Duratuf PL44 User manual

ASSEMBLY INSTRUCTIONS
PL44
BASE SIZE: 1.520m x 1.520m

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)

PL44 PARTS LIST
3
DESCRIPTION QTY DIAGRAM CHECKED
Front Wall - 1.980m 1
Back Wall - 1.890m 3
Side Wall Angle - 1.965m 2
Side Wall Angle - 1.935m 2
Side Wall Angle - 1.905m 2
Roof - 1.720m 3
Door Sheet Narrow - 1.940m 2
Door Sides - 1.940m 2
Door Jamb - 1.980m 1
Corner Door Jamb - 1.980m 1
Door Brace - 1.200m 2
Barge - 1.720m 2
Spouting - 1.555m 1
Door Top/Bottom - 0.945m 2
Hardware Pack 1
Touchup Paint & Brush 1
Checked: Date:
CLADDING + FLASHING + HARDWARE PACK 1

4
PL44 PARTS LIST
TIMBER PACK CHECK LIST INCLUDED IN PACK 2
DESCRIPTION QTY DIAGRAM
Front/Back Bottom Plates - H4 (Green)
1.520 m 2
Front/Back Top Plate - H1 (Red)
1.520 m 2
Side Wall Bottom Plates - H4 (Green)
1.520 m 2
Side Wall Top Plates - H1 (Red)
1.522m 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
Top Plate
Back
Side Wall Sheets
Barge
Spouting
Roof Sheets
Top Plate Side
Top Plate Front
Bottom Plate Front
Bottom Plate Side
Back Wall
Sheets
Front Wall Sheet
Door Jambs
Door Sheets
Door Side
Flashing
Padbolt Support
Door Brace
Door Top/Bottom Flashing

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 13 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
SELECT:
2 x 1.940 m Door Sheets (Narrow)
2 x 0.945 m Door Top/Bottom Flashings
2 x 1.940 m Door Side Flashings
3 x Hinges
1 x Padbolt Support Flashing
2 x 1.200 m Door Brace Flashings
59 x Rivets
STEP 1:
• Lay out door sheets on a flat surface
making sure narrow pans are on the
outside.
• Rivet sheets together in the centre en-
suring ends are flush with each other.
STEP 2:
• Position door side flashings and top
and bottom flashings and assemble
door as shown, ensuring narrow
face of flashing is on the front as
per fig.1
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

BOTTOM PLATE
BOTTOM PLATE
ASSEMBLE SIDE PANELS
8
SELECT:
2 x 1.905 m Side Wall Sheets (Angled)
2 x 1.935 m Side Wall Sheets (Angled)
2 x 1.965 m Side Wall Sheets (Angled)
2 x 1.522 m Top Plates (Red)
2 x 1.520 m Bottom Plates (Green)
72 x 30mm Galv Clouts
8 x Rivets
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.
BOTTOM PLATE
1857mm 1948mm
15mm
BOTTOM PLATE
1857mm
1948mm
Second Side
Panel
STEP 1:
• Lay out 1 x Top Plate and 1 x Bottom Plate on a flat surface (corner
cutouts to face as shown). Measurements between Top and Bottom
plates are critical to ensure wall panels fit together.
STEP 2:
• Place 1 x 1.905m, 1 x 1.935m and 1 x 1.965m Side wall sheets 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 of the sheets are flush with the top of
the Top Plate and 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, two clouts per pan (see fig. 1).
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).
Repeat with second side panel ensuring Top Plate is as shown.
fig.1
RIB
PAN
CLOUT
TIMBER PLATE
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.
15mm 15mm
1857mm 1948mm
15mm
RIVET
RIVET
RIVET
RIVET
BOTTOM PLATE
15mm

TOP PLATE
TOP PLATE
TOP PLATE
ASSEMBLE BACK PANEL
SELECT:
3 x 1.890 m Wall Sheets
1 x 1.520 m Top Plate (Red)
1 x 1.520 m Bottom Plate (Green)
36 x 30mm Galv Clouts
4 x Rivets
9
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.
1858mm
BOTTOM PLATE
1858mm
15mm 15mm
BOTTOM PLATE
BOTTOM PLATE
15mm 15mm
1858mm 1858mm
STEP 1:
• Lay out 1 x Top Plate and 1 x Bottom Plate on a
flat surface as shown (corner cutouts to face as
shown).
STEP 2:
• Place 3 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.
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.
TOP PLATE