Enclosure 1 - 60x60x28 Assembly Instructions.pdf

3255 North US 19 Perry, Florida 32347

1-800-277-8677 1-850-584-7786

FAX 011-850-584-7713

www.bigtopshelters.com sales@bigtopshelters.com

Project:

MCAS Japan 60x60x28

Fully read and understand all instructions before assembly http://www.bigtopshelters.com/ mailto:sales@bigtopshelters.com

Extreme Caution: Use extreme caution during the first phase of the installation of your framing system. The framing system is not capable of resisting high winds until the cross bracing, cable bracing, and anchoring are installed. Make sure that you tether/secure all framing with secure cables, straps, and/or ropes until the system has the required amount of support to be “free standing”. *Our “rule of thumb” is: At a minimum, the length of the structure must exceed the total height of the structure, including all cross braces, cable braces, and anchors (in that section) prior to releasing the tether cables, straps or ropes. It is a good practice, to make sure all components for the entire frame system are installed and are completely secure, prior to release from the tether. Pre-plan your installation for periods of low wind/snow exposure. Before you begin standing the framing, make sure you have ample time to complete these minimum tasks in order to leave the site with a secure frame. If you have any questions, about tethering of your frame, please do not hesitate to contact us for further detail. Your safety and the safety of your crew are paramount to our company.

Installation Guide line Sequence:

*Square the site to match building size –Set string lines, paint, Chalk, etc. to mark building lay out.

1. Assemble trusses and build components (x-braces and cover attachments)

2. Stand first truss using equipment capable of picking truss without bending the truss

3. Using a set of roof cable supplied by BTM in hardware package tether first truss forward and aft to stabilize.

4. Anchor first truss

5. Repeat step #2 and then place cover attachment at correct location with attachment angles. Also install all x-bracing to stabilize second truss. Repeat step #4.

6. Repeat steps #5 until you have enough trusses stood and anchored to install first set of side cable bracing. Now install first set of side cables to the correct attachment locations.

Do not remove the tether cable i.e. Step #3, Until all Side cables and one set of

Roof cables have been permanently

Installed to anchored frame.

7. Continue Step #5 until all trusses are stood, stabilized with bracing and trusses are anchored.

8. Add all cable bracing and ridge pole.

Caution:

Squaring the shelter You will need to mark out your shelter by using any means necessary, paint chalk, etc.

Mark the bases of every truss, even marking out the whole square if you’d like. This will help you keep you cover attachments straight while installing them on the base of each truss.

Be sure all placed marks are square.

Square the shelter by making sure that the shelters width is 60’ and the cross dimensions from front left corner to the back right corner is the same, as the front right to the back left dimension. Anchoring types change with the site.

Extreme Caution: Use extreme caution during the first phase of the installation of your framing system. The framing system is not capable of resisting high winds until the cross bracing, cable bracing, and anchoring are installed. Make sure that you tether/secure all framing with secure cables, straps, and/or ropes until the system has the required amount of support to be “free standing”. *Our “rule of thumb” is: At a minimum, the length of the structure must exceed the total height of the structure, including all cross braces, cable braces, and anchors (in that section) prior to releasing the tether cables, straps or ropes. It is a good practice, to make sure all components for the entire frame system are installed and are completely secure, prior to release from the tether. Pre-plan your installation for periods of low wind/snow exposure. Before you begin standing the framing, make sure you have ample time to complete these minimum tasks in order to leave the site with a secure frame. If you have any questions, about tethering of your frame, please do not hesitate to contact us for further detail. Your safety and the safety of your crew are paramount to our company.

Pre-Assembly of X-braces Pre-assemble all X- braces as shown in picture below before standing any trusses.

Pre-Assembly of Arches Each (Standard) Main Support truss has 4 components which consist of 2 roof arch bows, and 2 upright columns. The pre-assembly of trusses should be completed first. Use 5/8” x 2 1/4” A-325 structural bolts. There are a total of (7) each trusses set 10ft on centers to achieve the 60’overall length.

Prepare to Raise the Trusses

Start by connecting and standing truss #1 at the first layout mark. Find the 4ea 1/4” cables with your kit. These cables will be used to stabilize the 1st truss when it is released from the lifting equipment. (These cables are only temporary) Wrap one end of the cable around the inside chord of the truss and use 3 ea 1/4” cable clamps to secure each cable. They are positioned approximately 10’-0” each side of the centerline of the truss. There will be 4 each cables to stabilize the truss when this step is complete.

After lifting truss # 2, install (8ea. rows) x-braces. Once the truss is anchored to the foundation you can remove the rigging on the truss. Repeat this process until all (48) main arches are complete. See diagram below for truss components.

There are 48ea total sets of x-braces with ½” x 2” A 325 connection bolts.

Cable Bracing Installation Purpose of cable bracing:

1. To provide wind bracing in the lateral direction of the Structure.

2. To “Square up” the end of the structure. (i.e. perpendicular to the ground slope.)

To begin the installation, the cable bracing must be rigged with hardware properly to function per specification.

Cable bracing components Wire rope ¼” diameter Wire rope ¼” diameter Cable clamps Turn buckles. ½” x 6” 2”x5” cable tabs

Pre-assemble the turnbuckles on one end of each remaining wire rope cables. Loosen the nuts on (2) cable clamps and slide them onto one end of the cable. Then, proceed to loop the end of the cable through the loop on the turnbuckle. Once it is through the loop in the turnbuckle, send the end of the cable through the two cable clamps. Make sure that the “saddle is on the live horse”, the pulling cable, not the tail. The cable clamp has three components, a U-bolt, a saddle, and nuts. The saddle should always be positioned on the tension cable, not the loose end. Tighten the nuts securely alternating back & forth from nut to nut. The opposite end of the cable should wrap the truss tightly and secure with 2ea. cable clamps. Be sure to add the cable thimble wherever any cable makes a loop.

Cable Bracing Position

The cables form side x-bracing for the columns or sidewalls of the structure. They are attached at the inside chord above x-brace tab on the high side of the cable. On the low side of the cable, they are attached to the base of the upright section. The turnbuckle is attached at the base of the truss using a 2”x5” cable tab that bolts the baserail and base of the upright together. See cable diagram for placement details. The cables form roof x-bracing. The turnbuckle can be placed on either side of the structure. The loose end of the cable is looped around the inside chord of the truss at the same x-brace connection tab as the cable except it attaches below the tab.

Cables The shelter has cable bracing to increase rigidity and wind loading. The cable runs through the frame rather than inside the structure.

The above picture is somewhat different. The cable tabs will bolt to the connection at the base. The cable runs through the frame rather than inside the structure. Run the roof cables through the frame and back.

Installing the Main Cover Pre-cut 6ea 2” x 90ft straps. Throw these straps over the structure in each bay. You can actively throw over one strap and pull the others over with it. Be careful not to entangle the straps if you choose this method.

Unroll the cover down one side of the structure. Familiarize yourself with the cover’s interior and exterior. Make sure that you position the cover so that once pulled the interior will be on the inside of the shelter. The cover is folded in an accordion or layered format. This enables you to pull the leading edge up and over the frame. From one side the top fold and bottom fold of the stack will contain a pre-welded pocket. This pocket has several cut outs on a pre-determined pattern. This pattern corresponds with the key hole slots on the on the 2” x 3” cover attachments, and the holes in the cover tensioning tubes.

Before you pull the cover over the frame, first insert the cover tensioning tubes into the leading edge and trailing edge of the cover. First insert the tubes into the trailing edge by turning over the layers or folds to expose the trailing edge. Insert the tubes into the pocket.

Now fold it back up inserting the tubes into the leading edge. After all tension tubes have been installed in the cover insert the 18” long carriage bolts into the keyhole slots on the cover attachments at the ground level. Push the pocket onto the carriage bolts and secure with the washers and nuts provided. Tighten the nuts about halfway down the carriage bolts.

Pulling the cover can be very easy or disastrous.

RULES: (1) Always pull with the wind, NEVER against the wind.

(2) NEVER attempt in winds exceeding 15N.

(3) Pull Slowly

(4) Watch for snags and stop if you see something bind.

(5) Assign personnel specific tasks and make sure that everyone knows the hand signs.

Begin to move forward with the equipment until the leading edge begins to rise. STOP!

Make sure all straps are tight and the cover is raising level. Tag lines can be attached to each side of the cover to control the overlap.

Pull the cover over the frame until the center of the cover, which is marked with duct tape, is at the center of the frame. STOP! Back up the equipment and disconnect.

Attach the leading edge cover tensioning tubes to the 18” carriage bolts. Torque the nuts with the ½” impact and a 7/8” all thread tool.

Flop the ends of the cover over the end of the frame and attach the cables to the cover winches at all 4 corners. These should have already been installed when installing cover attachments. Use dish soap to lubricate each end of the cover so that it will slide over the frame easily. This will save time and effort in addition to giving you a much nicer finish.

Continue by tensioning the cover equally front and back. Tension the cover with a 1-1/8” socket on all four cover winches. Stop when the overlap flap is over the truss enough to hold the cover because you will have to lace the end lacing. Repeat on back of shelter. Next lace the grommet on the inside ends of the cover to the outside chord using the 1” black webbing.

Lacing consist of running the webbing through the eye hole under the chord then around and over the chord and then back through the next grommet or eye and continue on and on, you can start in center and work your way down one side of the shelter then go back to center and do the other half. Sometimes it is best to cut a 20’ section of webbing and tie one end off and lace until gone then tie the other end off and repeat until all grommets have been laced.

Your shelter is a 1 piece cover. Where each shelter adjoins to the next, install ratchets at junction by drilling holes in the 2” x 3”, 10” and 10” off the junction. Drill the holes in the 2” x 3” using the same hole pattern that’s in the back of the ratchet. The weather seal cable will then be installed in these ratchets.

Junction between the covers with the weather seal in place.

Shelter Cover

Shelter Cover

When the covers are on, laced and tensioned move the lifts to the junction and pull the weather seal to cover the gap. Run the cable through the cover just below the pocket seal being sure that the cable is pulling the flap away from the gap. Put the cable in the ratchet and tighten the cable until the fabrics interfere with each other causing the seal.

Shelter Cover

Weather Seal

Shelter Cover

Installing the Main Cover