. After inserting the cover conduits and with the cover positioned along the side of the frame, attach ropes to both ends of the cover conduit. Wrap the rope around the conduit a few times to prevent it from slipping off. For example, if you want a 36" sidewall opening when the sidewall is rolled up, remove 36" of the main cover hem. Maximum height of roll-up side is 48". ATTENTION: Do not cut the strap contained within the main cover. When properly cut, the hem is removed to just above the installed ratchet. 6. With all ropes attached to the cover conduit, lift the conduit and carry the cover toward the base of the frame. Rope may not be needed for small shelters. DO NOT pull the strap from the bonnet pocket. 12
MAIN COVER INSTALLATION (CONTINUED) 10. Repeat the steps to remove the hem from the remaining corners of the main cover as previously described. 11. With additional help, snug the cover into position by simultaneously pulling on the bonnet straps to seat the cover on the frame and over the end rafters. 12. Remove the excess strap. See the note that follows before you cut the strap. 16. Using scissors or a utility knife, trim the main cover flap around the 4-way connectors along each side of the frame. Do not cut through the main cover! Dashed lines below show the flap and where the cuts were made around the 4-way couplers. Fabric Clips Fabric Clips Main Cover Bonnet Main Cover Side Roll-up panel of the Main Cover Dashed line shows where the cut was made to remove the cover hem. End Panel ATTENTION: The length of strap depends on where you attached the ratchets. Verify that the cover is in position before you cut the strap to length. Use the ratchets as guides when cutting the strap to length. 13. Thread the straps through the center slots in the ratchets and slightly tighten the ratchets to remove slack. 14. Verify that the cover is positioned as desired and tighten the ratchets. NOTE: If the strap length is too long and binds in the ratchet, loosen the ratchet, shorten the strap, and retighten the ratchet as needed. 15. After tightening the ends of the main cover, take half of the CC6213 fabric clips that remain from the earlier procedure and Tek screws and move to the inside of the shelter. Photo shows the inside of the shelter. Frame shown may differ in length. Positions of clips will vary. NOTE: Do not to cut through the main cover when cutting the flap. 17. Fold the flap, which runs between each of the rafters, over the purlin pipe and secure the flap to the pipe using fabric clips and Tek screws. See the arrows in the previous photo. Evenly space the clips as needed. 18. Repeat the steps to secure the remaining side flap of the main cover to the side purlin pipes. 19. With the main cover secured at the ends and along the sides, install the crank assemblies for the roll-up sides of the main cover. 13
INSTALL ROLL-UP ASSEMBLY Gather the parts: Pipe 1.315'' x 49.5'' (#131P0495) Spin handle (#103395) Universal joint (#103396) Fabric clips (#CC6212) (Use remaining clips - half for each side.) 1. Move to a cover conduit, which was inserted into the pocket of the main cover and position the conduit in the pocket so that a few inches extends beyond the pocket at the end where the crank will be attached. Fabric Clip 5. 6. 7. 8. Add the spin handle to the extension pole and secure the connection with a Tek screw. 49.5" Repeat the steps to secure the remaining roll-up conduit to the main cover. With the crank assembly properly attached, test the operation of the crank assembly. Continue by installing the shade cover. 2. 3. Space evenly ATTENTION: A few inches of the conduit should extend beyond the edge of the cover. See diagram above. Evenly space the fabric clips to secure the main cover to the conduit. Attach the universal joint to the conduit in the pocket using a Tek screw to secure the connection. INSTALL SHADE COVER The shade cover is used on warm days with the roll-up sides raised completely. If the sides are lowered, the shade cover bungie straps cannot reach the attachment points on the frame. 1. 2. 3. Pull the shade cover over the top of your shelter. If necessary, use ropes to pull the cover over, as described in the Main Cover Installation section. Center the shade cover front-to-back and side-to-side. Secure shade cover in place with super straps (#FA1405) in all four corners and at the center of both sides as shown below. Wrap straps around frame or hook to an installed Tek screw. Verify that the strap "S" hooks do not poke or rub against the main cover. 4. Secure one (1) 49.5" plain pipe to the remaining end of the universal joint using a Tek screw. 4. Continue by reading the care and maintenance section that follows. NOTE: This extension pipe can be trimmed to the desired length. 14
Care and Maintenance Proper care and maintenance of the shelter will help to ensure years of service. The following items identify areas that should be periodically checked to ensure that your shelter is maintained properly: Regularly check the end panels and main cover to see that they remain tight and in proper repair. Check connections and all fasteners to verify that they remain tight. Do not climb or stand on the shelter at anytime. Remove debris and objects that can accumulate on the shelter. Use tools that will not damage the cover when removing debris. Remove snow to prevent excess accumulation. Use tools that will not damage the cover when removing snow. Check the contents of the shelter to verify that nothing is touching the cover that could cause damage. Check the anchoring system to ensure that all components are tight and in good repair. If the shelter is moved, inspect all parts and connections before reassembling. Never leave the end panel unzipped and in the down position. Always roll end panel to the open position and secure using straps and D-rings. For replacement or missing parts, call 1-800-245-9881 for assistance. Space below is reserved for customer notes. NOTE: With the exception of Truss Arch buildings, ClearSpan shelters and greenhouses do not have any tested loading criteria. 15
8'-4" Height Quick Start Guide 14' Wide Calf Hutch 4'-0" Sidewall Height 14'-6 1/4" Width FRONT Grid Represents 12" Squares Actual frame may differ in length from frame shown. 16
166P048 166P096 FRONT PROFILE Ends: 102193 Middle: 102194 166P096 166P048 17
166P034 3'-0" On-Center Rafter Spacing SIDE PROFILE - 102852 12'-0" Length Center-to-Center 18
166P034 3'-0" On-Center Rafter Spacing SIDE PROFILE - 102853 18'-0" Length Center-to-Center 19
166P034 3'-0" On-Center Rafter Spacing SIDE PROFILE - 102854 24'-0" Length Center-to-Center 20
CONNECTIONS Mid Rafter- Purlin Connection View 2 End Rafter- Purlin Connection View 1 21
Rafter 102193 View 1 End Rafter- Purlin Connection CONNECTION DETAILS Purlin Purlin 102194 Rafter Leg View 2 Mid Rafter- Purlin Connection 22
Space below is reserved for customer notes. 23