Duratuf Ponsonby Assembly Instructions Manual
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Duratuf Ponsonby Assembly Instructions Manual

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ASSEMBLY INSTRUCTIONS
PONSONBY
BASE SIZE: 2.400m x 1.000m

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Summary of Contents for Duratuf Ponsonby

  • Page 1 ASSEMBLY INSTRUCTIONS PONSONBY BASE SIZE: 2.400m x 1.000m...
  • Page 2 • If your shed is to be positioned on wet or damp ground, we recommend that your shed is raised up off the ground slightly. WARRANTY REQUIREMENTS The following maintenance process needs to be adhered to, to qualify for the steel warranty of your Duratuf Guardian 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.

  • Page 3: Parts List

    PARTS LIST TIMBER DESCRIPTION LENGTH DIAGRAM CHECKED Front/Back Base Plate 45 x 45 H4 (Green) 2.400m End Base Plate 45 x45 H4 (Green) 1.000m Front/Back Top Plate 45 x 45 H1 (Red) 2.400m End Top Plate 45 x 45 H1 (Red) 1.000m Lintel 45 x 45 H1 1.800m...
  • Page 4 DESCRIPTION LENGTH PART# DIAGRAM CHECKED Corner Flashing 2.364m 1001 Door Top Flashing 1995m 1002 Door Head Flashing 1.800m 1003 Door Jamb Flashing 1.970m 1004 Barge Flashing 1.188m 1005 Spouting 2.515m 1006 Ridge 2.515m 1007 HARDWARE/ACCESSORIES DESCRIPTION LENGTH DIAGRAM CHECKED Flathead Nails 75mm Tek Screws 55mm...

  • Page 5: Optional Extras

    OPTIONAL EXTRAS CLEAR ROOF DESCRIPTION LENGTH DIAGRAM CHECKED Clear Roof Panel 1.100m PLY FLOOR DESCRIPTION LENGTH DIAGRAM CHECKED Plywood 17mm treated 2.400m x 0.955m Plywood 17mm treated 0.165m x 0.045m Joists 45 x 45 H4 2.310m Joists 45 x 45 H4 0.865m Aluminium Door Step Flashing 1.795m...

  • Page 6: Concrete Base

    FOUNDATIONS • No doubt by now you will have decided what sort of base you are putting down. • If you choose a concrete base, the shed design prevents the water from fl owing inside the shed. • If you chose to position the shed directly onto the ground, the water can fl ow down the walls and under the bottom plate and into the shed. 10mm CONCRETE BASE • To build a concrete base we recommend the following. 80mm •...
  • Page 7 TIMBER FRAME End Base Plates - 2 Front/Back Base Plates - 2 End Top plates - 2 Front/Back Top Plates - 2 Studs - 9 Nogs - 6 Lintel - 1 TIMBER FRAME - BACK WALL Select 1 x 2400mm Base Plate 1 x 2400mm Top Plate 3 x 2295mm Studs 2 x 1132mm Nogs...
  • Page 8 TIMBER FRAME - FRONT WALL Select 1 x 2400mm Base Plate 1 x 2400mm Top Plate 1 x 1800mm Lintel 6 x 2295mm Studs 2 x 320mm Studs 2 x 165mm Nogs • Select one 2400mm base plate (Green), one 2400mm top plate (Red) and four studs (Yellow).
  • Page 9 TIMBER FRAME • Position Back wall frame on top of plates. While someone supports frame, nail in place. • Carefully roll frame over onto its base. (Pieces of timber from the packaging may be used to temporarily brace the frame before rolling it over).
  • Page 10 SECURE FRAME TO CONCRETE BASE • If your shed has a concrete base, position frame onto base. (Note: if access is an issue, you can position shed after the shed has been built but before you install Dyna bolts the roller door). •...
  • Page 11 ATTACHING DPC TO FRAME • Any shed that is positioned on a concrete base should have the DPC attached to prevent water fl owing between bottom plate and fl oor. • Using approx twenty fi ve 30mm clouts, nail DPC to bottom plate ensuring top is fl ush with top of base plate. • Note if the shed doesnt have a concrete base, and is positioned directly on the ground, you wont need to attached DPC on the base plate.
  • Page 12 WALL CLADDING TO AVOID CORROSION: • Where at all possible try not to trap metal fi lings between two sheets. Remove all metal fi lings before riveting. • Carbon in pencils reacts with the Zinc/Aluminium coating on steel. Use ink to mark steel. CLADDING DETAIL CLADDING DETAIL Side View Overlap WALL CLADDING FIXING PATTERN All Tek Screws fastened through trough TEK SCREWS...
  • Page 13 WALL CLADDING - BACK & ENDS • Note - When attaching wall cladding always ensure top sheet is level with top plate and ends of sheet are fl ush and parallel with studs. This will ensure that wall panels are square. (Always screw wall sheets through the trough of the profi le) • Position 1st sheet fl ush with top of top plate and both ends of sheet are fl ush with outside of studs.
  • Page 14 FLASHINGS • Screw corner fl ashings onto each corner, using six 55mm tek screws per corner. Top screws should be approx 250mm down from top of top plate. • Ensure corner fl ashings are square and parallel with walls panels.and top of fl ashings are level with top of top plate. • Position door jamb fl ashing, so top is level with underside of lintel. • Using tin snips, knotch bottom of fl ashing around concrete or ply fl oor if required. • Attach using three 30mm clouts, nailed to inside of stud and three 55mm tek screws, screwed through front wall cladding into stud.
  • Page 15 SPOUTING • If shed has an optional downpipe kit, fi t end caps now. • Using six rivets per end, fi t and rivet end caps to each end of spouting and silicone end caps to ensure there are no leaks. • Nail assembled spouting to top of top plate, using four 30mm clouts as shown. (Note - spouting will overhang corner fl ashing by approx 20mm, spouting will always be on the lower top plate.) •...
  • Page 16 ROOF • If an optional clear roof sheet has been supplied, this can be fi tted in any of the middle positions. (Note - both edges of clear roof sheet overlap standard sheets at each side.) • Position fi rst roof sheet into position ensuring sheet will correctly overlap the next sheet. Edge of sheet will be 10mm in from outside edge of timber frame. •...
  • Page 17 RIDGE & BARGE • Position ridge fl ashing into position ensuring soft edge is on top. Note ridge will overhang corner fl ashing by approx 20mm. • Using nine rivets (3 per sheet), rivet ridge to the ribs on roof sheets. • Using two rivets, rivet ridge to corner fl ashing. • Push soft edge down into roof corrogations to prevent water penetrating under the ridge fl ashing.

  • Page 18: Before You Begin

    ROLLER DOOR BEFORE YOU BEGIN • This Roll-A-Door is designed and tested to provide security, attractive appearance and smooth, low eff ort operation provided it is installed and operated in strict accordance with the following safety warnings. Failure to comply with the following instructions may result in death, serious personal injury or property damage. • NOTE: Do not unwrap packaging around roller door until requested, as this will untension the door. SERIES 1 ROLL-A-DOOR DESCRIPTION ITEM...

  • Page 19: Parts Checklist

    ROLLER DOOR PARTS CHECKLIST REQUIREMENTS BEFORE INSTALLATION • Level and plumb - The door must be installed in an absolutely level position, if opening is not level and square, appearance and/or sideroom requirements will be aff ected. The fl oor should be level or recessed across the opening to avoid gaps. MEASUREMENTS • Opening width - As the standard door overlaps each side by 30mm or more, the door should be 60mm wider than the 1800mm opening.
  • Page 20 ROLLER DOOR LINTEL HEIGHT DRIVE THROUGH CLEARANCE DRIVE THROUGH CLEARANCE for doods with handle HEADROOM REQUIREMENTS FOR DOORS • Headroom - A minimum of 410mm of headroom is required. If the door is installed lower into the opening than shown below, additional loss of door opening height will result.
  • Page 21 ROLLER DOOR INSTALL FIRST BRACKET • Measure the door curtain width and mark where edge of curtain will be, allowing for over lap on each side of the opening. • Add clearance of 20-30mm from edge of curtain to inside edge of bracket to determine positioning of the bracket.
  • Page 22 ROLLER DOOR centering axle WARNING! practice correct lifting techniques axle “fl oats” in either direction POSITION DOOR BOTTOM RAIL AT 3 O’CLOCK • Centre the door with the opening, while ensuring the fl oating axle is also centred with the door. Do this by lining up previous marks with the hub,then lift both the axle and the door together until it is centred with the opening.

  • Page 23: Attaching Stop

    ROLLER DOOR ATTACHING STOP To attach bottom rail stops (G) to bottom rail of door. • Hook stop behind lip in rail, as shown. • Secure from underneath the rail with screws (G) supplied. Trim the weatherseal fl ush with the end of the bottom rail. stop GUIDES • Check that curtain overlaps equally on both sides, and cut the guides (C) to the correct length that is, level with the brackets (B...

  • Page 24: Fitting Handle

    ROLLER DOOR FITTING HANDLE • Fit the handle (F) to the outside of the door using the screws (P), nuts and washers provided CENTRE LIFT LOCK LACERATION Wear appropriate gloves as some edges of the door are very sharp. • Raise the curtain until the lock corrugation is visible Raise the curtain until the lock corrugation is visible above the door guides.
  • Page 25 ROLLER DOOR Faceplate Lock Lock bar cover assembly Double sided adhesive tape WARNING: Locking bar covers must be installed to prevent Lock bar cover possible fi nger entrapment. CLEAN UP • Remove all swarf (drill fi lings) with a soft brush or rag. • Hose down roof and walls thoroughly. •...

  • Page 26: Troubleshooting

    ROLLER DOOR TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Door is hard to Door jamming in the guides Check: operate in ANY a) the guide clearances DIRECTION b) the guides are plumb c) that the guide surfaces are clean and free from oil d) that the locking bars are the correct length e) that the weatherseal is correct length The door is hard...

  • Page 27: After Installation Care

    ROLLER DOOR ADJUST TO SPRING TENSION WARNING: Ensure that pipe wrench is fi tted correctly to the axle and if it is gripped onto the axle do not underestimate the tension in the spring when undoing the clamps. CAUTION: THIS ADJUSTMENT REQUIRES 2 PERSONS TO COMPLETE. a) With the door rolled up tie two ropes around the door roll approximately 300mm from each end, as a safety precaution.
  • Page 28 ROLLER DOOR We suggest you record your full Key letter and Number on the front of this manual and if replacement keys are required they can be obtained from your nearest B&D office, simply by quoting this number. If the keys have been lost and the number not recorded, it can be found stamped into the locking arm at the back of the mechanism. NYLOFELT® On no account should you use grease or oil in the door guides or on the Nylofelt® running strips – the grease or oil will clog the Nylofelt® and spoil the operation of the door. An occasional wipe with a cloth dampened with mineral turps or methylated spirits, down the inside of each guide, is very beneficial in removing any trace of grease or dirt.

  • Page 29: Warranty Registration

    DURATUF PREMIUM SHED WARRANTY GUARANTEE TO CUSTOMER Congratulations on purchasing a Duratuf Storage Shed. With proper care and attention, this product will last any years. For your benefi t PLEASE READ THE FOLLOWING INFORMATION CAREFULLY. WARRANTY ON METAL CLADDING Riverlea Group Ltd guarantee that the metal roofi ng and wall cladding on Kiwi and Fortress Garden Sheds may be used in moderate and inland corrosion zones or areas where the fi rst year mild steel corrosion rate is less than 200g/m2, and that in these conditions, they will not perforate due to corrosion within 18 years of date of manufacture.

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