K2 Conservatories TGBv6.1 User manual

Page 1 Garden Building Installation Guide
Product Code: TGBv6.1 / November 2011
For Customer Services (parts & delivery enquiries only) call: 01254 683 079
For Technical Support (installation queries) call: 0871 574 7293
Technical support calls cost 10p per minute from BT landlines, other carriers and mobile networks may vary.
Garden Building Models

Page 2 Garden Building Installation Guide
Product Code: TGBv6.1 / November 2011
Please note that the conservatory product is complex, and often bespoke in nature. Accordingly, while this
document attempts to demonstrate the full installation procedure, it should be seen a guide to method and
technique, rather than a strict step-by-step guide. Methods and components are subject to change without
notice, and no responsibility will be accepted for any issues arising from such changes.
Printed installation guides for our products are supplied as necessary upon purchase however, due to the
limitations of promptly updating printed copies, the PDF versions available online at
www.k2conservatories.co.uk should be considered to supercede the printed versions.

Page 3 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
HOW TO USE THIS GUIDE, TOOL & TIPS
Using this Installation Manual –
READ THIS SECTION CAREFULLY
Contained within this Installation Manual are
step-by-step instructions to guide you through the
installation of your conservatory to successful
completion. Each build stage has been broken
down into sections and you will see an overview
of these build stages immediately following this
section.
IMPORTANT
Read ALL the instructions completely BEFORE
commencing any work, more than one reading
may be necessary. Understanding these
instructions and familiarity with procedures will
make the build process much easier and an
enjoyable project to undertake.
Cross Referencing
Your conservatory is supplied as several items of
packaging, some of which will be immediately
apparent (such as windows and doors) other
items will be labelled as a particular package
reference. Contained within the same pack as
these instructions is a set of component
checklists,which you will use to identify the items
contained within each pack. Within the checklists
is a ‘Roof Plan’. This diagram is very important as
it contains information specific to your
conservatory, such as, width, projection, height,
etc. Throughout this manual will be references to
your ‘Roof Plan’, please ensure that you refer to
this plan whenever requested to ensure all
dimensions, etc. correspond.
Working through the sections
The first part of the manual is an ‘Order of
Assembly’ chart, outlining the build stages for
your conservatory. Each diagram gives an
indication of what your conservatory will look like
at the end of each stage. Each section in this
manual is numbered to correspond with the
build stages and is structured as follows:
•Component reference page –
Here you will see a diagram showing details of
the parts required to complete the section.
The table shows an item number, description and
any specific comments if necessary.
The descriptions and item numbers are shown on
your checklists (along with another graphic for
identification) so you may sort out these parts
prior to commencing each section. You will not
need to collate any other parts from your
packaging until it is outlined in a ‘component
reference page’. The only exception is silicone
sealant, (as this is needed continually as you
work through the build process) which will be
outlined in the text as required.
•Section instructions pages –
Following the component reference page will be
the detailed step-by-step instructions to complete
the section. Once each section is complete the
format is re-produced again for the next section,
and so on. If at any point you feel you require any
assistance, the telephone number for our
technical helpline is shown at the bottom of each
page.
INSTALLATION TIPS
•All windows are a two person lift.
•Treat PVC-U in much the same way as
timber; however, use a finer saw when
cutting.
•All windows and doors can be either
internally or externally beaded, but
consistent throughout the conservatory.
When fitting the windows it is essential
that they are facing the correct way.
Use the drainage slots present along the
bottom of each window to determine the
outside of each window. The slots will
always be positioned to the outside face.
•When fitting your door outer frame, it
should be considered as a window and
fitted in the same manner.
•Ensure when fitting the door outer frame
that it is plumb and square. To check
this, the width must be constant all the
way up and the height constant all the
way across. In addition a diagonal
measurement across the corners must
be the same. If this is not addressed
correctly, it will most probably cause
problems when it comes to fitting your
doors.
•Try to avoid fitting opening windows
against the property wall. This will avoid
any conflicts with the openers and gutter
down pipes, etc.
•Ensure all drainage slots on windows
are at the bottom when positioning
windows.
All windows and doors are internally
reinforced at various positions with steel
sections. You may therefore feel
additional resistance when screwing into
the PVC as it cuts into the
reinforcement.

Page 4 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
RECOMMENDED TOOLS
•Tape measure (5m min.)
•2.5m (8’) step ladder.
•3.7m (12’) ladder –2 sections.
•Electric drill (hammer action).
•Steel drill bits: 3.0mm, 6.0mm long
reach (min. 120mm ) & 8.0mm
•Masonry drill bits (min 200mm reach):
8.0mm.
•Cordless screwdriver (12v min.).
•3 Clamps (G-Clamp or similar, one-
handed operation
if possible).
•1.2m (4’) spirit level.
•Silicone sealant gun.
•Plastic mallet.
•Work bench.
•Gasket pliers/cutters.
•Hacksaw
•Extension lead.
•Screwdrivers.
•Superglue.
•Cleaning materials.
•Cleaning equipment.
•Paper Towels.
HEALTH, SAFETY AND ENVIRONMENTAL
ISSUES
As with any type of construction work, there are
inherent dangers when assembling a
conservatory. The following supplement is
designed to supply the installer with general
health, safety and environmental information that
may be required during the assembly of a
conservatory. The appendix offers a guide to
“best practice” but cannot be considered as
comprehensive. You are advised to work safely
at all times.
1. General Site Safety
All sites are different and have different hazards.
Have a general regard to what potentially can
cause harm. The construction site itself should be
made a restricted area. Particularly at risk are
children and animals. You also need to consider
the security issue. Organise your space. Don’t
open boxes haphazardly and leave components
lying around that can get damaged, lost or pose a
trip hazard. Be aware of the weather forecast.
Wet and hot conditions cause specific hazards.
Put controls in place to manage any possible
vehicular movement on site. Protect the
environment by avoiding fugitive waste. Dispose
of your rubbish appropriately.
Personal Protective Equipment
The following PPE should be worn throughout the
construction:
A hard hat.
Safety foot wear.
The following PPE should be worn under certain
conditions:
(follow machinery guidelines where applicable)
Anti slip gloves (when handling glass roof
glazing units)
Wrist guards (when handling glass roof
glazing units)
Glass suction cups (when handling glass roof
glazing units)
Safety glasses (when handling glass roof
glazing units)
Hearing protection when drilling.
Dust mask if dust is likely to be generated.
Disposable or rigger gloves as applicable.
Advisable to keep arms and legs covered.
Fall arrest equipment if working above 2
metres in height.
When using a pre-fabricated steel base please
refer to the installation guide provided with
the base fixing kit for reference to safety
recommendations.
It is advisable to have a first aid kit handy –just in
case.
2. Working at Height
Be aware that Health and Safety legislation
states that fall protection measures must be put
in place by the employer of any person working
at a height of 2 metres or more where a fall
hazard exists. If it isn’t feasible to eliminate the
hazard using a collective system then a personal
protective equipment system must be selected
and used, be it for restraint, work positioning or
fall arrest purposes.
For further information, a useful specialist
company to contact for fall arrest guidance is
Bacou-Dalloz on 01256 693200
Some height work is inevitable during
construction. The majority of this work will
probably be done from a ladder.

Page 5 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
USE OF LADDERS
You are advised to adopt the following rules at all
times:
•Assess whether an alternative means of
access is more suitable. Take into
account the nature of the work, duration,
height being worked at, movements
required, equipment and materials being
used, type of ladder available etc.
•Ladders ideally should be of the “Class
1” type.
•Place them on a firm, stable and level
surface which is capable of supporting
the ladders and any intended load.
They must be erected so as to ensure
they won’t become displaced.
•Prior to use always check visually
whether the ladder is in good condition
and free of slippery substances such as
oil or mud.
•Check facilities for securing against
slipping –tied at top, secured at bottom,
or footed by a second person if no more
than 3m-height access is required.
IF ABOVE 3 METRES IN HEIGHT,
THEY MUST BE SECURED.
•The correct angle of rest is 75 degrees.
E.g. for every 4 metres in height, move
the base of the ladder out 1 metre.
•Metal ladders (and wooden ones when
wet) conduct electricity and should not
be used or carried near overhead power
lines.
•Ladders must be positioned the correct
way up –metal ladders often have rungs
with both flat and curved surfaces –the
flat surface is the one on which the
user’s feet should rest.
•The use of ad hoc and “botched” safety
devices must be avoided. For example
plywood base plates are not to be used.
If you require plant, equipment or
devices to do the job safely you are to
hire/buy them and not manufacture
them. This is a short cut to having an
accident.
•Never feel pressured to go up a ladder if
you are unhappy about its safety.
•Only use the ladders for the purpose for
which they were intended.
•Anyone below you? They could be
injured if you drop something.
If scaffolding is to be erected, this should be done
only by a suitably qualified contractor. You are
advised to ask the contractor to show you an
appropriate certificate of qualification. Ensure
any scaffold is “scaff -tagged”.
4. Tools
The tools you use are your responsibility. We
advise:
•Check the condition of your tools prior to
use, for obvious damage. Get them
checked out if you are in doubt. Arrange
for your tools to have a portable
appliance test.
•Any electric hand tools are 110 volt or
used in conjunction with a residual
circuit breaker.
•Don’t use tools other than for their
intended purpose.
•Follow manufacturer’s guidelines as
applicable.
FORMAL PROCEDURE FOR THE USE OF
KNIVES AND CHISELS
i. Ensure when using a knife / chisel you
always keep your hand that isn't in use
BEHIND the blade. Ensure that you cut
away from your body -NEVER towards
yourself.
ii. Ensure the position of others is away
from the cutting direction.
iii. Keep the tooling in a sharp condition so
you don't have to exert excessive force
to cut / slice.
iv. Always pick up the tool by the handle.
v. Always ensure the tool is stored safely
where a sharp edge cannot cause injury.
i. Only use the tooling for its intended
purpose where possible.
5. Manual Handling
As a general guideline, follow the “2 man lift”
stickers on the boxes. Lift correctly.
STOP AND THINK. Plan the lift.
Where is the load going to be placed?
Use appropriate handling aids if possible.
Do you need help with the load?
Remove obstructions such as discarded
wrapping materials. For a long lift –such as floor
to shoulder height –consider resting the load
mid-way on a table or bench in order to change
grip.
•PLACE THE FEET.
Feet apart, giving balanced and stable base for
lifting. Leading leg as far forward as is
comfortable.
•ADOPT A GOOD POSTURE.
Bend the knees so that the hands when grasping
the load are as nearly level with the waist as

Page 6 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
possible. Don’t kneel or over-flex the knees. Keep
the back straight and lean forward slightly over
the load if necessary to get a good grip. Keep the
shoulders level and facing in the same direction
as the hips.
•GET A FIRM GRIP
Try to keep the arms within the boundary formed
by the legs. The optimum position and nature of
the grip depends on the circumstances and
individual’s preference, but it must be secure.
A hook grip is less fatiguing than keeping the
fingers straight. If it is necessary to vary the grip
as the lift proceeds, do this as smoothly as
possible.
•DON’T JERK
•MOVE THE FEET
•KEEP CLOSE TO THE LOAD
•PUT DOWN, THEN ADJUST
If precise positioning of the load is necessary, put
it down first, and then slide it into the desired
position.
•TEAM LIFTING
It is important team members are physically
evenly matched. One person should take
responsibility and co-ordinate their actions.
•ADEQUATE VISION
Clear vision may mean multiple trips with smaller
loads, but it is safer.
6. Control of substances harmful
to health
The chemicals supplied by us for use when
assembling your conservatory are:
•SILICONE: Safety data sheet provided.

Page 7 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
7. COMPLAINTS PROCEDURE – IMPORTANT –PLEASE READ ON DELIVERY
Using your check list
It is recommended that all boxes are opened on delivery to ensure that all components listed on
your Customer Check List are present. This should be done before the specified F.O.C. buffer
period expires. The check list consists of quantities and component pictures to aid the
identification of parts. Use the check list to cross reference, examine and quantify your
components.
Missing and damaged components will have a cost implication after the specified buffer
period for F.O.C. parts after delivery. The F.O.C. buffer period will be noted on your
delivery check sheet.
If any components are missing, please contact the store where the conservatory was purchased
and provide the following;
•Your 6 digit order number –e.g. 177047
•The part reference code from your installation manual –e.g. C101
•The part description from your installation manual –e.g. 150mm Sill End Caps
•The page where the part is described in the installation manual –e.g. Page 9
Delivery damage
It is also recommended that all components are checked for delivery damage. On receipt of
delivery please check the packaging carefully prior to signing the delivery note. It is also good
practice to check your components prior to assembly to avoid your installation being halted. This
should also be done before the specified F.O.C. buffer period expires.
If any components are damaged, please contact the store where the conservatory was purchased
and provide the following;
•Your 6 digit order number –e.g. 177047
•The part reference code from your installation manual –e.g. C101
•The part description from your installation manual –e.g. 150mm Sill End Caps
•The page where the part is described in the installation manual –e.g. Page 9
8. QUERIES AND REQUESTS –IMPORTANT –PLEASE READ ON DELIVERY
If during your installation you are puzzled on any aspect of how components may fit together or
be positioned, you may call our Technical Assistance phone line which is highlighted at the foot of
every page.

Page 8 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
This installation guide provides information on the erection of the Garden Building.The
installation procedure on each model differs. These differences are outlined below.
The Square Garden Building
The free standing Square Garden Building model range also contains rectangular shaped
models. Both styles are joined at the corners by the 90° corner post (A109). The Square Garden
Building also uses a total of four Edwardian hip spars, which connect to a 25° Edwardian boss
end (C9170) situated on each end of the 25° ridge.
The Octagonal Garden Building
The Octagonal Garden Building has angled corners called ‘facets’. The windows around the
Garden Building are therefore joined by 135° corner posts (A110). The Octagonal Garden
Building uses a total of eight Victorian hip spars, which connect to a central circular 25° full boss
(C9026). There are two variations of the Octagonal Garden Building -the smaller model has only
one window on each facet unlike the larger model which has two windows per facet as shown
below.

Page 9 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
SECTION 2i
FITTING FIRST WINDOWS
SECTION 3i (Large Octagonal Garden Building Only)
FITTING WINDOWS IN A STRAIGHT RUN
SECTION 4
FITTING EAVES BEAM
SECTION 5i
GAZEBO RIDGE INSTALLATION (OCTAGONAL ONLY)
SECTION 7
GLAZING
SECTION 1i
BASE SILL INSTALLATION
OCTAGONAL GARDEN BUILDING ORDER OF ASSEMBLY

Page 10 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
SECTION 9
GAZEBO COVER INSTALLATION
SECTION 11
DOUBLE DOOR INSTALLATION
SECTION 12i
TRIMS & FINISHING
SECTION 13
GUTTER INSTALLATION
SECTION 8
SPAR CAPPINGS
SECTION 1ii
BASE SILL INSTALLATION
SQUARE GARDEN BUILDING ORDER OF ASSEMBLY

Page 11 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
SECTION 2ii
FITTING FIRST WINDOWS
SECTION 3ii
FITTING WINDOWS IN A STRAIGHT RUN
SECTION 4
FITTING EAVES BEAM
SECTION 5ii
RIDGE INSTALLATION (SQUARE GARDEN BUILDING ONLY)
SECTION 8
GLAZING
SECTION 6
INTERMEDIATE SPARS (SQUARE GARDEN BUILDING ONLY)
SECTION 7
TIE BARS (SQUARE GARDEN BUILDINGS ONLY)

Page 12 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
SECTION 11
RIDGE COVER INSTALLATION
SECTION 12
DOUBLE DOOR INSTALLATION
SECTION 13ii
TRIMS & FINISHING
SECTION 14
GUTTER INSTALLATION
SECTION 9
SPAR CAPPINGS

Page 13 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
1i –OCTAGONAL GARDEN BUILDING BASE SILL COMPONENT REFERENCE
Item No
Item Description
Comments
P106
150mm Sill
C109
External 135° Sill Connector
C110
In-line Sill Connector
Specific models only
SC025
3.9 x 16mm Reinforcing Screws
SC030
100mm Fixing Bolts
SC030
SC025

Page 14 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
1ii –SQUARE GARDEN BUILDING BASE SILL COMPONENT REFERENCE
Item No
Item Description
Comments
P106
150mm Sill
C108
External 90° Sill Connector
C110
In-line Sill Connector
Specific models only
SC025
3.9 x 16mm Reinforcing Screws
SC030
100mm Fixing Bolts
SC030
SC025

Page 15 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
Having already inspected the base for
LEVEL AND DIMENSIONAL ACCURACY
(against base plan), lay out the 150mm sill
pieces (P106) as per the conservatory plan.
Using Sealants
Wherever PVC-U is joined to PVC-U, ensure
that all jointing faces are silicone sealed
using a low-modulus, neutral cure silicone
sealant. The following sealants are
recommended:
Low-modulus silicone (brown):for sealing
woodgrain finish PVC-U conservatories
Low-modulus silicone (white):for sealing
white PVC-U to PVC-U.
Acrylic: for internal use where paint is to be
used.
All recommended sealants remain soft for
15-20 minutes (sufficient time for
repositioning if necessary). If excess sealant
is not removed immediately, wait until the
sealant is fully cured (about 24 hours) before
peeling the excess away cleanly.
When using sealant as a filler bead, mask
both sides of the bead area with masking
tape. Run a bead of sealant along the bead
area, exerting an even pressure on the
sealing gun.
Always refer to the manufacturers’
instructions for removing excess sealant.
Fitting the Sill
Please note the following section
describes the installation of the Square
Garden Building model, however the
process of installation is the same for the
Octagonal Garden Building model
Referring to your base plan diagram lay all
150mm sill pieces (P106) onto the base.
Approximate positioning is adequate at this
stage.
Ensure that every run of 150mm sill (P106)
has two 70mm sectionson one end of the
sill milled out as shown in the image below
This will allow the windows to be positioned
onto the sill and then along the groove of the
150mm sill (P106) throughout installation.
Sill Connectors
Progressively join the 150mm sill sections
(P106) together with the external 90° sill
connector (C108).

Page 16 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
Note: Some sections may require joining
by using in-line sill connector (C110).
Ensure that the external 90° sill connector
(C108) is silicone sealed on all contact
surfaces: top, bottom and sides.
Fix all sill connectors (C108/C110) to
150mm sill (PA1) with 3.9 x 16mm
reinforcing screws (SC025) as shown below.
IMPORTANT: Time spent getting the base
sill layout correct will save time later in
the installation, as paying attention to the
base sill dimensions, positioning, and
making sure it is level will ensure the
correct fitting of the rest of the
conservatory.
Lay the 150mm sill (P106) in position and
using your roof plan (located with your check
list), ensure that dimensions A and B are
consistent across the entire width and
projection and that both diagonals (C) are
equal.
Once level and in the correct position, using
the relevant drill bits, drill through the
150mm sill (P106) and into the base to at
least 100mm deep.

Page 17 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
Now permanently fix through the 150mm sill
(P106) to the base using the 100mm fixing
bolts (SC030).
The 100mm fixing bolts (SC030) should be
positioned 100mm from each end of the
150mm sill (P106) and equally spaced
between.
If your conservatory uses a pre-
fabricated steel base please use the self
drilling screws provided with the steel
base fixing kit referring to the installation
guide supplied.
Check your sill layout again for square.

Page 18 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
2i –OCTAGONAL GARDEN BUILDING FIRST WINDOWS COMPONENT
REFERENCE
Item No
Item Description
Comments
C105
Quarter Turn Button
C106
Sill Support Block
Pre-assembled
SC012
60mm Fixing Bolts
CON046
6mm Allen Key
A115
135° Corner Post
CON
046

Page 19 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
2ii –SQUARE GARDEN BUILDING FIRST WINDOWS COMPONENT REFERENCE
Item No
Item Description
Comments
C105
Quarter Turn Button
C106
Sill Support Block
Pre-assembled
CON046
6mm Allen Key
A109
90° Corner Post
CON
046

Page 20 Garden Building Installation Guide
Product Code : TGBv6.1 / November 2011
Select the first window to be installed. It is
imperative that the drain slots in every
window are located at the bottom of the
window and facing front as shown below.
Please also note that two sill support
blocks (C106) are attached to the bottom
of the windows also shown below.
Before installation commences check each
window for any defects such as scratches or
bowing. If you find any defects please follow
the complaints procedure highlighted at the
front of this manual.
Please note: Any slight bow in the
windows will be corrected as the window
connectors are slid into position.
You will notice that each window corner has
the inner legs on the window detail notched
away. It is imperative that this detail is
present to ensure that all 18mm inline
couplings (A104) can slide into position.
The notch detail is highlighted below.
Select the first window and position over the
milled out sections in the 150mm sill (P106).
Slide the window towards the corner of the
150mm sill (P106).
Prior to the positioning of the window into its
final place, apply a bead of silicone to the
top of the 150mm sill (P106) and inline with
the rear face of the 150mm sill (P106).
Continue to slide the window towards the
corner of the sill so that the front edge is
inline with the rear face of the 150mm sill
(P106) on the adjacent corner.