Duratuf MK4 User manual

Quality –Built In
ASSEMBLY INSTRUCTIONS
MK4
BASE SIZE 4210mm x 1715mm

 Drill
 Drill Bit 3.5mm
 Drill Bit 10mm
 Drill Bit 6mm (for clear roof panel only)
 Riveter
 Hammer
 Nail Punch
 Tape Measure
 Ladder or Saw stool
 Spanners x 2
 String Line
 Tin Snips
 Skillsaw and Jigsaw (for floor only)
 Masonry Drill and 10mm Masonry Bit (for Bolt Down Kit only)
 Read all instructions carefully.
 Identify all parts and check quantities against checklist.
 If you are making your own floor refer to Raised Base Plate section
now.
 Do not attempt to build your shed in high winds.
 Beware of sharp edges.
 Protect your eyes and ears.
 Use electric tools with care. Use a Safety Trip Switch.
 It is easier and quicker if this shed is erected by two people.
 Your shed must be level. Achieve this by either levelling the ground
or by using blocks.
 If you shed is to be positioned on wet or damp ground, we recom-
mend that your shed is raised up off the ground slightly.
Tools Required:
Select your site:
Safety:
Before you start:
ASSEMBLY INSTRUCTIONS
2

3
4
7
2
2
2
1
1
1
5
2.090m
1.890m
1.890m
0.200m
2.000m
Gable End Wall Sheets
Wall Sheets
MK4 1/2 Wall Sheets
Door - Standard Security
Instruction Booklet
Jack Studs - 70 x 45mm
Hardware Pack
Centre Door Stop
Touch-up Paint & Brush
Roof Sheets
0.580m
0.603 x 0.603m
0.588 x 0.150m
0.710 x 0.240m
1
Fixed Window Frame
Glaze Beads
Glass
Louvre Window Frame
Glass
Over Panel
Window Hardware Pack
2.000m
0.975m
0.975m
0.350m
0.900m
1
Roof Sheets
Flat Roof Sheet
Clear Roof Panel
Pressed Capping Sheet
Bevel Edge Support 45 x 45mm
Clear Roof Hardware Pack
Security Double Door Hardware Pack
Alarm - MA20
Shed light
Bolt Down Kit
Peg Down Kit
170 50mm Flooring Nails
675mm Flooring Nails

MK4 TIMBER FRAME
4
1900
(or 1870 for Raised Base Plate only)
45 45 45 45
1343 1343
1343
4210
45
45 45
BACK WALL
883
YELLOW
YELLOW
YELLOW
YELLOW
1.810
YELLOW
YELLOW
YELLOW
YELLOW
45 45 45 45 1185 11851660
4210
45
45 45
FRONT WALL
883

MK4 TIMBER FRAME
5
1
4
3
2
6
Step 3: Select two 1.715m Base Plates (Green) and two
1.715m Top Plates (Red). With front wall lying on
the ground, nail Plates to frame. Ensure Green
joins to Green and Red joins to Red.
Step 4: Position the back wall frame on top of plates.
While someone supports frame, nail in place.
Step 6: Position Jack Studs on each end of Ridge
Beam and nail in place using two 75mm nails
each end (fig. 1). Turnover Ridge Beam / Jack
Studs, position centrally on 1.715m Top Plates
and nail to Top Plates using 75mm nails.
Step 5: Carefully roll frame over onto its base. (Pieces of
timber from the packaging may be used to tem-
porarily brace the frame before rolling it over).
Position 1.575 End Wall Nogs .883m down from
Top Plate and nail in place. If fitting a Kiwi Floor,
fit Floor Joist now. Space joist centrally and nail
in place using three 75mm nails per end.
fig. 1
5
Step 2: Front Wall: Select one 4.210m Base Plate
(Green), one 4.210m Top Plate (Red), four
Studs (Yellow) and two 1.185m Nogs. Nail
studs to each end of Plates. Nail in remaining
two studs using 1.185m Nogs to get correct
position. Position Nogs .883m from Top Plate
and nail in place.
Note: If fitting a window in the back wall, there will be no centre stud on that side. Instead nail in a full length Nog
(4.120) using window studs (.883) to get correct height. Position one window stud centrally beneath the Nog
and nail in place. Further window studs and Nogs are fitted after the cladding is on.
Note: For sheds with the Raised Floor Modification option the studs will be 1.780m long to allow the Wall Sheets to pro-
trude 20mm below the Bottom Plate. Refer to Raised Floor Modification section (Page 15).
Step 1: Back Wall: Select one 4.210m Base Plate
(Green), one 4.210m Top Plate (Red) and four
Studs (Yellow). Lay out Plates and two Studs on
a flat surface and nail together using two 75mm
nails per join. Nail in remaining centre studs us-
ing 1.343m Nogs to get correct position. Position
Nogs .883m from Top Plate and nail in place.

MK4 WALL CLADDING
TO AVIOD CORROSION:
 Where at all possible try not to trap metal filings between two sheets. Remove all metal filings before riveting.
 Carbon in pencils reacts with the Zinc/Aluminium coating on steel. Use ink to mark steel.
TERMS EXPLANATION
 To Tack: To Tack on a wall sheet means to use minimum nails hammered partly in to hold Wall Sheets in position. Should
a Wall Sheet need to be re-positioned, the nails can easily be prized out.
 If a window is required, identify Wall Sheet(s) with window hole pre-cut. Lean up Wall Sheets where window(s) are to be located.
6
fig. 1
Note:
When fitting
Gable End
Sheets ensure
they overlap
correctly (fig 1).
The overlap
direction may
differ from clad-
ding detail be-
low.
CLADDING DETAIL
Birds Eye View

MK4 WALL CLADDING
7
Step 2: Back Wall: Position the first Wall Sheet with
the LIP on the right hand side. Ensuring the LIP
is flush with the side of the Studs and the top of
the Wall Sheet is flush with the top of the Top
Plate, tack in place. Position the next Wall
Sheet with the LIP on the right hand side. Over-
lap as shown in (fig 1). Ensuring Wall Sheet is
flush with top of Top Plate, tack in place. Re-
peat with remaining sheets.
Step 3: End Walls: Lean Gable Wall Sheets against
the shed to form gable shape. With the LIP
flush with side of Stud tack in place ensuring
the bottom of the Wall Sheet is 10mm above
the bottom of the Bottom Plate. Tack on re-
maining Wall Sheets. Repeat with other gable
end. If fitting a window, nail in Window Studs
and Nog now. Refer to Window instructions.
Step 4: Nailing Off: Nail one 30mm Clout each side of the Rib (two per Pan) into the Top Plates and Bottom
Plates. Nail Wall Sheets to mid wall Nogs (one per pan). Nail each corner Wall Sheet to Studs using
two 30mm Clouts evenly spaced.
Gable Ends: When nailing Gable Wall Sheets to the Top Plate, use a String Line. At the top of the gable
nail two 30mm Clouts into the end of the Ridge Beam. This will stop it from twisting.
EDGE
FLUSH
TOP
FLUSH
Step 1: Front Wall: Start at the left hand side. Posi-
tion the Wall Sheet with the LIP on the left hand
side. Ensuring the LIP is flush with side of the
Stud and the top of the Top Plate, tack in place.
Repeat with Wall Sheet on the right hand side
of doorway. Ensure Rib without LIP is on the
right hand side of stud then tack in place. Posi-
tion 1/2 Wall Sheets as shown in the Cladding
Detail and tack in place.

8
MK4 FIXED WINDOW (Optional)
Step 2: On the inside of the shed, position studs
and Nog centrally on window opening.
Make sure the studs are parallel and nail
into Top Plate and End Wall Nog.
Step 3: Nail wall Sheets to window
framing using 30mm clouts. (return to step
4 on page 7 and complete). Then fit Win-
dow Frame). Position Window Frame cen-
trally on window opening and rivet it to ribs.
Pre-drill holes in each corner and nail Win-
dow Frame to framing, using 50mm nails.
Step 4: If the Window is in the gable end, tempo-
rarily position the Over Panel above Win-
dow Frame. Following the same angle as
the gable, mark and cut to suit.
Step 5: Rivet Over Panel to the Window Frame
with rivets.
588mm
Step 1: Lay out the two window studs (883mm) and
Nog (634mm) on a flat surface. Position
Nog and nail in place using 2x 75mm nails
at each end.
Step 6: From the inside of the shed, slide Louvre
Glass into Louvre Units attached to the
Window Frame. Bend up tabs to keep
Glass in position.
50mm
NAILS
RIVITS

9
Step1: Fit Door Jamb Flashing (A104) in be-
tween Top and Bottom Plates and hard
against Stud. Attach Door Jamb Flash-
ing with three 30mm clouts into studs on
the inside and three 50 mm nails on the
outside. Pre-drill holes on the outside to
protect flashing. Repeat with the other
Door Jamb.
Step2: Measure and cut Doorstep Flashing (A106)
to fit in between Door Jambs. Positioning
the Doorstep Flashing in between Door
Jambs at bottom of doorway, nail through
top of flashing using five 30mm Clouts. Re-
peat with the Overdoor Flashing (A105).
Step 1: Lay out the two window studs (883mm) and
Nog (590mm) on a flat surface. Position
Nog and nail in place using two 75mm nails
at each end.
570mm
Step 6: From the outside of the shed, place glass
in Window Frame. Attach a Glazing Bead
(G100) with three rivets to each side of the
Window Frame to hold glass in place. Pre-
drilling Glazing Beads is recommended.
MK4 FIXED WINDOW (Optional)
Follow Steps 2 - 5 on page 8.
MK4 DOOR JAMB & CORNER FLASHINGS

10
MK4 DOOR JAMB & CORNER FLASHINGS
Step 3: Fit Corner Flashing (101) over
corner Ribs with the top flush
with the top of the Top Plate.
Rivet in place with six rivets,
three each side. Repeat with
other three Corner Flashings.
When fitting Corner Flashings
on front wall, ensure they are
parallel with Door Jambs.
MK4 ROOF
Note: Condensation can form on the under side of shed roof. If building paper is required, fit now. Building paper will
need to be supported by netting or roofing twine.
Step 1: Check that the diagonal measurements of the shed are the same. If building on unlevel ground it may be neces-
sary to temporarily brace the shed with pieces of timber from the packaging.
Step 2: Position first Roof Sheet centrally over Ridge
Beam on the right hand end of shed with the
LIP on the left hand side. (For sheds with a
Clear Roof Panel, go to the next page). Posi-
tion the next Roof Sheet. Ensure it overlaps
correctly then rivet together, 400mm down
from the centre on both sides. Fit remaining
Roof Sheets.
Step 4: Centralize Roof at the other end and nail
through pan into Ridge Beam and Top
Plates. Ensure Ridge Beam is straight, then
nail one 40mm Weatherseal into Ridge Beam
beside each overlap (one nail per sheet). At
the back, set up a String Line in centre of
Top Plate. Ensure Top Plate is straight and
nail off, using one 40mm Weatherseal per
Pan. Repeat at the front.
Step 3: Starting from the left hand end, centralise
Roof on Ridge Beam. Ensure Roof is tight
against end Wall Sheets and nail one 40mm
Weatherseal through Lip into the Ridge
Beam. At the back, line up Ribs on the Roof
Sheet with the Ribs on Wall Sheet. Using
one 40mm Weatherseal, nail through Lip into
Top Plate. Repeat at the front.
LIP

MK4 CLEAR ROOF PANEL (Optional)
Step 1: Leave a gap where the Clear Panel is to be fitted. Position the next Roof Sheet. Ensure it overlaps correctly, then
rivet together, one rivet in the centre and one approximately 600 mm down from the centre on both sides. Rit re-
maining Roof Sheets, overlapping and riveting as you go. Nail on first Roof Sheet (refer step 3 on page 10).
Step 2: Where the Clear Roof Panel is to be positioned, nail a 45x45mm Bevelled Edge Support on each side of the
Ridge Beam. (fig. 1)
Step 3: Position Clear Roof Panel and Flat Roof Sheet (or second Clear Panel). The Flat Roof Sheet underlaps one sheet
and overlaps the other. The Clear Roof Panel OVERLAPS both Roof Sheets. Ensure sheet joins are flush at the
outside edge then rivet flat sheets to pressed sheets, three rivets per join. Centralise Roof at the other end and
nail in place.
Step 4: Ensure Ridge Beam is straight, then nail the Clear Panel and Flat Roof Sheet (or second Clear Panel) to
45x45mm Bevelled Edge Supports using one 30mm Clout per Pan. Run two generous beads of Silicone on the
under side of the Pressed Capping Sheet. Position Pressed Capping Sheet on Ridge Beam and nail in place us-
ing three 40mm Weatherseals. Nail one 40mm Weatherseal into Ridge Beam beside each overlap (one nail per
sheet).
Step 5: At the Back set up a String line in the centre of the Top Plate. Ensure Top Plate is straight and nail off, one 40mm
Weatherseal per Pan. Repeat at the front.
Note: When nailing through the Clear Panel, pre-drill a 6mm hole.
11
Note: MK2 shown

12
MK4 DOORS
Step 2: Position right hand Door Track (D107) on front wall
up against underside of Roof, with left hand end
hard against the Centre Door Stop. Pre-drill hole in
centre and rivet in place. Remove ALL drill filings
Step 3: Hang right hand door in Door Track. At the right
hand end of Door Track, adjust up or down so that
the Door hangs parallel with shed. Fit one rivet at
right hand end to hold in place.
Step 4: Position left hand Door Track (C107). Follow Steps 2 and
3 to hang left hand Door. Where Door Tracks meet in the
centre, adjust up and down so that the Doors fit snuggly
together, then rivet in place. Remove Doors. Pre-drill
holes into each Rib and at similar spacings into Overdoor
Flashing. At approximately 1/3 in from each end of Door
Tracks put a 50mm nail. Rivet rest of holes.
Step 1: Top Door Tracks: Mark the centre of the doorway on
the Overdoor Flashing. Position Centre Door Stop on
the front face of the Overdoor Flashing and up against
the underside of roof. Pre-drill holes and nail in place
with 50mm nails.
Step 5: Clean out ALL drill filings. Also make sure the
Wheels are cleaned of drill filings. Re-hang Doors,
then insert door stops into the pre drilled holes at
end of tracks as shown in diagram. Tighten with
two spanners
Door Track
Bolt
Washer
Washer
Nut
Aluminium
Door Stop
DOOR
GUID
DOOR
CLADDING
BOT-
PLATE
Step 6: Bottom Door Guides: Slide Door to corner. Hang Door Guide (A108) on bottom of the Door. Lift up approximately
3mm so that the Door will Slide freely. Pre-drill hole and nail in place using a 50mm nail. Slide to centre. Ensuring Door slides
freely, pre-drill hole and nail Door Guide in place. Check Door is not binding in the middle then pre-drill holes into each Rib at
similar spacing into Door Step Flashing. Nail off using 50mm nails. Repeat with other Door.
Note: For sheds with Raised Base Plate option the Door Step Flashing will protrude down past the Bottom Plate. Attach Door Guide
with rivets.

Step 2: Centralise Barge Flashing on gable end
and rivet in place, one rivet into every
second Rib. Fit two rivets through top of
Barge into Rib. Repeat with other Barge
Flashing. Check Spoutings are straight,
then rivet to Roof one rivet every second
Rib.
13
MK4 BARGE & SPOUTING
Step 1: Position Barge Flashing (102) on gable
ends. Slide one Spouting (D103) inside
another until it measures the correct length.
Rivet together with four rivets. Repeat with
the other Spouting. Position Spouting on
the shed and rivet to barge Flashing at
each end. Repeat with other Spouting.
MK4 FLOOR
Step 1: Place shed in final position. Check the di-
agonal measurements are the same and
the shed is level before fitting Floor. It is
recommended that the shed is anchored
down with either a Duratuf Bolt Down Kit or
Duratuf Peg Down Kit depending on what
the shed is sited on.
Step 2:
Lay a Floor Board on top of Bottom Plates and
Joist and push up against end wall. Mark out
where Studs are. Cut checkouts with Electric Jig-
saw so Floor Board will fit around Studs.
Step 3: Re-position Floor Board. Lay out remaining
Floor Boards checking around Studs as
you go. The last Floor Board may have to
be cut to size.

MK4 FLOOR
Step 4: Nail in each Floor Board, two 50mm nails in
each end and two into Joists. Measure and
cut Floor Flashing (A110) to fit in between
Door Jamb Flashings and nail in place using
50mm Clouts.
14
Step 1: Attach “ T” locking handle with two 8x10mm
screws TO R/H door (Door without the weather-
strip). Slide hook onto square shaft and secure
with a lock washer.
Hook
Lock Washer
Step 2: Once doors are hung, position the Locking
Stays so they slide into the Locking Brackets
easily. Screw Locking Stays to Door Jamb.
SECURITY DOOR (Optional)
Step 3: On the back of the left hand door,
position latch so that the hook on
the door handle will be secure and
go in and out easily. Rivet in place
with four rivets.
Left Hand Door Right Hand Door
Hook
Latch

MK4 HASP & STAPLE
15
Using seven rivets attach hasp to Left
Hand Door and the staple to the Right
Hand Door as shown.
RAISED FLOOR MODIFICATION
For sheds being placed on a purpose built floor, (concrete, cob-
bles, ply etc.), the Wall Sheets will protrude 20mm below the
Base Plate. This will stop water flowing in between the Base
Plate and Floor.
The Floor should be made 15mm smaller than Base Size.
Note: Although it is not essential, fitting Damp Proof Course
in between the Base Plate and the Floor will give add-
ed protection against moisture.
CLEAN UP
 Remove all swarf (drill filings) with a soft brush or rag.
 Hose down roof and walls thoroughly.
 For Coloursteel sheds use touch-up paint provided on all nail heads, rivets and exposed cuts.

DURATUF PREMIUM SHED WARRANTY
GUARANTEE TO CUSTOMER
Congratulations on purchasing a Duratuf Storage Shed. With proper care and attention, this product will last many years.
For your benefit PLEASE READ THE FOLLOWING INFORMATION CAREFULLY.
WARRANTY ON METAL CLADDING
Riverlea Group Ltd guarantee that the metal roofing and wall cladding on Kiwi and Fortress Garden Sheds may be used in moderate and
inland corrosion zones or areas where the first year mild steel corrosion rate is less than 200g/m2, and that in these conditions, they will
not perforate due to corrosion within 18 years of date of manufacture.
TERMS AND CONDITIONS
1. Damage or corrosion due to the following circumstances is not covered by this warranty.
 Mechanical, chemical or other damage sustained during or after installation.
NOTE: Clean swarf off shed IMMEDIATELY after assembly
Do NOT mark cladding with pencil
Do NOT allow manures, chemicals or other corrosive materials to have direct contact with cladding
Chemical damage will result if these instructions are not carried out
 Force majeure or other causes beyond the control of Riverlea Group Ltd.
2. This warranty does not cover material installed in severe and very severe environmental situations, or in any area where the mild
steel corrosion rate (as published by BRANZ) exceeds 200g/m2.
3. Minimum maintenance must be carried out in accordance with instructions below.
Should the cladding fail to perform as specified above, the liability of Riverlea Group Ltd shall in all cases be limited to replacing or
repairing the defective product. The balance of the original warranty will cover any repaired or replaced material. Riverlea Group Ltd will
not be liable for any consequential loss or damage, labour or transport charges. All claims made in writing within 21 days of discovery,
quoting the reference number at the top right hand corner of this page.
MAINTENANCE
Following are the minimum maintenance requirements for cladding used in Kiwi Garden Sheds and Fortress Sheds.
 Washing all surfaces by rain, and annual hosing of sheltered areas using a hose and soft nylon brush.
 Within 2km 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 fallout from roof and gutters
 Gutters to be kept clean of leaves and dirt.
Should you require additional technical information please contact us at the details below.
Please visit http://www.riverleagroup.co.nz/warranty-garden-sheds to validate the Warranty on your shed.
Click on the Warranty Registration Link and complete all details.
If you are unable to access the computer, please phone us on 0800 438 274 and one of the customer services team will help you to acti-
vate the warranty on your garden shed.
Many thanks, from the Team at Riverlea Group.
WARRANTY REGISTRATION