Duratuf KAIPARA User manual

ASSEMBLY INSTRUCTIONS
BASE SIZE: 3.900m x 2.550m
KAIPARA

BEFORE YOU BEGIN THE ASSEMBLY PLEASE NOTE
SOME IMPORTANT POINTS
TOOLS REQUIRED
• Drill
• Hex Drive (5/16)
• Hex Drive (3/8)
• Drill Bit 3.5mm
• Drill Bit 10mm
• Square Drive Drill Bit
• Phillips Drill Bit
• Slotted Drill Bit
• Riveter
• Hammer
• Tape Measure
• Ladder
• String Line
• Adjustable Spanner
• Level
• Hand Saw
• Caulking Gun
• Tin Snips (Left & Right Hand)
• Flatle(ForRollerDoor)
• Pipe Wrench (For Roller Door)
• SkillsawandJigsaw(Foroptionaltimberoor)
• MasonryDrilland12mmMasonryBit(forconcreteoor)
BEFORE YOU START
• Read all instructions carefully.
• Identify all parts and check quantities against checklist, before starting.
SAFETY
• Do not attempt to build your shed in high winds.
• Beware of sharp edges.
• Protect your eyes and ears.
• Use electronic tools with care. Use a Safety Trip Switch.
• It is easier and quicker if this shed is erected by two people.
SELECT YOUR SITE
• Your shed must be level. Achieve this by either levelling the ground or by using blocks.
• Ifyourshedistobepositionedonwetordampground,werecommendthatyourshedisraisedupo󰀨the
ground slightly.
WARRANTY REQUIREMENTS
The following maintenance process needs to be adhered to, to qualify for the steel warranty of your Duratuf
Guardian 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.
2

33
3
PARTS LIST
TIMBER
DESCRIPTION LENGTH QTY DIAGRAM CHECKED
Front/Back Base Plate 70 x 45 H4 (Green) 3.900m 2
End Base Plate 70 x45 H4 (Green) 2.410m 2
Front/Back Top Plate 70 x 45 H1 (Red) 3.900m 2
EndTop Plate 70 x 45 H1 (Red) 2.410m 2
Lintel 70 x 45 2.400m 1
Stud 70 x 45 (Yellow) 2.295m 10
Stud 70 x 45 (Yellow) 2.440m 6
Stud 70 x 45 (Yellow) 0.320m 3
Nog 70 x 45 1.240m 3
Nog 70 x 45 1.137 4
Nog 70 x 45 0.615m 2
Ridge Beam 140 x 45 H1 with 67mm notch 3.900m 1
DESCRIPTION LENGTH QTY DIAGRAM CHECKED
Back Wall Sheet 3.900m 3
End Wall Sheet 2.550m 6
Roof Sheet 3.150m 5
Front Wall Sheet 0.750m 6
Half Front Wall Sheet (390mm wide) 3.900m 1
Roller Door 2.400m 1
CLADDING/FLASHING

44
DESCRIPTION LENGTH QTY PART# DIAGRAM CHECKED
Front Top Plate Flashing 3.900m 1 1001
Front Corner Flashing 2.540m 2 1002
Rear Corner Flashing 2.400m 2 1003
Door Top Flashing 2.590m 1 1004
Door Head Flashing 2.400m 1 1005
Door Jamb Flashing 2.105m 2 1006
Downpipe Cover Flashing 2.200m 1 1007
Barge Flashing 3.225m 2 1008
Front Spouting 4.005m 1 1009
Back Spouting 4.005m 1 1010
Spouting End Cap 0.120m 2 1011
4
HARDWARE/ACCESSORIES
DESCRIPTION LENGTH QTY DIAGRAM CHECKED
L-Brackets 40mm 2
Flathead Nails 90mm 160
Tek Screws 55mm 110
Tek Screws 25mm 220
Clouts 30mm 130
Tek Screws 100mm 16
Rivets 3.2mm 80
Dropper 80mm 1
Downpipe 80mm 3.000m 1
Downpipe Brackets 2
Silicone 1
Roll of DPC 30m 1
Touch up paint and brush 1

55
DATE: / / PACKED BY:
5
TIMBER FLOOR
DESCRIPTION LENGTH QTY DIAGRAM CHECKED
Floor Joists 100 x 50 H4 3.880m 6
Floor Boards 150 x 25 H3 2.530m 26
Door Step Flashing 2.400m 1
Floor Nails 50mm 330
OPTIONAL EXTRAS
CLEAR ROOF
DESCRIPTION LENGTH QTY DIAGRAM CHECKED
Clear Roof Panel 3.150m 1
PLY FLOOR
DESCRIPTION LENGTH QTY DIAGRAM CHECKED
Plywood 17mm treated 1.940m x 1.200m 4
Plywood 17mm treated 1.940m x 0.130m 2
Joists 70 x 45 H4 3.790m 6
Joists 70 x 45 H4 2.530m 2
Joists 70 x 45 H4 0.532m 1
Joists 70 x 45 H4 0.555m 3
Joists 70 x 45 H4 0.063m 1
Door Step Flashing 2.400m 1
Floor Screws 40mm 120
Floor Screws 75mm 100

66
6
FOUNDATIONS
• No doubt by now you will have decided what sort of base you are
putting down.
• If you choose a raised foundation, either a concrete base, plywood
oor,ortimberoor,thesheddesignpreventsthewaterfrom
owinginsidetheshed.
• If you chose to position the shed directly onto the ground, the
watercanowdownthewallsandunderthebottomplateandinto
the shed.
CONCRETE BASE
• To build a concrete base we recommend the following.
• Concrete base should be 3880mm x 2530mm (this is
20mm smaller than the shed frame size, which allows
for a 10mm gap around the perimeter of the shed).
• Concrete base to be a minimum of 80mm thick and at least 100mm thick around the perimeter. Base should
be at least 50mm above ground line.
• Concrete base should be laid on a solid or compacted base.
• Plastic sheeting underneath concrete will prevent moisture coming through underneath.
• Ideallytheareaaroundthedoorwayshouldhaveaslightslopetoallowwatertoruno󰀨.Refertoplansfor
doorway position.
10mm
100mm
80mm

77
PLYWOOD FLOOR
Select
6 x 3790mm Joists
2 x 2530mm Joists
1 x 532mm Joists
1 x 63mm Joists
3 x 555mm Joists
4 x Ply 1945mm x 1200mm
2 x Ply 1945mm x 130mm
• Layoutoorjoistsandassemblesuboor
frame as shown, nailing joists together
with two 90mm nails per join.
7
SUB FLOOR FRAME
• Positionsuboorframeensuring
frame is well supported, level and
diagonals are correct.
• Using 40mm screws, screw plywood
tosuboorframeasshown.
• Ensuretimberoorissu󰀩ciently
secured down to foundation.
PLYWOOD SHOWING SCREWS Screws
1200mm1200mm
Screws
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1945mm
1945mm
130mm
C
L
130mm
130mm
3790mm
532mm
555mm
555mm
555mm
2530mm
63mm
1895mm 1895mm
C
L

88
TIMBER FLOOR
8
Select
6 x 3880mm Joists
26 x 2530mm Floor boards
• Layoutoorjoistsasshown,ensuring
joists are spaced evenly apart.
• Using50mmooringnails,nailaoor
board on each end, ensuring ends are
ushwithjoists.Makesureoorislevel
and joists are well supported.
SUB FLOOR FRAME
• Layoutremainingoorboards.
• Measure diagonals to ensure
measurementsareequalandooris
sqare.
• Ripdownlastoorboardtosuitgap
andnailo󰀨oorwith50mmooring
nails (12 nails per board).
• Ensuretimberoorissu󰀩ciently
secured down to foundation.
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3880mm
2530mm
TIMBER SHOWING NAILS
2530mm
Nails
..........................................
..........................................
..........................................
..........................................
..........................................
3880mm
..........................................

99
9
TIMBER FRAME
2385
A
A
B
End Base Plates - 2
C
BFront/Back Base Plates - 2
CEnd Top plates - 2
DFront/Back Top Plates - 2
EStuds - 19
FRidge beam - 1
GNogs - 9
D
E
F
G
HLintel - 1
H
3900
2550
TIMBER FRAME - END WALLS
Select
2 x 2410mm Base Plates
2 x 2410mm Top Plates
6 x 2295mm Studs
4 x 1137mm Nogs
• Select one 2410mm base plate
(Green), one 2410mm top plate
(Red) and three studs (Yellow).
• Lay out plates and three studs
onaatsurfaceandnail
together using two 90mm nails
per join. Studs are positioned
1137mm apart.
• Position nogs 1200mm up from
underside of bottom plate to
centre of nog and nail in place.
• Repeat with second end wall
frame.
9
45 45 45
45 45 45
11081132
2375
1137
2410
1137
TIMBER SHOWING NAILS

1010
TIMBER FRAME - BACK WALL
10
TIMBER FRAME - FRONT WALL
• Nail lintel to studs using the 320mm studs to establish correct height.
• Nail 320mm studs to top plate and lintel, spacing these evenly apart.
Select
1 x 3900mm Base Plate
1 x 3900mm Top Plate
1 x 2400mm Lintel
6 x 2440mm Studs
3 x 320mm Studs
2 x 615mm Nogs
• Select one 3900mm base plate
(Green), one 3900mm top plate
(Red) and four studs (Yellow). Lay
outplatesandtwostudsonaat
surface and nail together using two
90mm nails per join.
• Nail one stud each side of doorway
to top and bottom using the 615mm
nogs to establish correct position.
• Nail remaining two studs to inside
of studs and top and bottom plates
to make a double stud each side of
doorway opening.
320
2110
615
3900
2530
2400
615 90
45 90
45
45 45
45
1132 1263
Select
1 x 3900mm Base Plate
1 x 3900mm Top Plate
4 x 2295mm Studs
3 x 1240mm Nogs
• Select one 3900mm base plate
(Green), one 3900mm top plate
(Red) and four studs (Yellow).
• Lay out plates and four studs on a
atsurfaceandnailtogetherusing
two 90mm nails per join. Studs are
positioned 1240mm apart.
• Position nogs 1200mm up from
underside of bottom plate to centre
of nog and nail in place. 45 45 45
45
45 45 45
1118
1132 2385
1240
3900
1240
1240

1111
11
TIMBER FRAME - ASSEMBLE FRAME
• Stand up back wall frame and one end wall frame.
• Using a 10mm drill, predrill and screw both frames
together using four 100mm tek screws per corner.
(100mm down from top and 100mm up from base
and remaining screws evenly spaced in between.)
• Ensureendwallpanelstinbetweenfrontandback
frames.
• Repeat with remaining frames untill all frames are
screwed together.
• Position ridge beam onto top plates, ensuring it is
directly above studs.
• Using two 90mm nails, skew nails to top plate.
• Using four 55mm tek screws, screw bracket to
underside of ridge beam and studs as shown.
• Position frame onto base (either concrete,plywood or
timberoor).
• Ensure frame is straight and check that frame is
square by ensuring diagonal measurements are the
same.
• Screwbaseplatetooorusing100mmtekscrewsor
100mm dyna bolts as shown.
• Using a hand saw, remove base plate between door
studsbycuttingushwithinsideofdoorstudsas
shown.
• (Note - you may choose to leave base plate attached,
ifyoursheddoesnothaveaoor).
• Ifyourshedhasanoptionaltimberorplyoor,attach
doorstepashingnow.Predrillandnailthroughtop
ofashing,usingthree50mmooringnails
SECURE FRAME TO FLOOR
CUT
CUT
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....
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Tek screw/Dynabolts
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1212
12
• AnyshedthathasaoorshouldhavetheDPCattachedto
preventwaterowingbetweenbottomplateandoor.
• Using approx forty 30mm clouts, nail DPC to bottom plate
ensuringtopisushwithtopofbaseplate.
• Noteifthesheddoesnthaveaoor,andispositioneddirectly
on the ground, you wont need to attached DPC on the base
plate.
• Using ten 30mm clouts, attach 75mm wide DPC membrane
to each corner as shown. DPC should be level with top of top
plate and botom of base plate.
• Repeat above, attaching DPC to door studs with the Top of
DPC level with underside of lintel.
• Usingsix30mmclouts,naildoorheadashingtounderside
and outside of lintel as shown.
BOTTOM PLATE
DPC
WALL CLADDING
DPC
LINTEL
OUTSIDE INSIDE
ATTACHING DPC TO FRAME
CLOUT
ATTACHING DOOR HEAD FLASHING

1313
13
WALL CLADDING
TO AVOID CORROSION:
• Where at all possible try not to trap metal
lingsbetweentwosheets.Removeallmetal
lingsbeforeriveting.
• Carbon in pencils reacts with the Zinc/
Aluminium coating on steel. Use ink to mark
steel.
CLADDING DETAIL
Side View
CLADDING DETAIL
Overlap
WALL CLADDING FIXING PATTERN
TEK SCREWS
WALL CLADDING FIXING PATTERN
TEK SCREWS

1414
14
WALL CLADDING - BACK & ENDS
• Note - When attaching wall cladding always ensure
top sheet is level with top plate and ends of sheet
areushandparallelwithstuds.Thiswillensurethat
wall panels are square. (Always screw wall sheets
throughthetroughoftheprole)
• Position1stsheetushwithtopoftopplateandboth
endsofsheetareushwithoutsideofstuds.
• Using a 25mm tek screw, screw one end of sheet to
frame. (Note - screw approx 30mm back from end
ofsheet.Cornerashingwillcoverscrewswhen
attached.)
• Repeatattheotherend,ensuringtopofsheetisush
with top of top plate.
• Screw sheet near the bottom, ensuring the ends of
sheetareushorparallelwithstud.
• Position2ndsheetunderneaththerstsheet,
repeat above. Make sure the above sheet is always
overlapped correctly.
• Using four 25mm tek screws, repeat above steps
ensuringsheetislevelandushateachend.
• Position and screw bottom sheet using four 25mm tek
screws.
• Using 25mm tek screws in the middle of the sheet,
screwthethreewallsheetso󰀨asperplan.(ve
screws per end of each sheet and two in the middle).
• Repeat above steps with each side wall.
WALL CLADDING - FRONT
• Position and screw sheet above doorway ensuring
sheetisushwithtopoftopplateandbothends
ofsheetareushwithoutsideofstuds.(Usethree
screws in each end and three screws along top plate
and one in each 320mm stud)
• Fit remaining sheets each side of doorway and screw
o󰀨asabove.
• Note - When attaching wall cladding always ensure
areushandparallelwithstuds.Thiswillensurethat
• Position1stsheetushwithtopoftopplateandboth
• Using a 25mm tek screw, screw one end of sheet to
• Screw sheet near the bottom, ensuring the ends of
repeat above. Make sure the above sheet is always
• Using four 25mm tek screws, repeat above steps
ofsheet.Cornerashingwillcoverscrewswhen
• Repeatattheotherend,ensuringtopofsheetisush

1515
15
FLASHINGS
FLASHINGS
• Centralisefronttopplateashingontopoftopplate
andattachashingwithfour30mmcloutstotop
plate.
• Screwcornerashingsontoeachcorner,usingsix
55mm tek screws per corner. Top screws should be
approx 250mm down from top of top plate.
• Ensurecornerashingsaresquareandparallelwith
wallspanels.andtopofashingsarelevelwithtopof
top plate.
• Positiondoorjambashing,sotopislevelwith
underside of lintel.
• Usingtinsnips,knotchbottomofashingaround
concreteorplyoorifrequired.
• Attach using three 30mm clouts, nailed to inside of
stud and three 55mm tek screws, screwed through
front wall cladding into stud.
• Positiondoortopashingintoposition.(Noteashing
length will protrude approx 10mm past outside edge
ofeachdoorjambashing).
• Using three 55mm tek screws,(one each end and one
inmiddle)screwashingtolintel.
• Centralisefronttopplateashingontopoftopplate

1616
16
BACK SPOUTING
• Usingsixrivetsperend,tandrivetendcapstoeach
end of back spouting.
• Determine position of downpipe and cut hole in
underside of spouting. (Note - hole needs to be at
least 300mm or more from end of spouting, and
slightly smaller than plastic dropper supplied.)
• Using four rivets, rivet plastic dropper to underside of
spouting.
• Silicone both end caps and plastic dropper to back
spouting to ensure there are no leaks.
• Nail assembled spouting to top of back top plate,
using four 30mm clouts as shown. (Note - spouting
willoverhangcornerashingbyapprox20mm.)
• Attach plastic downpipe to shed, riveting the two
brackets to rear wall cladding. (Note - downpipe may
have to be cut down in length.)
• Rivet downpipe to plastic dropper, using one rivet.
• Positiondownpipecoverashingoverdownpipeand
rivet to wall cladding.

1717
17
ROOF
• If an optional clear roof sheet has been supplied, this
canbettedinanyofthemiddlepositions.(Note
- both edges of clear roof sheet overlap standard
sheets at each side.)
• Positionrstroofsheetintopositionensuringsheet
will correctly overlap the next sheet. Edge of sheet
willbeushwithoutsideedgeoftimberframe.
• Positionsheet500mmpastfronttopplateashingso
that sheet overlaps rear spouting as shown.
• Using one 55mm tek screw, screw roof sheet to front
topplate.Ensureroongscrewisscrewedthrough
thetopofthecrestoncorrugateprole.(Seeroof
xingpatternbelow)
• Repeat using one 55mm tek screw, screw roof sheet
to back top plate through rib of corrugate, ensuring
sheetisushwithtimberframe.
• Check that top plates and ridge beam are straight,
before screwing remaining sheets.
• Position remaining sheets, using just two screws per
sheet, until all sheets are in place.
• Screwo󰀨allsheetsasshown,using4screwsper
sheet per top plate/ridge beam.
ROOF FIXING PATTERN
ROOF SHEET
• If an optional clear roof sheet has been supplied, this
canbettedinanyofthemiddlepositions.(Note
- both edges of clear roof sheet overlap standard
• Positionrstroofsheetintopositionensuringsheet
will correctly overlap the next sheet. Edge of sheet
willbeushwithoutsideedgeoftimberframe.
ROOF SHEET
• Repeat using one 55mm tek screw, screw roof sheet
to back top plate through rib of corrugate, ensuring
• Check that top plates and ridge beam are straight,
• Position remaining sheets, using just two screws per
• Screwo󰀨allsheetsasshown,using4screwsper

1818
18
SPOUTING & BARGE
• Position front spouting onto front of
roof sheets.
• Using 15 rivets (3 per sheet), rivet
spouting to the ribs on roof sheets.
• Usingtinsnips,trim25mmo󰀨bottom
fold from front spouting to allow barge
totintofrontspouting.
 Usingtinsnips,trim100mmo󰀨bottom
fold at the rear of both barges, to allow
bargetotintorearspouting.Itis
easier to temporary position barge and
mark barge before cutting.
• Position barges as shown, riveting top
of barge to front and back spouting.
• Rivet underside of barge to underside
of front spouting and back spouting.
• Rivet top of barge to roof sheets, using
6 rivets per barge.
25mm
TRIM

1919
19
ROLLER DOOR
BEFORE YOU BEGIN
• ThisRoll-A-Doorisdesignedandtestedtoprovidesecurity,attractiveappearanceandsmooth,lowe󰀨ort
operation provided it is installed and operated in strict accordance with the following safety warnings.
Failure to comply with the following instructions may result in death, serious personal injury or property
damage.
• NOTE: Do not unwrap packaging around roller door until requested, as this will untension the door.
SERIES 1 ROLL-A-DOOR
DESCRIPTION ITEM QTY PACKED CHECKED
Rolled plastic wrapped door A 1
“A” Style brackets, left & right hand side B 2
Door guides, left & right hand side C 2
Steel locking bars D 2
SMALL PARTS BAG CONTAINING:
Guide clips (door size dependent) E 4-10
Doorhandleandxingtosuit F 1
Bottom rail stops and 6mm screws G 2
Faceplate and lock assembly (2 keys) H 1
Locking bar retainer I 2
Locking bar covers J 2
“U”Bolts K 2
Axel / bracket saddles L 2
8mm nuts for “U” bolts M 4
Counter sunk screws for lock and fascia N 2
7mm x 4mm mushroom head screws for locking bar O 2
4mm x 6mm screws for handle P 2
10mm washers Q 4
8mm washers (door size dependent) R 8-12
TOOLS
• A professional installers tool kit is required to install the
door. You will need assistance to help you lift the door up
safely and carry out some other steps. A Soft Wood Chock
willhelpholdthedooruntiltheguidesandstopsaretted.
Prepare a 400mm long Wood Chock as per diagram. Wood chock

2020
20
PARTS CHECKLIST
A
BN
D
E
F
G
H
I
J
K
L
O
M
R
Q
P
C
ROLLER DOOR
REQUIREMENTS BEFORE INSTALLATION
• Level and plumb - The door must be installed in an absolutely level position, if opening is not level and
square,appearanceand/orsideroomrequirementswillbea󰀨ected.Theoorshouldbelevelorrecessed
across the opening to avoid gaps.
MEASUREMENTS
• Opening width - As the standard door overlaps
each side by 30mm or more, the door should be
60mm wider than the 2400mm opening.
• Opening height - The door opening height (or
drive through clearance) indicates the distance
between the ground and rubber seal at the bottom
of the door, with door fully open. For doors with a
handle, the bottom rail is recommended to hang a
minimum of 80mm below the lintel.
HEADROOM
BACKROOM
OPENING
WIDTH
LINTEL HEIGHT
SIDEROOM
SIDEROOM