Duratuf KAIPARA User manual

11
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) 2.250m 10
Stud 70 x 45 (Yellow) 2.400m 6
Stud 70 x 45 (Yellow) 0.310m 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 73mm Tongue 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 2.510m 2 1002
Rear Corner Flashing 2.365m 2 1003
Door Top Flashing 2.595m 1 1004
Door Head Flashing 2.400m 1 1005
Door Jamb Flashing 2.100m 2 1006
Downpipe Cover Flashing 2.200m 1 1007
Barge Flashing 3.225m 2 1008
Fascia 4.025m 1 1009
Back Spouting 4.025m 1 1010
Spouting End Cap 0.040m 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- 75mm wide 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
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1945mm
1945mm
130mm
C
L
3790mm
532mm
555mm
555mm
555mm
2530mm
63mm
1895mm 1895mm
C
L
Rear of the shed
Rear of the shed

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
2340
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 2250mm 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
10731132
2340
1137
2410
1137

1010
TIMBER FRAME - BACK WALL
10
TIMBER FRAME - FRONT WALL
• Nail lintel to studs using the 310mm studs to establish correct height.
• Nail 310mm 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 2400mm Studs
3 x 310mm 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.
310
2090
615
3900
2490
2400
615 90
45 90
45
45 45
45
1132 1223
Select
1 x 3900mm Base Plate
1 x 3900mm Top Plate
4 x 2250mm 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
1073
1132
2340
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.
DPC
LINTEL
OUTSIDE INSIDE
ATTACHING DPC TO FRAME
ATTACHING DOOR HEAD FLASHING
BASE PLATE
DPC
FLOOR

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.
TEK SCREWS
WALL CLADDING FIXING PATTERN
All Tek Screws fastened through trough
CLADDING DETAIL
Side View
CLADDING DETAIL
Overlap
Outside Inside

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. Ensure top edge is protruding outwards, to allow correct
overlap on second sheet.
• 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. Bottom sheet
shouldnishapprox30mmbelowbottomofbaseplate.
• 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 310mm stud)
• Fitremainingsheetseachsideofdoorwayandscrewo󰀨asabove.

1515
15
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.

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

1818
18
FASCIA, SPOUTING & BARGE
Barge Flashing
Back Spouting
Barge Flashing
Barge Flashing
Back
Spouting
• Selectthelefthandbargeashing.Thiswilltin
between the fascia and the back spouting. We will
be attaching the barges to the spouting at the back
rstandttingthefascialast.
• Holdtheashinginrmlyagainstthesideofthe
shed spanning over the roof corrugate and down
the side of the shed.
• Line the end of the barge up with the back of the
spouting.Thebargeshouldtover the top and
bottom of the spouting. Drill a 3.5mm hole into
thetopofthespoutinginthecornerandx2x
rivets.
• Using 3 rivets equally spaced per barge, secure top
ofbargeashingstoroofsheets.
• Repeat the process with the barge on the other
side.
• Installfascia,andscrewitsendstobargeashingsatboth
top and bottom using four 25mm Hex head Tek screws.
• Fasten the underneath of the fascia to the roof sheets
using rivets, equally spaced, 3 rivets per sheet.
• Fasten top of the fascia to the roof sheeting, one 25mm
Hex head Tek screw in the centre of each sheet.

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