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 :
2
DRILL RIVETER 3.5mm DRILL BIT
HAMMER
LADDER
TAPE MEASURE HEX DRIVENAIL PUNCH
SQUARE DRILL BIT
SKILL SAW
(timber floor only)

PG99 PARTS LIST
3
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
4
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
5
5
ASSEMBLE FRONT
PANEL
6
ASSEMBLE WALLS
7
ASSEMBLE ROOF
8
SECURE SHED
4
ASSEMBLE BACK
PANEL
3
ASSEMBLE SIDE
PANELS
1
LAY FOUNDATION
2
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
6
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
7
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
8
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 RIVET
TOP PLATE
15mm 15mm
BOTTOM PLATE
1850mm 1850mm
TOP PLATE
BOTTOM PLATE
15mm 15mm
1850mm
TOP PLATE
RIVET
RIVET
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.
9
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
TOP PLATE
15mm 15mm
1854mm 1854mm
BOTTOM PLATE
15mm 15mm
TOP PLATE