Duratuf KS1 Instructions

Quality – Built In
ASSEMBLY INSTRUCTIONS
KS1
BASE SIZE 1715mm x 876mm
CHECK OUT OUR ASSEMBLY VIDEO
Let Keith and Justin show you how to build your
Kiwi shed like a professional.
When used in conjunction with these assembly instructions, Keith’s practical tips and tricks will
make your assembly experience that much simpler, giving you visual guidance through sections
that seem tricky on paper, and help you achieve a flawless end result.
To view the video visit www.duratuf.co.nz/kiwi-assembly
Note: Assembly video features a MK2. But can be used for reference for any other Kiwi model.
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ASSEMBLY INSTRUCTIONS
Tools Required:
• Drill
• Drill Bit 3.5mm
• Drill Bit 6mm (for clear roof panel only)
• Hex Drive 5/16
• Riveter (free Duratuf riveter supplied in kit)
• Hammer
• Nail Punch
• Tape Measure
• Ladder or Saw stool
• Spanners x 2
• String Line
• Tin Snips
• Skillsaw and Jigsaw (for floor only)
• Masonry Drill and 10mm Masonry Bit (for Bolt Down Kit only)
Before you start:
• Read all instructions carefully.
• Identify all parts and check quantities against checklist.
• If you are making your own floor refer to Raised Base Plate section
now.
Safety:
• Do not attempt to build your shed in high winds.
• Beware of sharp edges.
• Protect your eyes and ears.
• Use electric tools with care. Use a Safety Trip Switch.
• It is easier and quicker if this shed is erected by two people.
Select your site:
• Your shed must be level. Achieve this by either levelling the ground
or by using blocks.
• If you shed is to be positioned on wet or damp ground, we recommend that your shed is raised up off the ground slightly.
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KIWI KS1 PARTS LIST
5
1.890m
2
1.000m
Wall Sheets
Roof Sheets
Door - Standard
1
Security
1
Instruction Booklet
1
Hardware Pack
Touch-up Paint & Brush
1
Duratuf Riveter
84
50mm
Flooring Nails
6
75mm
Flooring Nails
Fixed Window Frame
0.580m
0.603 x 0.603m
Glaze Beads
Glass
Louvre Window Frame
0.588 x 0.150m
1
Glass
Window Hardware Pack
1.000m
Clear Roof Panel
1.000m
Roof Sheet
Security Single Door Hardware Pack
Alarm - MA20
Shed light
Bolt Down Kit
Peg Down Kit
4
45
45
883
883
45
90
0.786
1900
(or 1870 for Raised Base Plate only)
45
45
45
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
1.810
KS1 TIMBER FRAME
0.876
45
END WALL
5
795
1715
45
45
FRONT WALL
785
45
KS1 TIMBER FRAME
Note:
For sheds with the Raised Floor Modification option the studs will be 1.780m long to allow the Wall Sheets to protrude 20mm below the Bottom Plate. Refer to Raised Floor Modification section (Page 15).
Note:
Studs and Nogs surrounding a window opening are to be fitted once the wall cladding is nailed in place.
Step 1: End Walls: Select 1 x 0.876m End Base Plate
(Green), 1 x 0.876m End Top Plate (Red) and 2 x
Studs (Yellow). Lay out Plates and two Studs on
a flat surface and nail together using two 75mm
nails per join. Position 0.786m Nog 0.883m down
from Top Plate and nail in place. Repeat with
other end wall.
1
Step 2: Select one 1.715m Base Plate (Green), one
1.715m Ridge Beam (90 x 45). Stand up End
frame with the Stud side of the frame on the
ground. Nail 1.715m plates to frame using two
nails per join. Ensure Green joins to Green and
Red joins to Red. Repeat with other end frame.
Nail in back wall centre stud using 0.876m Nogs
to get correct position. Position Nogs 0.883m
down from the bottom of the Top Plate and nail in
place.
2
Step 3: Select one 1.715m Base Plate (Green) and one
1.715m Top Plate (45 x 45). Nail in place. Ensure
Green joins to Green.
3
Step 4: Carefully roll the frame over so that the Ridge
Beam and Base Plate (Green) aren’t on the
ground. Select one stud (Yellow) and two
0.785m Nogs. Nail in Stud using the 0.785m nog
to get the correct position top and bottom. Position nogs .883m down from the bottom of the
Top Plate and nail in place.
4
Step 5: Carefully roll frame over onto its base. If fitting a
Kiwi Floor, fit Floor Joist now. Place the joist centrally and nail in place using three 75mm nails
per end.
5
6
KS1 WALL CLADDING
TO AVIOD 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 either crayon or ink to mark steel.
TERMS EXPLANATION
• To Tack: To Tack on a wall sheet means to use minimum nails hammered partly in to hold Wall Sheets in position. Should a Wall
Sheet need to be re-positioned, the nails can easily be prized out.
• If a window is required, identify Wall Sheet(s) with window hole pre-cut. Lean up Wall Sheets where window(s) are to be located.
CLADDING DETAIL
Birds Eye View
fig. 1
7
KS1 WALL CLADDING
Step 1: Front Wall: Position wall sheet on the right hand side
of the doorway with the sheet LIP on the left hand
side. Ensuring the LIP is flush with the side of the
Stud and the top is 45mm below the top of the Ridge
Beam, tack in place.
EDGE
FLUSH
Step 2: Back Wall: Position the first Wall Sheet with
the LIP on the right hand side. Ensuring the LIP
is flush with the side of the corner Stud and the
top of the Wall Sheet is 45mm down from the
top plate, tack in place. Position the next Wall
Sheet with the LIP on the right hand side. Overlap as shown in fig 1 pg 6. Ensuring Wall Sheet
is 45mm down from the top plate, tack in place.
Step 3: End Walls: Position wall sheet with the LIP
flush with the side of the stud and the top of
the Wall Sheet is flush with the top of the Top
Plate, tack in place. Repeat with the other end.
If fitting a window, nail in Window Studs and
Nog now. Refer to Window instructions—Pg.8
Step 4: Nailing Off: Nail one 30mm Clout each side of the Rib (two per Pan) into the Top Plates and Bottom Plates. Nail
Wall Sheets to mid wall Nogs (one per pan). Nail each corner Wall Sheet to Studs using two 30mm Clouts evenly
spaced.
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KS1 WINDOW (Optional)
LOUVRE WINDOW
588mm
Step 2: On the inside of the shed, position studs
and Nog centrally on window opening.
Make sure the studs are parallel and nail
into Top Plate and End Wall Nog.
Step 1: Lay out the two window studs (883mm) and
Nog (634mm) on a flat surface. Position
Nog and nail in place using 2x 75mm nails
at each end.
50mm
NAILS
RIVITS
Step 3: Nail wall Sheets to window framing using
30mm clouts. (return to step 4 on page 7
and complete). Then fit Window Frame).
Position Window Frame centrally on window opening and rivet it to ribs. Pre-drill
holes in each corner and nail Window
Frame to framing, using 50mm nails.
Step 6: From the inside of the shed, slide Louvre
Glass into Louvre Units attached to the
Window Frame. Bend up tabs to keep
Glass in position.
FIXED WINDOW
570mm
Step 6: From the outside of the shed, place glass
in Window Frame. Attach a Glazing Bead
(G100) with three rivets to each side of the
Window Frame to hold glass in place. Predrilling Glazing Beads is recommended.
Step 1: Lay out the two window studs (883mm) and
Nog (590mm) on a flat surface. Position
Nog and nail in place using two 75mm nails
at each end.
9
KS1 DOOR JAMB & CORNER FLASHINGS
END
PLATE
CLADDING
STUD
FRONT PLATE
DOOR JAMB
CORNER
FLASHING
Step1:
Fit Door Jamb Flashing (104) in between Top
and Bottom Plates and hard against Stud.
Attach Door Jamb Flashing with three rivets
into Rib on the outside and three 30mm
clouts into studs on the inside. Repeat with
the other Door Jamb.
Step 2: On the left hand side of the front wall fit Corner
Flashing (101) over Door Jamb Flashing and
rib . With top of the Corner Flashing flush with
the top of the Top Plate, rivet in place using six
rivets.
Step 4: Fit the two short front Corner Flashings over corner
Ribs and rivet in place using six rivets per flashing.
Fit the two longer back Corner Flashings over corner Ribs and rivet in place using six rivets ensuring
the flashing is flush with the top plate. When fitting
right hand Corner Flashing on the front wall, ensure
it is parallel with the Door Jamb.
Step3: Measure and cut Doorstep Flashing (106) to fit in
between Door Jambs. Position the Doorstep Flashing in between the Door Jambs at bottom of doorway, nail through top of flashing using three 30mm
Clouts. Repeat with the Overdoor Flashing (105).
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KS1 DOOR
Step 1: Position the Door Track (107) on the front wall with the top
of the track 7mm below the top of the timber frame. The
end of the door track should be 20mm in from
outside of the right-hand corner flashing.
7mm
Pre-drill a hole in the centre of the track and screw in place
using one 45mm door track screw. Remove ALL drill
filings
20mm
Note: Ensure Door Track screws are screwed in horizontal and
screwed hard into flashing. Protruding screw heads
can cause door rollers to bind on the screw heads.
Step 2: Hang the door in the Door Track. At the right hand end of
Door Track, adjust up or down so that the Door hangs
parallel with shed. Fit one rivet at right hand end to hold in
place. Repeat with left hand end of track.
Note: Only use rivets at each end of track.
Step 3: Remove the Door. Pre-drill and screw another 2 screws
between the centre screw and the rivets at each end
(5 screws per track). Screw track using 45mm door track
screws.
Step 4: Clean out ALL drill filings. Also make sure the Wheels
are cleaned of drill filings. Re-hang Door.
Door Stops: Predrill a hole in right-hand end of track,45mm
in from outside edge of Corner Flashing.
Predrill hole in left-hand end of track, 45mm from outside of
door jamb. (60mm for Security door option.)
Screw door stops in using 1 x Roofing screw per stop.
Check door doesn't protrude past outside edge of shed.
KS1 DOOR
Step 5: Bottom Door Guide: Slide the Door to the corner of the shed.
Place the Door Guide (108) over the Guide Brackets on the
door and align the end of the Door Guide 20mm in from outside
of the right-hand corner flashing.
Step 6: Lift the door guide up approximately 3mm so that the Door will
Slide freely. Pre-drill a hole through the door guide and the end
rib of the cladding and screw in place using a 45mm screw.
Step7:
Note:
Slide the door to the centre, ensuring that it slides freely. Predrill and insert a screw in the other end of the Door Guide.
Check that the Door is not binding in the middle then pre-drill
and fix with 3 more screws, one in the centre of the guide and
the other 2 evenly spaced between (5 screws per guide) into
the door step flashing and rib.
For sheds with Raised Base Plate option the Door Step Flashing will protrude down past the Bottom Plate.
Attach Door Guide with rivets.
11
CLADDING
DOOR
BOTPLATE
GUIDE BRACKET
DOOR
GUIDE
KS1 ROOF
Note:
Condensation can form on the under side of shed roof. If building paper is required, fit now. Building paper will need to be
supported by netting or roofing twine.
Roof with Clear Panel: Handle Clear Panel with care. The Clear Panel will crack if not fitted correctly.
Riveting: Pre-drill 3.5mm hole through Clear Panel and Steel. Enlarge hole in Clear Panel with drill to allow for expansion
and contraction.
Screwing: Pre-drill a 6mm hole through the Clear panel.
Step 1: Check that the diagonal measurements of the shed are the same. If building on unlevel ground it may be necessary to
temporarily brace the shed with pieces of timber from the packaging.
Step 2: Position first Roof Sheet on the right hand
side of the shed with the LIP on the left hand
side. Position the next Roof Sheet. Ensure it
overlaps correctly (when fitting a Clear Roof
Panel, ensure it OVERLAPS Roof Sheet).
Rivet sheet joins 500mm from edge, front and
back. Position and rivet remaining sheet.
Step 3: Position Roof Sheets. They should overhang
the back top plate by 20mm. Ensure timber
plates are straight then screw roof to Top
plates using one 50mm Roofing Screw on
each Rib at the front. Repeat along the back
wall using 50mm clouts, instead of Roofing
Screws to allow Ridge Cap Flashing to sit
correctly on roof sheets.
12
KS1 BARGE & SPOUTING
Step 1: Position Barge Flashing on End wall. Ensure
that the front of the Barge is flush with the
front of the Roof sheets. Rivet Barge through
the Roof sheet Rib using 1 rivet at the front,
middle and back of the Barge. Repeat on other side.
Step 2: Position Spouting at the front of the roof
ensuring that the ends are flush with the
End of the Barge flashings. Rivet spouting onto the Roof at every second Rib.
Use 2 rivets per end and rivet into Barge
Flashing.
Step 3: Position Ridge Cap at the back of the
roof ensuring that the ends are flush with
the End of the Barge flashings. Rivet
Ridge Cap onto the Roof and onto the
Back Wall sheet through every second
Rib. Use 2 rivets per end and rivet into
Barge Flashing.
13
KS1 FLOOR (Optional)
Step 1: Place shed in final position. Check the diagonal measurements are the same and
the shed is level before fitting Floor. It is
recommended that the shed is anchored
down with either a Duratuf Bolt Down Kit or
Duratuf Peg Down Kit depending on what
the shed is sited on.
Step 2: Lay a Floor Board on top of Bottom Plates
and Joist and push up against end wall.
Mark out where Studs are. Cut checkouts
with Electric Jigsaw so Floor Board will fit
around Studs.
Step 3: Re-position Floor Board. Lay out remaining Floor Boards checking around Studs
as you go. The last Floor Board may
have to be cut to size.
Step 4: Nail in each Floor Board, two 50mm
nails in each end and two into Joist.
Measure and cut Floor Flashing (110) to
fit in between Door Jamb Flashings and
nail in place using 50mm Clouts.
14
KS1 HASP & STAPLE
Using six rivets and one 50mm clout
attach hasp to Door Jamb Flashing and
the staple to the Door as shown.
(Note: See below for security
option.)
SECURITY DOOR (Optional)
Step 1: Attach “ T” locking handle with two 8x10mm
screws. Slide hook onto square shaft and
secure with a lock washer.
Hook
Lock Washer
Step 2:
Once door is hung, position the Locking Stays so
they slide into the Locking Brackets easily. Screw
Locking Stays to Door Jamb.
15
SECURITY DOOR (Optional)
Step 3:
On the left hand Door Jamb, position latch as
shown, at correct height to door handle. Rivet
in place with four rivets.
RAISED FLOOR MODIFICATION
For sheds being placed on a purpose built floor, (concrete, cobbles, ply etc.), the Wall Sheets will protrude 20mm below the
Base Plate. This will stop water flowing in between the Base
Plate and Floor.
The Floor should be made 15mm smaller than Base Size.
Note:
Although it is not essential, fitting Damp Proof Course
in between the Base Plate and the Floor will give added protection against moisture.
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.
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COMPLETE OUR CUSTOMER SURVEY
Thank you for investing in a Duratuf Garden Shed.
We are sure that it will provide excellent long-term storage and add value to your property. To continually improve our products and
service, we would love to hear about your Duratuf experience and why you chose us.
Further to that, we would also love to see a picture or a short video of your shed installed and doing its job so that we can share this
with others for their inspiration. Thank you in advance and we look forward to receiving your feedback!
To complete the survey please visit
www.duratuf.co.nz/customer-survey
Complete the survey for your chance to
WIN a $100 Prezzy Card!
DURATUF PREMIUM SHED WARRANTY
GUARANTEE TO CUSTOMER
Congratulations on purchasing a Duratuf Storage Shed. With proper care and attention, this product will last many years.
For your benefit PLEASE READ THE FOLLOWING INFORMATION CAREFULLY.
WARRANTY ON METAL CLADDING
Riverlea Group Ltd guarantee that the metal roofing and wall cladding on Kiwi and Fortress Garden Sheds may be used in moderate and
inland corrosion zones or areas where the first year mild steel corrosion rate is less than 200g/m2, and that in these conditions, they will
not perforate due to corrosion within 30 years of date of manufacture.
TERMS AND CONDITIONS
1.
Damage or corrosion due to the following circumstances is not covered by this warranty.

Mechanical, chemical or other damage sustained during or after installation.
NOTE: Clean swarf off shed IMMEDIATELY after assembly
Do NOT mark cladding with pencil
Do NOT allow manures, chemicals or other corrosive materials to have direct contact with cladding
Chemical damage will result if these instructions are not carried out

2.
Force majeure or other causes beyond the control of Riverlea Group Ltd.
This warranty does not cover material installed in severe and very severe environmental situations, or in any area where the mild
steel corrosion rate (as published by BRANZ) exceeds 200g/m2.
WARRANTY REGISTRATION
Please visit www.duratuf.co.nz/warranty to validate the Warranty on your shed.
Click on the Warranty Registration Link and complete all details.
If you are unable to access the computer, please phone us on 0800 438 274 and one of the customer services team will help you to activate the warranty on your garden shed.
Many thanks, from the Team at Riverlea Group.