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Dunster House THEODORE Installation Manual

3.8m x 3.3m garden office
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INSTALLATION MANUAL
for
3.8m x 3.3m THEODORE Garden Office
WARNING:
- Please read these instructions carefully before starting to assemble the product.
- This product will require a minimum of two people for installation.
- Please keep these instructions for future reference.
Unique Garden Office Reference Number:
.........................
www.dunsterhouse.co.uk

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Summary of Contents for Dunster House THEODORE

  • Page 1 INSTALLATION MANUAL 3.8m x 3.3m THEODORE Garden Office WARNING: - Please read these instructions carefully before starting to assemble the product. - This product will require a minimum of two people for installation. - Please keep these instructions for future reference.
  • Page 2 E-Mail: cs@dunsterhouse.co.uk Fax: (01234) 224497 Post: Dunster House Ltd., Caxton Road, Elms Farm Industrial Estate, Bedford MK41 0LF, England. Our Customer Service team aim to respond within 2-3 hours of receipt, however, this may be longer during busy periods. Please include your Sales Order (SO) number in any correspondence with Customer Services to enable them to locate your file.

  • Page 3: Getting Ready

    The Nature of Wood The wood provided for your Garden Office external cover boards, bearers and decking is soft wood which has been kiln dried and treated for protection against rot and insect infestation. Wood is a natural product, which may have knots, knotholes, imperfections, cracks and warping. It can be affected by variations in weather conditions and can be susceptible to mould in unheated buildings.
  • Page 4 Foundation A correct foundation is paramount to installing your Garden Office correctly. Only a completely level and square load bearing foundation will ensure a stable and problem free installation, especially when aligning the doors. Foundations can be prepared using: • sleepers •...
  • Page 5 Please contact our customer service team in writing, by either: E-maill: cs@dunsterhouse.co.uk Fax: (01234) 224497 Post: Dunster House Ltd., Caxton Road, Elms Farm Industrial Estate, Bedford MK41 0LF, England. Please include your Sales Order (SO) number in any correspondence with Customer Services to enable them to locate your file.
  • Page 6 3.8m x 3.3m THEODORE Garden Office - Components Page 5 E.3770 1x Pressure Treated Bearer 3770 E.3630 2x Pressure Treated Bearer 3630 E.3490 2x Pressure Treated Bearer 3490 E.2630 2x Pressure Treated Bearer 2630 E.2490 2x Pressure Treated Bearer 2490 E.2350...
  • Page 7 3.8m x 3.3m THEODORE Garden Office - Components Page 6 E35.495 2x Pressure Treated Bearer E35.475 5x Pressure Treated Bearer E35.530 2x Pressure Treated Bearer E35.537 4x Pressure Treated Bearer Deck.95x20x3790 6x Decking board pressure treated 3790 Door.Post 2x Door post assembly...
  • Page 8 3.8m x 3.3m THEODORE Garden Office - Components Page 7 Door Packer-70x25x647 2x Door Packer Door Packer-70x25x1822 1x Door Packer 1822 Ladder.FL.MKII 1x Ladder Shape Support 2135 2098 Ladder.FR.MKII 1x Ladder Shape Support 2135 2098...
  • Page 9 3.8m x 3.3m THEODORE Garden Office - Components Page 8 WP-L.F.G.150 WP-R.F.G.150 1x Wall Panel 1x Wall Panel...
  • Page 10 3.8m x 3.3m THEODORE Garden Office - Components Page 9 WP-B.M WP-W.M.LN 6x Wall Panel 1x Wall Panel 1214 1214...
  • Page 11 3.8m x 3.3m THEODORE Garden Office - Components Page 10 1200x2415.Plasterboard 1175x2415.Plasterboard 1x Roof Panel Assembly 2x Roof Panel Assembly 1200 1175...
  • Page 12 3.8m x 3.3m THEODORE Garden Office - Components Page 11 595x2500x10.MFP 655x2500x10.MFP 1200x2500x10.MFP 2x MFP Roof Board 2x MFP Roof Board 1x MFP Roof Board 1200 1250x775x10.MFP 1200x775x10.MFP 2x MFP Roof Board 1x MFP Roof Board 1250 1200 70x70x2120 2120...
  • Page 13 3.8m x 3.3m THEODORE Garden Office - Components Page 12 Roof.Cover.3.8.MKIII 3700 1x Roof Back Cover CB.293x87.N CB.293x83.N 60x45x190 60x45x100 1x Finishing Trim 1x Finishing Trim 2x Roof profile 6 of required Guttering support 19x19x2000 2000 1x Door Finishing Trim...
  • Page 14 3.8m x 3.3m THEODORE Garden Office - Components Page 13 FP.1125x2405 FP.1210x2405 1x Floor Sandwich Panel 2x Floor Sandwich Panel 1125 1210...
  • Page 15 3.8m x 3.3m THEODORE Garden Office - Components Page 14 70x70x3795 1x Roof Beam 3795 Middle.Purlin.3223 7x Purlin Assembly 3223 Theodore Front.Purlin.3.8.L 1x Front Purlin 3818 Left.Purlin.3.3.L.MKII 1x Left Purlin 3256 Right.Purlin.3.3.L.MKII 1x Right Purlin 3256 35x45x3190 1x Floor Distance Trim...
  • Page 16 3.8m x 3.3m THEODORE Garden Office - Components Page 15 Roof.Capping.3.8.F 1x Roof Profile 3860 Roof.Capping.3.3.L 1x Roof Profile 3340 Roof.Capping.3.3.R 1x Roof Profile 3340 30x45x3710 2x Roof Profile 3710 30x45x5000 5000 1x Roof Profile Bottom.Cladding.A.MKII 1x Bottom Canopy Cladding...
  • Page 17 3.8m x 3.3m THEODORE Garden Office - Components Page 16 38x8x1276 2x Finishing Trim 1276 (Pressure Treated) 38x8x1820 2x Finishing Trim (Pressure Treated) 1820 45x10x1986 2x Door Finishing Trim 1986 38x8x1990 2x Door Finishing Trim 1990 38x8x2000 4x Finishing trim...
  • Page 18 3.8m x 3.3m THEODORE Garden Office - Components Page 17 CB.2135 6x Finishing Trim 2135 (Including 2 spares) CB.25x2135.G 1x Finishing Trim 2135 CB.28x2135.T 1x Finishing Trim 2135 CB.35x2135.G 1x Finishing Trim 2135 CB.40x2135.T 1x Finishing Trim 2135 CB.70x2135.G 1x Finishing Trim 2135 CB.74x2135.T...
  • Page 19 3.8m x 3.3m THEODORE Garden Office - Components Page 18 Patio Door Fixed Window Panel 70x35x2050 1 x Patio Door 2 x Window Panels 2 x Timber Posts 1822 820x1190.Window 1x UPVC Window ACCESSORIES FIXING PACK NAME UNIT Name Gypsum...
  • Page 20 3.8 x 3.3m THEODORE Garden Office - Assembly Page 19 We suggest you prepare a full concrete base, Step 1 minimum dimensions 3970x3430 mm. Please predrill holes before screwing to avoid timber cracking. Bearers The base of the Garden office must be completely flat, level and square before commencing installation.
  • Page 21 3.8m x 3.3m THEODORE Garden Office - Assembly Page 20 Step 1 cont. Bearers 2630 E.2630 E.3630 E.3630 E.2630 For the 4 remaining external bearers use 120mm screws in the position shown Use 1 screw per connection.
  • Page 22 3.8m x 3.3m THEODORE Garden Office - Assembly Page 21 Step 1 cont. Decking Bearers Assembly 3770 Decking Bearers 3230 Assemble the veranda bearers using 2x120mm screws per connection. Position them in place and join with the office bearers using 1x120 mm screw in the...
  • Page 23 3.8m x 3.3m THEODORE Garden Office - Assembly Page 22 Step 1 cont. Bearers Bearers Layout E.2630 E35.530 E35.3700 E.3770 E.2490 E35.537 E35.475 E.2350 E35.537 E.3630 E35.495 E.3490 E.3490 E.2350 E.3630 E35.495 E35.475 E35.537 E.2350 E35.475 E35.537 E.2490 E.2630 E35.530...
  • Page 24 3.8m x 3.3m THEODORE Garden Office - Assembly Page 23 Step 1 cont. Rapid Pad layout If you have purchased our optional Rapidpad foundation system you will need to position all components in the configuration specified below. Refer to the separate Rapidpad foundation system assembly instruction.
  • Page 25 3.8m x 3.3m THEODORE Garden Office - Assembly Page 24 Step 2 Corner posts The wall panels are designed to work in any configuration. It is up to you where you would like to position the window panel. All panels are fitted with interlocking brackets on both sides to enable this.
  • Page 26 3.8m x 3.3m THEODORE Garden Office - Assembly Page 25 Step 3 Wall assembly When the bearers layout is assembled and looks as illustrated below you may start assembling wall panels on it. Front of office Please be aware that the wall panels are quite heavy and we strongly recommend that at least 2 people hold it in place, whilst they are being fixed into position by a third person.
  • Page 27 3.8m x 3.3m THEODORE Garden Office - Assembly Page 26 WP-B.M Connect this Step 3 cont. panel using built-in connectors Wall assembly With corner post pre-assembled WP-B.M Position this WP-B.M panel third Rear of office WP-B.M Front of office Connecting the wall panels using built-in connectors.
  • Page 28 3.8m x 3.3m THEODORE Garden Office - Assembly Page 27 Steps 3 cont. Wall assembly Continue assembling the remaining wall Connect this panel using built-in connectors. panels around in a clockwise direction. WP-B.M WP-B.M Connect this panel by Front of office...
  • Page 29 3.8m x 3.3m THEODORE Garden Office - Assembly Page 28 Step 4 Door.Post Patio door posts 120 mm screws When all the wall panels are assembled fix the door posts to both front wall panels using 4x120mm screws. 120 mm...
  • Page 30 3.8m x 3.3m THEODORE Garden Office - Assembly Page 29 Step 5 Patio door assembly 5.1- Place all three patio door bottom packers (70x25x1822 and 70x25x647) as shown on the diagram and screw them into the bearers using 50 mm screws.
  • Page 31 3.8m x 3.3m THEODORE Garden Office - Assembly Page 30 5.3 - Position one UPVC fixed window panel (pre-assembled on the previous step 5.2) on top of the bottom packer 70x25x647 and fix to the packer and the timber door post using 95 mm screws as shown on the diagram.
  • Page 32 3.8m x 3.3m THEODORE Garden Office - Assembly Page 31 5.5 - Place the door frame into the aperture and on top of the middle bottom packer (70x25x1822). Fix it into the 70x35x2050 timber posts on both sides (150mm from the top,...
  • Page 33 3.8m x 3.3m THEODORE Garden Office - Assembly Page 32 5.7- Finally, screw through the bottom of the door frame and Patio Door Lintel into the bearers and also through the top of the frame and into the preassembled Patio Door...
  • Page 34 3.8m x 3.3m THEODORE Garden Office - Assembly Page 33 Step 6 Wall panel brackets Before you will start assembling the roof you need to secure wall panels to bearers using 35x35x40 angle metal brackets. It will make walls more rigid whilst laying out the purlins.
  • Page 35 3.8m x 3.3m THEODORE Garden Office - Assembly Page 34 Step 7 Decking board assembly When the patio door is fixed you may start fixing decking boards to the bearers using 1x50mm screw per connection. Lay out the decking boards starting from the wall side. Keep approximately an 8mm gap between the wall and the first decking board, this will allow water drainage from the walls.
  • Page 36 3.8m x 3.3m THEODORE Garden Office - Assembly Page 35 Step 8 Ladder support fixing Fix two ladder shape canopy supports to the garden office walls and decking boards using 35mm and 50mm screws. Do not mix the left and right components as preassembled corner T&G strips will not match the other corner. Nail the CB.2135 boards to the front corner posts.
  • Page 37 3.8m x 3.3m THEODORE Garden Office - Assembly Page 36 Step 9 Beam assembly When all wall panels are secured to bearers you may start assembling the roof. Start from fixing 70x70x3795 beam to the top of the front wall.
  • Page 38 3.8m x 3.3m THEODORE Garden Office - Assembly Page 37 Step 10 Purlins assembly The next stage is assembling the roof purlins. Position all purlins as illustrated below and fix them to the beam 70x70x3795 on the front side of office and to the top of the back wall panels on the rear side of office using 70x70x15 angle metal brackets.
  • Page 39 3.8m x 3.3m THEODORE Garden Office - Assembly Page 38 Step 10 cont. Purlins assembly Middle.Purlin.3223 70x70x15.Angle.Metal.Bracket Left.Purlin.MKII.3.3.L Middle.Purlin.3223 Flush Use 120mm screws (screwing at an angle) to fix the side purlins to Use 4x35mm screws the top of the wall and per each bracket ladder posts.
  • Page 40 3.8m x 3.3m THEODORE Garden Office - Assembly Page 39 Step 11 Roof components assembly Fix the front purlin to the front of the purlins using 80mm screws. To close the roof structure from the rear side use Roof Cover and screw it to the top of the back wall and from the outside to the back of purlins using 50mm screws. Predrill holes to help prevent timber splitting.
  • Page 41 3.8m x 3.3m THEODORE Garden Office - Assembly Page 40 Step 11 cont. Roof components assembly Use 2x50mm screws per each connection to fix the roof cover to the back of the roof purlins. Use 3x50mm screws between the purlins to fix roof cover to the top of the wall panels.
  • Page 42 3.8m x 3.3m THEODORE Garden Office - Assembly Page 41 Step 12 Make sure that all your 35mm screws are on the line with the structural MFP roof boards assembly components underneath, then fix MFP sheets to the purlins and noggins.
  • Page 43 3.8m x 3.3m THEODORE Garden Office - Assembly Page 42 Plasterboard assemblies are already precut to the proper size and contain bonded PUR insulation sheets on the top side. Use provided 25mm twin thread black phosphate drywall screws, approx. every 400-500mm.
  • Page 44 3.8m x 3.3m THEODORE Garden Office - Assembly Page 43 Step 15 Floor panels assembly Next step is to assemble floor panels to bearers. 1. First position the floor distance trim 35x45x3190 directly on the bearers in the patio door, but do not fix it yet.
  • Page 45 3.8m x 3.3m THEODORE Garden Office - Assembly Page 44 Step 16 Bottom canopy cladding The next step is fixing the bottom canopy cladding. Attach first the finishing profiles around the door and the side panels using 40mm nails. Position and fix the cladding panels to the roof components using 35mm screws.
  • Page 46 3.8m x 3.3m THEODORE Garden Office - Assembly Page 45 Step 16 cont. Finishing trims Fix the remaining CB trims in the corners of the garden office as shown on the detail. Use 40mm nails every 400-500mm. Position to fix the finishing CB profiles on the rear corners of the office...
  • Page 47 3.8m x 3.3m THEODORE Garden Office - Assembly Page 46 Step 16 cont. Finishing trims Attach 38x8mm pressure treated trims in the corners and on the bottom of the front, side purlins and roof covers at the perimeter of the office. Use 40mm nails every 400-500mm. If you have bought the guttering, do not fix the rear wall trims.
  • Page 48 3.8m x 3.3m THEODORE Garden Office - Assembly Page 47 Step 17 Timber Support Trims Attach the 45x45mm roof trims to the back roof covers so that the top of the trims touches the MFP roof boards. Use 80mm screws every 500-600mm, screwing into the roof purlins wherever possible. Also attach the 60x45x190 trims to the back of the side purlins using 2x 80mm screws per trim.
  • Page 49 3.8m x 3.3m THEODORE Garden Office - Assembly Page 48 Step 18 Parapet capping assembly The last step required to complete external assembly work on this garden office is fixing the parapet profiles on the top of the roof. Use 35mm screws every 400-500mm, fixing through the side of the capping trims into the parapet walls.
  • Page 50 3.8m x 3.3m THEODORE Garden Office - Assembly Page 49 Step 19 Window fitting Fit the UPVC window frame into the window aperture by placing it from outside. Remember to predrill the holes in the UPVC frame. Place the window frame into the aperture and first screw it to the left timber post using 95mm screws (100mm away from the top, 100mm from the bottom and 2 equally spaced between).
  • Page 51 3.8m x 3.3m THEODORE Garden Office - Assembly Page 50 Step 20 Fitting the sealed units Remove the plastic beading from the frame one by one and mark on the inside “top”, “bottom”, “left” and “right” accordingly with a pencil to allow for correct reinstallation. Place the bridge packers on the frame (indicated below) so that the packer lies flat and parallel to the frame, with the channel side towards the frame and the ridge side facing upwards to allow for correct drainage.
  • Page 52 3.8m x 3.3m THEODORE Garden Office - Assembly Page 51 Step 21 65mm Duropolymer coving Fitting the coving When the Garden Office assembly is completed outside, complete coving underneath the ceiling around the walls. We provide 2m long 65mm duropolymer coving profiles. You will need to cut them to size on site to match your garden office interior.
  • Page 53 3.8m x 3.3m THEODORE Garden Office - Assembly Page 52 Please note! All electrical fittings should only be installed by a qualified electrician. These drawings are for illustration purposes only. Pre-drill holes for lighting circuit wiring (30mm max.) Ready board to be placed at customer discretion.
  • Page 54 3.8m x 3.3m THEODORE Garden Office - Assembly Page 53 Please note! All electrical fittings should only be installed by a qualified electrician. If power cables are to be run through the trunking for power sockets; a conduit will need to be run to the skirting from the Ready Board.
  • Page 55 3.8m x 3.3m THEODORE Garden Office - Assembly Page 54 To install the accessory box first decide the position and cut the skirting cover, using a hacksaw, to fit either side of the adaptor back plate. Next remove the required knock-out in the back segregator, feed through cables and secure using two diagonally opposite screw holes.
  • Page 56 3.8m x 3.3m THEODORE Garden Office - Assembly Page 55 Installation of guttering (optional extra) Thank you for purchasing the guttering pack. Read these instructions carefully. Predrill holes for all screws to help prevent timber cracking. Please note: screws are not supplied because there is a surplus with the main office kit.
  • Page 57 I t is essential that you are aware of the following to understand the correct method in storing and handling the roofing materials. * Read instructions on the adhesive products that have been supplied by Dunster House. * Use & Store all adhesives in a well ventilated place.
  • Page 58 Assembly EPDM Garden Office - Page R2 Backplate Trim -EPDM Trim Measurements Once the timber support is in place, you can now install the gutter edge trim. Measure the rear end of your build to get the correct measurement to use as a guide to cut the EPDM Trim. You will need Dimension A Dimension B.
  • Page 59 Assembly EPDM Garden Office - Page R3 EPDM BACKPLATE TRI M Side with Lip Dimension Backplate Trim Side Placed on Timber Screw Position -EPDM Trim Once Dimension A Dimension B have been measured, take the EPDM backplate trim and cut enough to make 1x Dimension A and 2x Dimension B.
  • Page 60 Assembly EPDM Garden Office - Page R4 Substrate & EPDM Membrane -Preparation Prepare the surface of the roof ensuring all rough edges are sanded down, and there are no staples, nails, or sharp edges that could potentially rip or puncture the membrane. Once the surface has been prepared, place the EPDM membrane on top of the roof ensuring it covers the whole roof perimeter with equal overhangs left to right and front to back.
  • Page 61 Assembly EPDM Garden Office - Page R5 EPDM Membrane -Securing the Membrane When the membrane has had time to relax and minimize the number of folds and creases that it has, roll the membrane half way back as shown in the diagram. I t is important to have a tightly wound roll rather than a loose roll and when rolling ensure that you don't twist the membrane in relation to one side compared to the other, so take time to roll it evenly.
  • Page 62 Assembly EPDM Garden Office - Page R6 EPDM Membrane -Securing the Membrane After the adhesive has been applied slowly roll back the membrane evenly so that the adhesive on the roof top sticks the membrane down with minimal bubbles being trapped under the surface of the EPDM. Unrolling the membrane bit by bit whilst smoothing out any bubbles that form using your hands before you roll too far past them will ensure a much better result when finished.
  • Page 63 Assembly EPDM Garden Office - Page R7 EPDM Membrane -Securing the Membrane Repeat the process of attaching the membrane with the other half of the roof using the same principles as the previous steps. Starting with rolling the other half of the EPDM membrane back into a tightly wound roll, ensure that all steps are followed and none are missed out.
  • Page 64 Assembly EPDM Garden Office - Page R8 EPDM Membrane -Securing the Membrane Taking the penny roller supplied, roll the tool down the fold of the roof between the roof and the upstand of the parapet to help define the shape. This tool will aid in getting the desired definition and not rip, tear or puncture the membrane.
  • Page 65 Assembly EPDM Garden Office - Page R9 EPDM Membrane -Securing the Membrane Trim the membrane at the back of the roof ensuring that you keep your knife in the groove identified in the close up below. The groove is at the bottom of the trim. The excess membrane will need to be removed before the EPDM Backplate Clip can be fixed into position.
  • Page 66 Assembly EPDM Garden Office - Page R10 EPDM Membrane -Securing the Membrane Membrane on the ends of the parapet will need to be trimmed down for it to be secured. Please ensure that you fully understand the steps before proceeding as it is vital that this part is done without error. (This must be done for both sides of the roof) Cut 25mm away from the face of the backplate trim...
  • Page 67 Assembly EPDM Garden Office - Page R11 EPDM Membrane - Securing the Membrane This process is similar to how you have clipped in the backplate trim and backplate clip for the rear end of the roof. Using the same principles and methods shown below, attach the backplate clip to the backplate trim for the rear sides of the roof.
  • Page 68 Assembly EPDM Garden Office - Page R12 EPDM Membrane - Parapet Capping Assembly Once all the trim clips have been attached and the membrane is secure at the back, return to the parapet capping assembly in the installation manual to complete the rest of the build. I t is vital that you do not screw through the top of the membrane but through the side as shown in the parapet capping assembly installation manual.