Duratuf PL46 User manual

ASSEMBLY INSTRUCTIONS
PL46
BASE SIZE: 1.520m x 2.020m

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)

PL46 PARTS LIST
DESCRIPTION QTY DIAGRAM CHECKED
Front Wall - 1.980m 1
Back Wall - 1.860m 3
Side Wall Angle - 1.965m 2
Side Wall Angle - 1.935m 2
Side Wall Angle - 1.905m 2
Side Wall Angle - 1.875m 2
Roof - 2.200m 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 - 2.200m 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
3

PL46 PARTS LIST
4
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)
2.020 m 2
Side Wall Top Plates - H1 (Red)
2.022m 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
ensuring 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 us-
ing 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.2
fig.3
fig. 1

ASSEMBLE SIDE PANELS
8
SELECT:
2 x 1.875 m Side Wall Sheets (Angled)
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 2.022 m Top Plates (Red)
2 x 2.020 m Bottom Plates (Green)
96 x 30mm Galv Clouts
12 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
BOTTOM PLATE
BOTTOM PLATE
1827mm 1948mm
15mm
BOTTOM PLATE
1827mm1948mm 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 1.875m, 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
1827mm 1948mm
15mm
RIVET
RIVET
RIVET
RIVET
BOTTOM PLATE
15mm
RIVET
RIVET

TOP PLATE
TOP PLATE
TOP PLATE
ASSEMBLE BACK PANEL
SELECT:
3 x 1.860 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.
1828mm
BOTTOM PLATE
1828mm
15mm 15mm
BOTTOM PLATE
BOTTOM PLATE
15mm 15mm
1828mm 1828mm
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 1.860 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

SELECT:
1 x 1.980 Wall Sheets
1 x 1.520 Top Plate (Red)
1 x 1.520 Bottom Plate (Green)
1 x 1.980 Door Jamb Flashing
14 x 30mm Galv Clouts
4 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. Note the difference between left and right hand
flashing. 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 1 x Wall Sheet on timber plates.
• Ensure that the top of the sheet is flush with the top of the
Top Plate and that the sides of the wall sheet overhang the
Top Plate by 15mm as shown. Nail wall sheets to Top Plate
(two clouts per pan)
• Nail the wall sheet 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 the left-hand end but can
be put on the right-hand end..
NOTE: Door can be hinged on either side.
ASSEMBLE FRONT PANEL
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
1948mm 1948mm
TOP PLATE
960mm
TOP PLATE
DOOR OPENING
15mm
15mm
Plan View
TOP
PLATE
DOOR
JAMB
NAIL
x3
x3
x3
15mm
530mm

WALL PANEL ASSEMBLY
11
SELECT:
4 x Pre-made Wall Panels
16 x 40mm Screws
16 x Rivets
X 2
BACK WALL
SIDE
WALL
SIDE
OVERLAPS
BACK
TOP PLATE
BOTTOM PLATE
BACK WALL
SIDE
WALL
SIDE
OVERLAPS
BACK
X 2
TOP PLATE
BOTTOM PLATE
DOOR JAMB
OVERLAPS
SIDE
X 4
SIDE
WALL
BACK WALL
SIDE
WALL
FRONT WALL
X 4
X 4
X 4
TOP PLATE
BOTTOM PLATE
FRONT
OVERLAPS
SIDES
X 2
X 2
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 as shown.
• Using 2 x 40mm screws, screw Top
Plates together in the corner.
• Using 2 x 40mm screws (2 per join) screw
the Bottom Plates together in the corner.
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 (2 per join), screw
the Top and Bottom Plates together.
STEP 4:
• Rivet the wall sheets together at the corners
using 4 equally spaced rivets as shown.

ROOF ASSEMBLY
SELECT:
3 x 2.200 m Roof Sheets
1 x 1.555 m Spouting
2 x 2.200 m Barges
16 x 50mm Roofing Screws
24 x Rivets
4 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. Pre drill and fasten with the 50mm roofing
screws provided. Ensuring screws are not overtightened as this can damage
the seals and cause the shed to leak.
12
IMPORTANT
Use 50mm Clouts only on outside ribs covered by Barge flashings. Predrill
holes using a 3.5mm drill bit. Use Roofing Screws on all other ribs.
STEP 1:
• Ensure Shed is sitting level and square.
• Lay Roof Sheets on the Top Plates.
• Rivet sheets together at overlaps with 2 x rivets per join.
STEP 2:
• Position the Roof Sheets with front overhang of 130mm at each
end (fig. 1).
• Using 4 x 50mm Clouts, predrill and nail the Roof Sheets to the Top
Plates through the ribs, at each corner, ensuring ribs on the Roof
Sheets line up with ribs on the Wall Sheets (fig.2).
STEP 3:
• Ensure the Front and Back Top Plates are straight.
• Screw the roof sheets to the front & back Top Plates, using 1 x
Roofing Screw per rib. (fig.2).
STEP 4:
• Place barge flashings on roof at end of shed ensuring the diagonal
trimmed end is at the front. (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).
Pan Rib
fig.2
130mm
SIDE
WALL
FRONT
WALL
BACK WALL
SIDE
WALL
BOTTOM PLATE
TOP PLATE
fig.1
130mm
fig.3
X 4
X 4
Barge
Spouting
fig.4
STEP 5:
• Place spouting in position and rivet to Barge Flashings at each end
and rivet to roof sheets (1 rivet per 1 sheet) (fig.4).

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.
13
YOUR DURATUF GARRISON SHED IS NOW COMPLETE. RELAX…...
FITTING A GARRISON FLOOR KIT (OPTIONAL)
• Position the Floor Joists equally 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.
FRONT BASE PLATE
BACK BASE PLATE
JOIST
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 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 activate the warranty on your garden shed.
Many thanks, from the Team at Riverlea Group.
20 YEAR WARRANTY
WARRANTY REGISTRATION