Duratuf Kinloch, Assembly Instructions Manual

Page 1: ...Kinloch Base size 2400 x 4200 Assembly Instructions Dura LIFESTYLE LIFESTYLE ...

Page 2: ......

Page 3: ...20 2 2 Front wall cladding attachment 22 3 Flashing attachment 24 3 1 Top plate and door flashing attachment 24 3 2 Corner flashings attachement 25 3 3 Back spouting assembly 26 3 4 Back spouting attachment 27 4 Roof sheets attachment 28 4 1 Layout for fastening roof sheets 28 4 2 Optional clear roof sheet attachment 28 4 3 Roof sheets fastening 29 5 Front spouting and barges attachment 32 5 1 Bar...

Page 4: ...nner Hammer Hand saw Level Flat file Tape measure String line Riveter Pipe wrench Caulking gun Tin snips left right hand Hex drive 5 16 Hex drive 3 8 Philips drill bit Square drive drill bit Slotted drill bit Drill bit 3 5mm Drill bit 7mm Hammer drill and 10mm and 12mm masonry bits Hacksaw Utility knife ...

Page 5: ...nts The following maintenance process needs to be adhered to to qualify for the steel warranty of your shed Using water and soft nylon brush wash all surfaces annually Within 2km 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 corrisive salt deposits Volcanic ash fallout wash as soon as possible removing fallout from ro...

Page 6: ...op plate 7 Front Back 70x45 2 2400 TN003 Nog 3 Back 70x45 2 1131 TN004 Nog 4 Side 70x45 4 1154 TN006 Nog 6 Front 70x45 2 162 TN007 Nog 7 Side 70x45 4 761 TS001 Stud 1 Front 70x45 3 310 TS003 Stud 3 Back Side 70x45 13 2250 TS005 Stud 5 Front 70x45 4 2399 TS006 Stud 6 Front 70x45 2 2044 TL002 Lintel 2 70x45 1 1892 TR016 Ridge beam 19mm Notch 140x45 1 2400 TR017 Ridge beam 63mm Notch 140x45 1 2400 TR...

Page 7: ...0 FBS003 Back spouting 3 1 2525 FS001 Spouting end cap 2 FBC001 Back corner flashing 2 2365 FB007 Barge flashing 4 2 4860 FB008 Barge support 4 2 4060 FFS003 Front spouting 3 1 2525 FDP001 Downpipe cover flashing 1 2170 FDJ002 Door jamb flashing 2 2 2115 FFC002 Front corner flashing 2 2 2515 FFT003 Front top plate flashing 3 1 2400 FDF002 Door top flashing 2 1 1995 PVC downpipe 1 3000 Steel roller...

Page 8: ...90mm nails framing 200 pcs Rivets 80 pcs 25mm Tek Screw coloured zinc 240 pcs 55mm Tek Screw coloured zinc 220 pcs 100mm Tek Screw coloured zinc 20 pcs M12 X 135 through bolt 17 pcs Purlin concealed cleats 86x40mm 18 pcs Dome washer for clear roof sheet 20 per clear sheet Silicone tube 1 Hardware list ...

Page 9: ...positioned on either a concrete base or plywood floor 4180 2380 1800 Plas c sheet 150 min 10mm overhang over concrete base Ground levelled solid or compacted substrate 30mm cladding overhang 200 Approx 200 100 Base thickness 150 20 Door slope 665 or SE62 mesh 60mm bo om cover 20MPA 100 thick slab with 200mm thick perimeter Concrete to NZS 3101 HD12 con nuous perimeter bar approximately 30mm from e...

Page 10: ...due to inaccuracies inherent in rough cut sections of timber 1 Lay out joists and assemble sub floor frame as shown nailing joists together with two 90mm nails per joint 2 Position sub floor frame ensuring frame is well supported and level and diagonals are correct Trim supplied plywood sheets to 2090x1190 Using 40mm screws screw plywood to sub floor frame as shown Ensure timber floor is sufficien...

Page 11: ...IFESTYLE Kinloch 1 Timber frame assembly Arrange the parts specified in the following steps on a flat surface and attach them together using two 90mm nails at each join Studs should be positioned between top and bottom plates ...

Page 12: ...d to be trimmed due to stud thickness 1 1 Back wall assembly TT007 TB007 TS003 TS003 1 2 TS003 1131 1131 3 1132 TN003 Regarding Part IDs refer to the Parts list in pages 4 5 Nail top and bottom plates to end studs Nail remaining studs in correct position Nail in nogs at correct height TN003 ...

Page 13: ...y TT008 TB008 TS003 TS003 1 2 TS003 761 1154 1154 3 TN004 1132 Regarding Part IDs refer to the Parts list in pages 4 5 TN007 Nail top and bottom plates to end studs Nail remaining studs in correct position Nail in nogs at correct height TS003 TS003 TN007 TN004 761 ...

Page 14: ...Nail top and bottom plates to end studs Nail remaining studs in correct position Nail in nogs at correct height Nail shorter studs each side of doorway using 4 nails evenly spaced into longer stud and 2 nails through bottom plate Nail lintel to studs at each end Nail studs above doorway to top plate and lintel TS001 438 438 439 439 1132 TN006 TN006 TS005 162 1892 TS005 162 ...

Page 15: ...h 1 4 DPC attachment to bottom plate Cut pieces of the DPC roll to the length of each wall panel and nail them to underside of bottom plate on wall panels using 30mm clouts underneath each stud flush with the outside edge of the bottom plate ...

Page 16: ...h other Back wall Side wall Front wall 1 0 0 10 0 100mm Tek Screw Even spacing Pre drill side wall frames as shown using 7mm drill bit Screw frames together using a cordless drill screwdriver and four 100mm Tek Screws at each corner 1 2 Back wall Side wall Side wall ...

Page 17: ...ts 3 outside 3 underside Fix each ridge beam s 2 ends to the side walls above each stud using 3 cleats 2 at the top and 1 underneath and four 25mm Tek Screws per cleat 1 6 Ridge beam and door head flashing attachment Regarding Part IDs refer to the Parts list in pages 4 5 1 2 TR016 TR017 TR018 25mm Tek Screw ...

Page 18: ...hen make sure diagonal measurements as shown are the same to ensure frame is straight and square 1 10 Pre drill a hole within 50mm from one side of studs as shown through timber and concrete base using hammer drill and 12mm masonry drill bit 18 holes in total Fasten timber frame to the base through the holes using M12x135 through bolts ...

Page 19: ...ottom plate between door studs using a hand saw flush with inside of front wall studs 4 Ensure diagonal measurements on front wall are the same Then attach brace strapping in a cross on both left and right sides of the front door using 30mm nails 3 ...

Page 20: ...nd nail to inside of frame to temporarily hold wall panel square Staple building paper to outside of frame and proceed with wall claddings Once the cladding is complete remove timber bracing Using ten 30mm clouts attach DPC to each corner as shown DPC should be level with top of top plate and 20mm below bottom of bottom plate Repeat above attaching DPC to door studs with top of DPC level with unde...

Page 21: ...ews at every stud Top sheet must be flush with the top of the top plate Ends of the corrugated sheets must be flush with outside of studs Ensure metal filings have been removed from between sheets and between sheets and fasteners Pre drill cladding using 3 5mm drill bit for easy fastening 25mm Tek Screw Always fasten through the trough of profile Ensure top sheet overlaps bottom sheet Trough Rib ...

Page 22: ...late TT006 Fasten two 25mm Tek Screws 2 ribs up from the bottom of sheet ensuring end of sheet is flush with outside of studs 2 Position the second sheet underneath the first sheet ensuring top sheet overlaps the outside of the bottom sheet and bottom of sheet is approximately 1612mm down from side top plate TT006 Attach the sheet to timber frame using two 25mm Tek Screws at the top corners in the...

Page 23: ... 3 4 Screw the 3 sheets of back and side walls using 25mm Tek Screws in the middle of each sheet 5 screws per end of each sheet and 2 in the middle Repeat these steps for remaining back and side walls sheets 5 Position and attach third sheet ...

Page 24: ...p plate 1 Tek Screw in each 310mm stud Top of this sheet to be flush with top of the top plate For all sheets both ends should be flush with outside of studs 2 Ensure bottom of first row of front wall sheets is approximately 1147mm down from top of front top plate TT007 and front wall cladding profile height matches side wall profile height Ensure bottom of front wall half sheet is approximately 3...

Page 25: ...s list in pages 4 5 Ensure bottom of second row of front wall sheets is approximately 1832mm down from top of front top plate TT007 and front wall cladding profile height matches side wall profile height Attach third row of front wall sheets and screw off sheets as per cladding plan ...

Page 26: ... so top is level with underside of lintel TL002 If required notch bottom of flashing around concrete using tin snips Nail door jamb flashing to inside of stud using three 30mm clouts and screw it into stud through the front of wall cladding using three 55mm Tek Screws 3 Screw door top flashing FDF002 to lintel TL002 using three 55mm Tek Screws 1 at each end and 1 in the middle Door top flashing le...

Page 27: ...o the Parts list in pages 4 5 Attach corner flashings onto corners using six 55mm Tek Screws per corner approximately 250mm down from top of the top plate Ensure corner flashings are square and parallel with wall panels Ensure bottom of flashings are level with bottom of cladding FFC002 FFC002 FBC001 ...

Page 28: ... back and mark diameter of dropper Drill a small hole and using tin snips cut a larger hole slightly larger than the diameter of dropper 2 Silicone around the hole and insert dropper into hole Screw sleeve onto dropper from underneath 3 Fit and rivet end caps to each end using 6 rivets per end Silicone both end caps to back spouting to ensure there is no leak FBS003 Dropper FS001 Dropper Sleeve 3 ...

Page 29: ...rhangs corner flashings by approximately 25mm at each end 2 Cut downpipe to desired length Insert downpipe into dropper and fasten it using 1 rivet Fix downpipe to the back wall cladding using 2 downpipe brackets equally spaced riveting them into back wall cladding 3 Using 6 rivets equally spaced attach downpipe flashing to wall cladding 3 4 Back spouting attachment Spouting assembly Downpipe Brac...

Page 30: ...of rib of profile Use 4 Tek Screws per sheet top plate ridge beam An optional clear roof sheet if supplied needs to be fitted so both edges of the clear roof sheet overlap standard sheets on either side For fastening clear sheet follow the screw pattern of standard roof sheets On clear sheet use dome washers under the screw heads 4 2 Optional clear roof sheet attachment ...

Page 31: ...the previous sheet Sheets must be 480mm past front top plate flashing FFT001 and overlap back spouting FBS001 After fastening all roof sheets ensure metal filings have been removed from between sheets and between sheets and fasteners 4 3 Roof sheets fastening Regarding Part IDs refer to the Parts list in pages 4 5 ...

Page 32: ...m and correct front overhang of distance of 480mm from top flashing Packaging timber You may temporarily brace top plates and ridge beams to ensure they are straight by nailing timber from packaging crate as shown Nail to underside if you are using building paper or netting Condensation can form on underside of the shed roof If building paper is required fit it now Building paper will need to be s...

Page 33: ...ct overlap and 762mm from edge of previous sheet 4 Position and attach remaining roof sheets ensuring correct front overhang and each sheet is 762mm from previous sheet Position and attach last sheet to ensure it overhangs end of ridge beams by 0 30mm Remove bracing timber after roof is attached ...

Page 34: ...list in pages 4 5 Position barge support flashings FB008 on each side of shed so bottom of barge support flashing is 190mm below top of ridge beams parallel with roof slope and centrally between corner flashings 1 Attach barge support to wall sheet using 5 rivets at either side 2 FB008 5 1 Barge support attachment 190 ...

Page 35: ...hment FB007 Regarding Part IDs refer to the Parts list in pages 4 5 Using five 55mm Tek Screws equally spaced per barge secure barge flashings through roof sheets into the end of ridge beams and top plates Attach bottom of barge to barge support using 3 rivets equally spaced per side 1 ...

Page 36: ...all the front spouting and rivet spouting ends to barge flashings at both top and bottom Then fasten front spouting to the roof sheets using rivets equally spaced 3 rivets per sheet 2 FFS001 Regarding Part IDs refer to the Parts list in pages 4 5 ...

Page 37: ... parts bag E Guide clips door size dependant 4 F Door handle and fixing to suit 1 G Bottom rail stops and 6mm screws 2 H Faceplate and fixing to suit 1 I Locking bar retainer 2 J Locking bar covers 2 K U Bolts 2 L Axle Bracket saddles 2 M 8mm Nuts for Ubolts 4 N Counter sunk screws for lock and facia 2 O 7mm x 4mm Mushroom head screws for locking bar 2 P 4mm x 6mm Screws for handle 2 Q 10mm Washer...

Page 38: ...above and make sure it is level with the first bracket 6 1 Brackets installation 6 2 Door placement on brackets Centralise shaft on roller door and fit plastic clamp onto shaft at one end to ensure shaft stays centralised Do not cut plastic yet Using 2 persons and correct lifting techniques lift door onto brackets right way around so door will roll down from the front of the opening Immediately lo...

Page 39: ...e bottom rail is at 3 o clock Ensure U bolts are tightened then rotate the door one turn in a forward direction to apply tension Do not let go off the door as the springs are now tensioned Hold the door firmly and cut the plastic wrap along the bottom rail take care not to damage the door surface Slowly pull the curtain down and carefully position a wooden chock or any other appropriate stop betwe...

Page 40: ...sition the bottom clip 200mm from the floor with the rest evenly spaced along the guide Position 1 guide over the edge of the door curtain Mark and drill the top fixed guide clip and secure it using 40mmx8mm coach screw and washer allowing 3mm clearance between inside of guide and plastic roll a guide Ensuring guide is plumb fix remaining clips Repeat with second guide Remove the wooden chock and ...

Page 41: ...nting screws and washers Do not overtighten the screws With the door in the closed position slide the end of the locking bars D through the locking bar retainers and while holding the bars level mark the side of the guides Drill and file out a rectangular slot no longer than 25mm and no wider than 10mm ensuring top of the slot remains in line with top of the locking bar Slide bars through the guid...

Page 42: ...are plumb Refer to page p37 Centralise the axle Refer to section Centralise the axle when door is mounted 6 10 Troubleshooting WARNING Ensure pipe wrench is fitted correctly to axle and it is gripped onto the axle Do not underestimate the tension in the spring when undoing the clamps CAUTION This adjustment requires two persons to perform If the door rolls up crooked with one side than the other p...

Page 43: ... Stillson at least 450mm long Loosen the U bolt nuts at both ends and KEEP A FIRM GRIP ON WRENCH Rotate the axle in the required direction see diagram Re tighten the U bolts BEFORE releasing pipe wrench Test and repeat if further adjustment is necessary WARNING Ensure that pipe wrench is fitted correctly to axle and it is gripped onto the axle Do not underestimate the tension in the spring when un...