Duratuf PG99 User manual

ASSEMBLY INSTRUCTIONS

PG99

BASE SIZE: 3.020m x 3.020m

CHECK OUT OUR ASSEMBLY VIDEO

BEFORE YOU START:

• Read all instructions carefully

• Identify all parts and check quantities against parts list

• Select a level site

• Do not mark cladding with pencil as lead can cause corrosion to cladding

• During assembly, ensure all drill filings are removed between layers of steel, before riveting together

SAFETY:

• Do not attempt to build your shed in high winds

• Beware of sharp edges, we recommend that you use gloves

• Protect your eyes and ears

• For ease of assembly, use a friend to help

TOOLS REQUIRED:

WARRANTY REQUIREMENTS:

The following maintenance process needs to be adhered to, to qualify for the steel warranty of your Duratuf Garrison

shed.

• Wash all surfaces annually using a hose and soft nylon brush.

• Within 2 km of coast – wash every 3 months as above. After a storm, wash the cladding and the gutters as soon

as possible to remove any highly corrosive salt deposits.

• Volcanic Ash Fallout – wash as soon as possible, removing fall out from roof and gutters.

• Do not allow manures, chemicals or other corrosive materials to have direct contact with cladding.

CONGRATULATIONS ON PURCHASING A DURATUF GARRISON SHED.

BEFORE YOU BEGIN THE ASSEMBLY PLEASE NOTE SOME IMPORTANT POINTS

DRILL RIVETER 3.5mm DRILL BIT

HAMMER

LADDER

TAPE MEASURE HEX DRIVENAIL PUNCH

SQUARE DRILL BIT

SKILL SAW

(timber floor only)

PG99 PARTS LIST

DESCRIPTION QTY DIAGRAM CHECKED

Front & Back Wall - 1.890m 9

Side Wall Angle- 1.920m 4

Side Wall Angle- 1.980m 4

Side Wall Angle - 2.040m 4

Roof - 1.600m 12

Door Sheet Narrow -1.850m 3

Door Sides - 1.850m 4

Door Jamb - 1.890m 2

Door Brace - 1.160m 2

Door Brace - 0.915m 2

Double Door Weatherstrip - 1.850m 1

Barge - 1.602m 4

Ridge Cap - 1.800m 2

Door Top/Bottom - 0.945m 2

Door Top/Bottom - 0.495m 2

Hardware Pack 1

Touchup Paint & Brush 1

Checked: Date:

CLADDING + FLASHING + HARDWARE PACK 1

PG99 PARTS LIST

TIMBER PACK CHECK LIST INCLUDED IN PACK 2

DESCRIPTION QTY DIAGRAM

Front/Back Bottom Plates - H4 (Green)

3.020 m 2

Front & Back Top Plate - H1 (Red)

3.020 m 2

Side Wall Bottom Plates - H4 (Green)

3.020 m 2

Side Wall Top Plates - H1 (Red)

3.020 m 2

Ridge Beam - 140 x 45

3.020m 1

Jack Studs - 45 x 45

0.200m 2

Spouting - 3.055m 2

PARTS LOCATION

ASSEMBLE FRONT

PANEL

ASSEMBLE WALLS

ASSEMBLE ROOF

SECURE SHED

ASSEMBLE BACK

PANEL

ASSEMBLE SIDE

PANELS

LAY FOUNDATION

ASSEMBLE DOOR

QUICK OVERVIEW

Door Sheets

Padbolt Support

Top Plate Back

Side Wall Sheets

Roof Sheets

Top Plate Side

Top Plate Front

Bottom Plate Front

Bottom Plate Side

Back Wall Sheets

Front Wall Sheets

Door Jambs

Front Wall Sheet Door Side Flashing

Hinge

Door Top/Bottom Flashing

Ridge Beam

Jack Stud

Ridge Flashings—x 2

Barge

Spouting

Door Brace

FOUNDATION

GARRISON WOODEN FLOOR

• The optional Garrison kitset wooden floor boards are cut to

length and designed to be fitted into the shed after the shed is

assembled.

• Assemble shed as per instructions and fit floor last.

(see page 14 for details).

CONCRETE SLAB FOR RAISED BASE PLATE SHED

To build a raised concrete slab for your shed to sit on, we recom-

mend the following:

• The raised slab size should be 15mm smaller than the base

size of the shed and at least 30mm above ground line.

• The slab should be 80mm thick in the middle and 100mm

thick around the edges.

• The slab should be laid on a solid or compacted base.

• Plastic sheeting under slab will prevent moisture coming

through from underneath.

• During construction, you may raise the bottom timber

plate to allow the wall cladding to protrude 20mm below

the bottom plate. This will stop water flowing between

the bottom plate and the concrete floor.

See note on page 8.

80mm

100mm

7.5mm

20mm

Concrete Floor

Base Plate

Wall Cladding

RAISED BASE PLATE OPTION

(For sheds placed on a raised concrete floor)

No doubt by now you will have decided what sort of base you are putting down.

Please read the section that applies to your situation.

If you choose to pour a concrete base you will need to decide whether you wish to raise the base plate of your shed.

This allows the cladding to protrude below the surface of the concrete and ensures a water tight pad.

See concrete pad specifications below.

By choosing this option you will need to make the concrete pad to the specification below.

fig.2

ASSEMBLE DOOR

SMALL DOOR:

• Assemble small door in same way as large door using 0.495 m top and bottom flashings.

• Before screwing on 0.915m door braces, attach weather strip flashing to back of door side flashing using six rivets

ensuring it protrudes 20mm out from door side.

SELECT:

3 x 1.850 m Door Sheets (Narrow)

2 x 0.945 m Door Top/Bottom Flashings

2 x 0.495 m Door Top/Bottom Flashings

4 x 1.850 m Door Side Flashings

6 x Hinges

1 x Padbolt Support Flashing

2 x 1.160 m Door Brace Flashings

2 x 0.915 m Door Brace Flashings

1 x 1.850m Weatherstrip Flashing

108 x Rivets

STEP 1:

• Lay out 2 x door sheets on a flat surface

making sure narrow pans are on the outside.

• Rivet sheets together ensuring ends are

flush with each other.

STEP 2:

• Position door side flashings and 0.945m top

and bottom flashings and assemble door as

shown, ensuring narrow face of flashing is on

the front as per fig. 1

• Drill and rivet as per diagram.

STEP 4:

• On the back of the door, place door braces in posi-

tion as shown in fig.4.

• Ensure that the top and bottom ends of the braces

are under the door flashings as shown in fig.5 and

opposite ends of the braces overlap in the middle.

• Rivet door brace flashings onto back of door as

shown. Where possible, rivet from front of door.

STEP 3:

• Attach hinges to door side flashing using rivets provided.

Ensure hinge is flush with back of door, and 60mm in from

each end as per fig.2.

• Using six rivets, attach padbolt support as shown in fig. 3

NARROW PANS

fig.4

fig.5

Hinges

fig.3

fig. 1

ASSEMBLE SIDE PANELS

SELECT:

4 x 1.920 m Gable Wall Sheets (Angled)

4 x 1.980 m Gable Wall Sheets (Angled)

4 x 2.040 m Gable Wall Sheets (Angled)

2 x 3.020 m Top Plates (Red)

2 x 3.020 m Bottom Plates (Green)

144 x 30mm Galv Clouts

20 x Rivets

STEP 1:

• Lay out 1 x Top plate and 1 x Bottom plate on a flat surface as shown

(corner cut-outs to face outwards). Measurements between Top and

Bottom plates are critical to ensure wall panels fit together.

STEP 2:

• Place 2 x 1.920 m wall sheets, 2 x 1.980 m wall sheets and 2 x

2.040m wall sheet on top of timber plates with bottom of sheets

flush with each other.

• Rivet sheets together on overlaps as shown.

STEP 3:

• Nail wall sheets to the Top Plate at each end making

sure that the top corners of the sheets are flush with

the top of the Top Plate and that the sides of the wall

sheet overhang the Top Plate by approx 15mm as

shown.

• Check that the Top Plate is straight then nail the

Wall sheet to the Top Plate, 2 clouts per pan.

(see fig. 1).

Standard Shed — Bottom Plate will protrude be-

low wall sheet by approximately 10mm.

Raised base plate shed — Wall sheet will protrude

below the Bottom Plate by 20mm.

STEP 4:

• Nail the wall sheets to the Bottom Plate at each end ensuring each side

of wall sheets overhangs the end of Bottom Plate by 15mm. Check that

the distance between the Top and Bottom Plates is correct. (As per

diagram in step 1)

• Check that the Bottom Plate is straight then nail the wall sheets to the

Bottom Plate, two clouts per pan (see fig.1).

fig.1

RIB

PAN

CLOUT

TIMBER PLATE

REPEAT THESE STEPS TO MAKE SECOND SIDE WALL PANEL

15mm

TOP PLATE

BOTTOM PLATE

RIVET

RIVET RIVET

TOP PLATE

15mm 15mm

BOTTOM PLATE

1850mm 1850mm

TOP PLATE

BOTTOM PLATE

15mm 15mm

1850mm

TOP PLATE

RIVET

RIVET RIVET

RIVET

IMPORTANT—IF YOU CHOOSE TO RAISE YOUR TIMBER

BASE PLATE –READ THE FOLLOWING;

For sheds with Raised Base Plate option only (see page 6), deduct

30mm from measurement shown between Top and Bottom Plates on

all wall panels, so cladding protrudes 20mm below bottom plate.

Ie. reduce 1850mm to 1820mm between Plates.

1850mm

ASSEMBLE BACK PANEL

SELECT:

6 x 1.890 m Wall Sheets

1 x 3.020 m Top Plate (Red)

1 x 3.020 m Bottom Plate (Green)

72 x 30mm Galv Clouts

10 x Rivets

STEP 1:

• Lay out 1 x Top Plate and 1 x Bottom Plate on a

flat surface as shown (corner cutouts to face in-

wards).

STEP 2:

• Place 6 x 1.890 m wall sheets on top of timber

Plates with bottom of sheets flush with each other.

• Rivet the sheets together on overlaps as shown.

STEP 3:

• Nail the wall sheets to the Top Plate at each end making sure

that the top of the sheets are flush with the top of the Top

Plate and that the sides of the wall sheets overhang the Top

Plate by 15mm as shown.

• Check that the Top Plate is straight then nail wall sheets to

the Top Plate, using two clouts per pan.

STEP 4:

• Nail the wall sheets to the Bottom Plate at each end,

ensuring that each side of the wall sheets overhangs the

Bottom Plate by 15mm and that the distance between

the Top and Bottom Plates is correct. (As shown)

• Check that the Bottom Plate is straight then nail

wall sheets to the Bottom Plate, using two clouts per pan.

Standard Shed — Bottom Plate will protrude below wall

sheet by approximately 10mm.

Raised base plate shed — Wall sheet will protrude below

the Bottom Plate by 20mm.

IMPORTANT—IF YOU CHOOSE TO RAISE YOUR TIMBER

BASE PLATE –READ THE FOLLOWING;

For sheds with Raised Base Plate option only (see page 6), deduct

30mm from measurement shown between Top and Bottom Plates on

all wall panels, so cladding protrudes 20mm below bottom plate.

TOP PLATE

BOTTOM PLATE

1854mm 1854mm

BOTTOM PLATE

TOP PLATE

15mm 15mm

1854mm 1854mm

BOTTOM PLATE

15mm 15mm

TOP PLATE

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