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

ASSEMBLE FRONT PANEL
10
SELECT:
3 x 1.890 Wall Sheets
1 x 3.020 Top Plate (Red)
1 x 3.020 Bottom Plate (Green)
2 x 1.890 Door Jamb Flashings
40 x 30mm Galv Clouts
28 x Rivets
STEP 1:
• Lay out 1 x Top Plate and 1 x Bottom Plate on a flat
surface as shown
STEP 2:
• Using 2 x 30mm clouts, nail the Door Jamb Flashing flush with
the top of the Top Plate at the correct measurement as shown
in plan view. Pre drill holes using a 3.5mm drill bit
• Check the distance between the top and bottom plates then use
a further 2 x 30mm clouts to nail the Door Jamb Flashings to
the bottom Plate. Pre drill holes.
STEP 4:
• Place the door on the panel (In open position, approx
20mm below top of top plate). Using two rivets, rivet the top
and bottom hinges to the Door Jamb Flashing, ensuring
door closes properly.
• Fit remaining rivets.
STEP 3:
• Place 3 x Wall Sheets on timber, ensuring wall sheets fit un-
derneath door jamb flashings.
• Ensure 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. Nail wall sheets to Top Plate
(two clouts per pan)
• Nail the wall sheets to the Bottom Plate making sure that the
Plates are the correct distance apart and that the sides of the
wall sheets overhang the Bottom Plate by 15mm.
• Drill & rivet Door Jamb Flashings to wall sheets using four
rivets equally spaced on each side.
NOTE: The Doorway is standard at 530mm from left-hand end.
To shift the doorway to the right-hand side of the front
wall, simply measure 530mm from the right-hand end.
NOTE: Door can be hinged on either side.
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.
1854mm 1854mm
TOP PLATE
TOP PLATE
BOTTOM PLATE
15mm 15mm
15mm 15mm
530mm 1460mm
TOP PLATE
DOOR OPENING
x3
x3
x3
Plan View
TOP PLATE
TOP
PLATE
DOOR
JAMB
NAIL
x3
x3
x3

WALL PANEL ASSEMBLY
X 2
X 2
BACK WALL
SIDE
WALL
SIDE
OVERLAPS
BACK
X 2
BACK WALL
SIDE
WALL
SIDE
OVERLAPS
BACK
X 2
SELECT:
4 x Pre-made Wall Panels
16 x 40mm Screws
16 x Rivets
STEP 1:
• Stand the Back Panel and the Side Panel
up using someone to support the panels
while they are screwed together.
• Before fixing, ensure that the Side Panel
overlaps the Back Panel.
• Using 4 x 40mm screws (2 per join) screw
the Top and Bottom Plates together in the
corners.
STEP 2:
• Repeat Step 1 with the second Side Panel,
ensuring that the Side Panel overlaps the
Back Wall Panel.
STEP 3:
• Stand up the Front Wall Panel.
• Ensure that the Front Wall Sheets overlap
the Side Wall Sheets.
• Using 8 x 40mm screws, screw the Top and
Bottom Plates together.
STEP 4:
• Rivet the wall sheets together at the corners
using 4 equally spaced rivets as shown.
11
TOP PLATE
TOP PLATE
BOTTOM PLATE
BOTTOM PLATE
FRONT
OVERLAPS
SIDES
X 4
SIDE
WALL
BACK WALL
SIDE
WALL
FRONT WALL
X 4
X 4
X 4
TOP PLATE
BOTTOM PLATE

ROOF ASSEMBLY
12
SELECT:
12 x 1.600 m Roof Sheets
2 x 3.055 m Spouting
4 x 1.602 m Barges
2 x 1.800 m Ridge Flashing
1 x 3.020 m Ridge Beam
2 x 0.200 m Jack Studs
8 x 75mm Screws
34 x 50mm Roofing Screws
66 x Rivets
42 x 50mm Clouts
IMPORTANT—FOR SHEDS WITH OPTIONAL CLEAR ROOF PANEL
Assemble as below, making sure that the Clear Roof Sheets overlap the stand-
ard roof sheets on both sides.
The Clear Roof Panel must be secured to the Top Plate and the Ridge Beam.
Pre drill and fasten with the 50mm roofing screws provided..
STEP 1:
• Place the Ridge Beam on a level surface and use 2 x 75mm screws
to secure the Jack Studs to the underside of the Ridge Beam, one at
each end (fig. 1).
• Turn the Ridge Beam /Jack Stud assembly over and place it on the
timber Top Plate in a central position.
• Secure with 2 x 75mm screws through the top of the Jack Studs
into the Timber Top Plate (fig. 2).
• Check that the shed is sitting level and square and that the diagonal
Top Plate measurements are the same.
fig. 1
JACK STUD
TOP PLATE
RIDGE BEAM fig. 2
fig. 3
15mm
JACK STUD
RIDGE BEAM
TOP PLATE
ROOF SHEET
STEP 2:
• Position the first Roof Sheet so that the top of the sheet is at the
centre of the Ridge Beam and the side of the sheet over hangs the
end of the Ridge Beam (fig .3). Using 1 x 50mm Clout, predrill and
nail through the rib into the top corner. Repeat above and nail the
lower corner ensuring 15mm overhang.
• Position the remaining front Roof Sheets and rivet them together as
shown.
• Nail the last sheet to the Ridge Beam and the Top Plate ensuring
the Roof Sheet overhangs the end of the Ridge Beam and the Top
Plate by 15mm.
• Nail front Roof Sheets to Ridge Beam using 1 x 50mm clout per rib.
Screw to Top Plate using 1 x Roofing screw per rib (fig.4) ensuring
Ridge Beam and Top Plate are straight.
• Repeat with remaining roof sheets.
fig.4
Pan Rib
IMPORTANT
Use the 50mm Clouts only on ribs covered by flashings, shown on pg 13 fig.2.
Predrill holes using a 3.5mm drill bit. Use Roofing Screws on all other ribs.
Ensuring screws are not overtightened as this can damage the seals and cause
the shed to leak.
SIDE
WALL
FRONT WALL
BACK WALL
SIDE
WALL
TOP PLATE
BOTTOM PLATE
RIDGE BEAM
SIDE
WALL
FRONT WALL
BACK WALL
SIDE
WALL
TOP PLATE
BOTTOM PLATE

ROOF ASSEMBLY CONT...
13
STEP 5:
• Place barge flashings on roof at end of shed
ensuring the diagonal trimmed end is facing
out. (See diagram on pg 5)
• Rivet the Barge Flashings to the roof and the
side wall, using four rivets on top of barge and
four into the side (fig.3).
STEP 4:
• Position the second Roof Sheet, and rivet to first roof sheet as
shown.
• Fasten off as per Step 2.
• Rivet and nail/screw off the remaining Roof Sheets, ensuring
the ribs line up with the front Roof Sheets and the back Wall
Sheets.
STEP 3:
• Position 1 x roof sheet so that the top of the sheet is at the
centre of the Ridge Beam and the side of the sheet over hangs
the end of the Ridge Beam and the Top Plate by 15mm.
• Ensure the Ridge Beam and the Top Plate are straight.
• Nail /screw 4 x corners of the Roof Sheet as shown, ensuring
the ribs on the Roof Sheet line up with the front Roof Sheet
and the back Wall Sheet. Fasten off the first sheet.
STEP 6:
• Rivet the 2 Ridge Caps together using 4 x
rivets, so total flashing is 3.050m long.
Rivet the Ridge Cap to the centre of the roof
using 10 x rivets as shown (fig.2).
= Clout
= Screw
SIDE
WALL
BACK WALL
TOP PLATE
BOTTOM PLATE SIDE
WALL
RIDGE
FRONT
WALL
SIDE
WALL
fig.1
FRONT WALL
BACK WALL
SIDE
TOP PLATE
BOTTOM PLATE
SIDE
WALL
FRONT WALL
BACK WALL
SIDE
TOP PLATE
BOTTOM PLATE
fig.3
X 4
X 4
Barge
Spouting
fig.4
STEP 7:
• Place spouting in position and rivet to Barge Flashings
at each end and rivet to roof sheets (1 rivet per 1
sheet) (fig.4).
fig.2

SECURING SHED
Secure your shed using Treated Timber Pegs or a Bolt Down Kit
TIMBER PEGS—WOODEN FLOOR
• The optional Duratuf Timber Peg Down Kit includes six H5 treated timber
pegs that can be hammered into the ground and then attached to the
Base Plate with stainless steel screws. A Garrison timber floor can then
be fitted on top of the Base Plate if required.
BOLT DOWN KIT—CONCRETE
• The optional Duratuf Bolt Down Kit includes 6 x galvanised
brackets, screws and dynabolts.
• Space the brackets evenly around the shed and fix to the Bottom
Plate and the concrete slab. A 10mm masonry drill bit is required.
IMPORTANT— CLEAN UP
REMOVE ALL DRILL FILINGS FROM ROOF, WALLS AND CHANNELS
THOROUGHLY. FAILURE TO DO THIS WILL RESULT IN CORROSION AND
COULD THEREFORE VOID THE WARRANTY.
FIT PADBOLT
• Rivet Padbolt to door and keeper onto Door Jamb as shown.
14
YOUR DURATUF GARRISON SHED IS NOW COMPLETE. RELAX…...
FRONT BASE PLATE
BACK BASE PLATE
JOIST
JOIST
JOIST
FIT BACK PADBOLT
• Rivet back pad bolts to pad bolt supports then rivet pad bolt sup-
ports to back of small door (Top and bottom)
• Using 10mm drill bit, drill hole into top and bottom timber plates
FITTING A GARRISON FLOOR KIT (OPTIONAL)
• Position the Floor Joists centrally between the side Base Plates
and skew nail each end with two 75mm nails.
• Check that the shed is sitting level and square . Check that the
diagonal Bottom Plate measurements are the same.
This ensures that the shed base is square.
• Place the Floor Boards in position. (You may need to cut the last
Floor Board to the correct width using a Skill Saw.) Nail each
Floor Board in, using two 50mm nails each end and two nails
into each floor joist.

Riverlea Group Ltd warrant that the cladding used in the manufacture of the Garrison shed will not rust within 20 years from the
date of purchase.
Any liability for product failure that may arise will be limited to repair or replacement of the defective product and will only apply for
the benefit of the original purchaser. Riverlea Group Limited will not be liable for any consequential loss or damage, labour, or
transport charges.
This warranty is conditional on:
• Construction, installation and maintenance being carried out as specified in the Assembly Instruction Manual.
• The shed being installed in modest inland corrosion zones or areas where the steel corrosion rate is less than 200g/m2
(as published by Branz).
• Warranty certificate being returned to manufacturer within 21 days of purchase together with proof of purchase.
This warranty does not cover the following:
• Fastenings and fixings.
• Normal wear and tear, damage by impact or acts of God.
• Situations where the shed has been used for storage of chemicals, manure or corrosion causing products.
• Unauthorized modification of the structure, including painting of the cladding.
Please visit www.duratuf.co.nz/warranty 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 activate the warranty on your garden shed.
Many thanks, from the Team at Riverlea Group.
20 YEAR WARRANTY
WARRANTY REGISTRATION
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$100 Prezzy Card!
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www.duratuf.co.nz/customer-survey
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