Duratuf KAIPARA Assembly Instructions Manual
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Duratuf KAIPARA Assembly Instructions Manual

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ASSEMBLY INSTRUCTIONS
KAIPARA
BASE SIZE: 3.900m x 2.550m
1 1

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Summary of Contents for Duratuf KAIPARA

  • Page 1 ASSEMBLY INSTRUCTIONS KAIPARA BASE SIZE: 3.900m x 2.550m...
  • 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 70 x 45 H4 (Green) 3.900m End Base Plate 70 x45 H4 (Green) 2.410m Front/Back Top Plate 70 x 45 H1 (Red) 3.900m EndTop Plate 70 x 45 H1 (Red) 2.410m Lintel 70 x 45 2.400m...
  • Page 4 DESCRIPTION LENGTH PART# DIAGRAM CHECKED Front Top Plate Flashing 3.900m 1001 Front Corner Flashing 2.510m 1002 Rear Corner Flashing 2.365m 1003 Door Top Flashing 2.595m 1004 Door Head Flashing 2.400m 1005 Door Jamb Flashing 2.100m 1006 Downpipe Cover Flashing 2.200m 1007 Barge Flashing 3.225m...

  • Page 5: Optional Extras

    OPTIONAL EXTRAS TIMBER FLOOR DESCRIPTION LENGTH DIAGRAM CHECKED Floor Joists 100 x 50 H4 3.880m Floor Boards 150 x 25 H3 2.530m Door Step Flashing 2.400m Floor Nails 50mm CLEAR ROOF DESCRIPTION LENGTH DIAGRAM CHECKED Clear Roof Panel 3.150m PLY FLOOR DESCRIPTION LENGTH DIAGRAM...

  • 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 raised foundation, either a concrete base, plywood floor, or timber floor, the shed design prevents the water from flowing inside the shed. • If you chose to position the shed directly onto the ground, the water can flow 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 PLYWOOD FLOOR Select SUB FLOOR FRAME 6 x 3790mm Joists 2 x 2530mm Joists 1 x 532mm Joists 3790mm 1 x 63mm Joists 3 x 555mm Joists 4 x Ply 1945mm x 1200mm 2 x Ply 1945mm x 130mm 532mm • Layout floor joists and assemble sub floor frame as shown, nailing joists together with two 90mm nails per join.
  • Page 8 TIMBER FLOOR SUB FLOOR FRAME Select 6 x 3880mm Joists 26 x 2530mm Floor boards 3880mm • Layout floor joists as shown, ensuring joists are spaced evenly apart. • Using 50mm flooring nails, nail a floor board on each end, ensuring ends are flush with joists. Make sure floor is level and joists are well supported. TIMBER SHOWING NAILS Nails ......... . • Layout remaining floor boards.
  • Page 9 TIMBER FRAME End Base Plates - 2 Front/Back Base Plates - 2 End Top plates - 2 Front/Back Top Plates - 2 Studs - 19 Ridge beam - 1 Nogs - 9 Lintel - 1 TIMBER FRAME - END WALLS Select 2 x 2410mm Base Plates 2 x 2410mm Top Plates...
  • Page 10 TIMBER FRAME - BACK WALL Select 1 x 3900mm Base Plate 1 x 3900mm Top Plate 4 x 2250mm Studs 3 x 1240mm Nogs • Select one 3900mm base plate (Green), one 3900mm top plate (Red) and four studs (Yellow). • Lay out plates and four studs on a flat surface and nail together using two 90mm nails per join.
  • Page 11 TIMBER FRAME - ASSEMBLE FRAME • Stand up back wall frame and one end wall frame. • Using a 10mm drill, predrill and screw both frames together using four 100mm tek screws per corner. (100mm down from top and 100mm up from base and remaining screws evenly spaced in between.) • Ensure end wall panels fit in between front and back frames.
  • Page 12 ATTACHING DPC TO FRAME • Any shed that has a floor should have the DPC attached to prevent water flowing between bottom plate and floor. • Using approx forty 30mm clouts, nail DPC to bottom plate ensuring top is flush with top of base plate. • Note if the shed doesnt have a floor, and is positioned directly on the ground, you wont need to attached DPC on the base plate. • Using ten 30mm clouts, attach 75mm wide DPC membrane to each corner as shown. DPC should be level with top of top plate and botom of base plate. BASE PLATE •...
  • Page 13 WALL CLADDING TO AVOID CORROSION: • Where at all possible try not to trap metal filings between two sheets. Remove all metal filings before riveting. • Carbon in pencils reacts with the Zinc/Aluminium coating on steel. Use ink to mark steel. Outside Inside CLADDING DETAIL CLADDING DETAIL Overlap Side View WALL CLADDING FIXING PATTERN All Tek Screws fastened through trough TEK SCREWS...
  • Page 14 WALL CLADDING - BACK & ENDS • Note - When attaching wall cladding always ensure top sheet is level with top plate and ends of sheet are flush and parallel with studs. This will ensure that wall panels are square. (Always screw wall sheets through the trough of the profile) • Position 1st sheet flush with top of top plate and both ends of sheet are flush with outside of studs. Ensure top edge is protruding outwards, to allow correct overlap on second sheet.
  • Page 15 FLASHINGS • Centralise front top plate flashing on top of top plate and attach flashing with four 30mm clouts to top plate. • Screw corner flashings onto each corner, using six 55mm tek screws per corner. Top screws should be approx 250mm down from top of top plate. • Ensure corner flashings are square and parallel with walls panels.and top of flashings are level with top of top plate. • Position door jamb flashing, so top is level with underside of lintel. • Using tin snips, knotch bottom of flashing around concrete or ply floor 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 16 BACK SPOUTING • Using six rivets per end, fit and rivet end caps to each end of back spouting. • Determine position of downpipe and cut hole in underside of spouting. (Note - hole needs to be at least 300mm or more from end of spouting, and slightly smaller than plastic dropper supplied.) • Using four rivets, rivet plastic dropper to underside of spouting. •...
  • Page 17 ROOF • If an optional clear roof sheet has been supplied, this can be fitted in any of the middle positions. (Note - both edges of clear roof sheet overlap standard sheets at each side.) • Position first roof sheet into position ensuring sheet will correctly overlap the next sheet. Edge of sheet will be flush with outside edge of timber frame. ROOF SHEET • Position sheet 500mm past front top plate flashing so that sheet overlaps rear spouting as shown. • Using one 55mm tek screw, screw roof sheet to front top plate. Ensure roofing screw is screwed through the top of the crest on corrugate profile.(See roof fixing pattern below) • Repeat using one 55mm tek screw, screw roof sheet to back top plate through rib of corrugate, ensuring sheet is flush with timber frame.
  • Page 18 FASCIA, SPOUTING & BARGE • Select the left hand barge flashing. This will fit in between the fascia and the back spouting. We will be attaching the barges to the spouting at the back first and fitting the fascia last. Barge Flashing • Hold the flashing in firmly against the side of the shed spanning over the roof corrugate and down the side of the shed. •...

  • Page 19: Before You Begin

    ROLLER DOOR BEFORE YOU BEGIN • This Roll-A-Door is designed and tested to provide security, attractive appearance and smooth, low effort 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 20: 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 affected. The floor 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 2400mm opening.
  • Page 21 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 22: Install First Bracket

    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 23: Position Door

    ROLLER DOOR centering axle WARNING! practice correct lifting techniques axle “floats” in either direction POSITION DOOR BOTTOM RAIL AT 3 O’CLOCK • Centre the door with the opening, while ensuring the floating 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 24: 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 flush 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 roll-a-guide...

  • Page 25: 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 above the door guides.
  • Page 26 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 finger entrapment. CLEAN UP • Remove all swarf (drill filings) with a soft brush or rag. • Hose down roof and walls thoroughly. • For Coloursteel sheds use touch-up paint provided on all nail heads, rivets and exposed cuts.

  • Page 27: 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 28: After Installation Care

    ROLLER DOOR ADJUST TO SPRING TENSION WARNING: Ensure that pipe wrench is fitted 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. b) With a person at each end of the door, hold the axle firmly with a large pipe wrench (Stillson) at TO LOOSEN...
  • Page 29 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 30 • In the rare event of a claim and upon receiving proof of purchase and defect, Duratuf will at its option repair or replace defective parts, or provide a prorated refund for the remaining life of the applicable warranty. Any replacement product provided will be covered by the Warranty for the balance of the Warranty term as if the replaced product were the original product.

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