1 P a g e THIS IS A GENERIC MANUAL AND MAY NOT BE INDICATIVE OF YOUR CONSTRUCTION.

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Abner Hood
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2 INDEX SECTION DESCRIPTION PAGE 1 TOOLS REQUIRED 3 2 GENERAL PARTS IDENTIFICATION Structural Members Brackets Fasteners and Bolts Roof and Wall Cladding Gutters and Rainwater Other Optional Products Doors and Windows Flashings. 8 3 FRAME ASSEMBLY PROCEDURE Frame Assembly CONSTRUCTION GUIDE STEP 1 Laying out the Panels STEP 2 Standing up the Walls STEP 3 Installing Portal Rafters STEP 4 Installing Top Hats STEP 5 Finishing the Frame STEP 6 Installing the Rolladors STEP 7 Installing Head Flashings STEP 8 Roof and Wall Sheeting STEP 9 Barge Cap and Corner Flashing STEP 10 Installing the PA Door STEP 11 Installing the Gutter STEP 12 Installing the Ridge Cap STEP 13 Cleaning up GALLERY - FINISHED PROJECTS P a g e

3 TOOLS REQUIRED 1.0 Tools Required Impact Drill Hammer Drill Safety Switch Extension Cord Cordless Box Tape Measure Spirit Level Marker Pen Builders Square Tin Snips Hacksaw Rivet Gun Silicone Gun Step Ladder C - Clamps Socket Ratchet 12, 14 & 18mm Sockets 10mm Concrete Drill Bit Shifting Spanner Chalk/String Line 1/8 Drill Bit Phillips No.2 Driver Bit 5/16 Hex Head Driver 3 P a g e

4 GENERAL PARTS IDENTIFICATION 2.1 Structural Members C Section Purlins (Rafters, Beams and Columns) All purlins will be clearly labelled with Mark Numbers Top Hat 64 x 1.0mm 73 x 1.0mm Stud 76 x 1.0mm PLATE/NOG 75 x 1.0mm Stud, Plate & Nogging Sections (Modular Frames) 64 Top hats (Roof Purlins) All Framing will be clearly labelled with Mark Numbers 2.2 Brackets Apex Bracket Haunch Bracket Column Base General Purpose (Stud to Rafter no Awning) Bracket Haunch Bracket Haunch Bracket Haunch Bracket (Awning Col Awning Rafter) (Stud to Rafter with Awning) (Front Garaport Col to Rafter) (Mid Garaport - Col to Rafter) 4 P a g e

5 GENERAL PARTS IDENTIFICATION 2.3 Fasteners and Bolts Hex Tek M6-50 Hex Roof Zip 12-14x20 Hex Tek (Wall Cladding) (Roof Cladding) (Top hats/frames) Wafer Tek M6-50 Poly Zip Pop Rivets M10-25 Bolt & Nut (Gutter Brackets/General Fixing) (Translucent Cladding) (Stop-ends/Gutters/Downpipes) (Stud Frame Panel Joins) M12-30 Purlin Bolt M12-30 Fascia Bolt M10-75 Masonry Bolt 28mm Galv Washer (Brackets/Columns/Rafters) (Awning/Carport Brackets) (Frame Hold Downs) (Frame Hold Downs) 2.4 Roof and Wall Cladding CORODEK (Colorbond/Zinc) TRIMCLAD (Colorbond/Zinc) POLYCARB - Translucent Sheet (Corodek/Trimclad) 5 P a g e

6 GENERAL PARTS IDENTIFICATION 2.5 Gutter and Rainwater 150 Big Front Quad 150 Big Front Quad Gutter Brackets Gutter Stop Ends (Colorbond/Zinc) (Colorbond/Zinc) Big M Square Big M Square Gutter Drop Gutter Stop Ends (Colorbond/Zinc) (Colorbond/Zinc) 90mm PVC down pipe Down Pipe Straps Roof & Gutter Silicone 2.6 Other Optional Products 300mm Rotary Vents Roof & Wall Insulation Vermin Proofing 6 P a g e

7 GENERAL PARTS IDENTIFICATION 2.7 Door & Windows Roll-a-doors 2.65m Wide x various Heights 820mm Wide PA Doors Pre-skinned and Bored Sliding Glass Doors 1800mm High x 2100mm Wide (Aluminium all Colorbond colours) Sliding Glass Windows 900mm High x 600/900/1370mm wide (Aluminium all Colorbond colours) PA Door Lock-sets Sliding Glass Door Lock-sets Butt Hinges Knob or Lever Sets 7 P a g e

8 GENERAL PARTS IDENTIFICATION 2.8 Flashings 8 P a g e

9 GENERAL PARTS IDENTIFICATION 9 P a g e

Studs/Jambs Marks to BOTTOM FRAME ASSEMBLY

1 Frame Assembly (Fig 1) (Fig 2) You will

the components required to finish the frame

Nogging or Stud (Fig 2) will be identified

After the member identification, the Wall

10 Studs/Jambs Marks to BOTTOM FRAME ASSEMBLY PROCEDURE 3.1 Frame Assembly (Fig 1) (Fig 2) You will receive a large flat pack (Fig 1) with all the components required to finish the frame bundled together there will be several packs corresponding to each individual frame. Each individual member whether it be Plate, Nogging or Stud (Fig 2) will be identified on the left hand of the member (Fig 3). After the member identification, the Wall Frame is also identified (Fig 3). (Fig 3) Mark No Plate/Noggin/Heads Marks to the LEFT 10 P a g e

11 (Fig 4) FRAME ASSEMBLY PROCEDURE Using your detail frame drawings provided (Fig 5), you will find a drawing for each wall and truss. (Fig 5) All pieces are individually marked with part number. EG. Wb1 being the first and Wb3 being the third piece. Always use drawing marks on detail drawings to locate the member in frame and ensure correct orientation of member before assembly e.g. (Fig 5: Section A-A) Plates/Nogging (Horizontal members) ensure the mark numbers are to the LEFT side of the frame. (Fig 4) Studs (Vertical members) ensure the mark numbers are to the BOTTOM of the frame. (Fig 4) When constructing a wall place the bottom on its edge on your workbench/floor. Then begin to place/insert studs laying left to right. Ensure the screw dimples are aligned. Repeat this procedure until all studs are in place. Then slide the nogging and head members through the studs and ensure screw dimples are aligned. Position the top plate onto the frame and align screw dimples. Start to insert screws, ensuring the wall is square. Please ensure all service holes/utility holes are in line. If not, you are using the components in the incorrect location or rotation. 11 P a g e

12 CONSTRUCTION GUIDE STEP 1 - LAYING OUT PANELS a) Place all the wall panels around slab as per your design requirements, orientating the corner panels to ensure the diagonal bracing in the panels is positioned towards the corners. (Fig 6) (Fig 6) 12 P a g e

CONSTRUCTION GUIDE b) Fit the rafters haunch brackets in between side panels where rafters are required with (6) x M10x25 bolts while on the ground.

(Fig 7) (Fig 7) c) Bolt half trusses and gable panels together while on the ground using M10x25 flanged bolts at verticals.

upwards. Fix with 12-14x20 tek screws (Fig 8) e) Fix and screw full truss and truss stiffener to gable panels with 12-14x20 tek screws.

b) Continue around the slab until all walls are stood and fixed together. c) Square all walls to the slab with a string line.

13 CONSTRUCTION GUIDE b) Fit the rafters haunch brackets in between side panels where rafters are required with (6) x M10x25 bolts while on the ground. Use M10x25 flange bolts top, middle and bottom and bolt wall panels together. (Fig 7) (Fig 7) c) Bolt half trusses and gable panels together while on the ground using M10x25 flanged bolts at verticals. Use M10x25 flange bolts top, middle and bottom and bolt all wall panels together d) Position truss stiffeners to the centre of the wall with the flanges facing upwards. Fix with 12-14x20 tek screws (Fig 8) e) Fix and screw full truss and truss stiffener to gable panels with 12-14x20 tek screws. STEP 2 - STANDING WALLS (Fig 8) a) Stand gable walls and fix to side wall using 12-14x20 Teks. b) Continue around the slab until all walls are stood and fixed together. c) Square all walls to the slab with a string line. Ensure that sheeting can extend past the slab by 40mm. d) Where rolladoor panels are located use a marking pen to mark hold down bolt holes, move frames back and pre-drill holes using 10mm masonary drill bit, ensure you have the recomended depth and blow out all the debris. Move frames back into position and re-check for sqareness. e) If the slab is uneven pack out underneath the panels to produce a straight line to the bottom plate of panels. 13 P a g e

g) Using a 10mm masonary drill bit, drill through inner holes in bottom of frames (Fig 9) where holes are next to the verticle members in the panel, ensure

14 CONSTRUCTION GUIDE f) **CRITICAL** Where panels meet at the corners they must be vertically plumb - BOTH of the corner panels. If required pack out underneath both panels at the corners and use a long spirit level to check verticles at corners are plumb. g) Using a 10mm masonary drill bit, drill through inner holes in bottom of frames (Fig 9) where holes are next to the verticle members in the panel, ensure you have the recomended depth of 90mm and blow out and remove all the debris. h) Install the M10x75mm masonary bolts with 30mm washers using a impact drill and socket driver. (Fig 10) (Fig 9) (Fig 10) 14 P a g e

STEP 3 - INSTALLING PORTAL RAFTERS CONSTRUCTION GUIDE a) While on the ground bolt together the apex bracket and rafter purlins using M12x30

Not cut in Collar tie (Fig 10b). Refer to Drawings for cut in details below (Fig 10c) (Fig 10d) (Fig 10e) for your Collar tie.

5m spans - SF2550 (Fig 10d) 9m spans - SF3050 (Fig 10e) c) Bolt Collar tie using M12x30 flanged purlin bolts.

15 STEP 3 - INSTALLING PORTAL RAFTERS CONSTRUCTION GUIDE a) While on the ground bolt together the apex bracket and rafter purlins using M12x30 flanged purlin bolts. (Fig 10) b) At this point you can choose to cut your Collar tie or not. Cut in Collar Tie (Fig 10a). Not cut in Collar tie (Fig 10b). Refer to Drawings for cut in details below (Fig 10c) (Fig 10d) (Fig 10e) for your Collar tie. (Fig 10a) (Fig 10b) 6m spans - SF2050 (Fig 10c) 7.5m spans - SF2550 (Fig 10d) 9m spans - SF3050 (Fig 10e) c) Bolt Collar tie using M12x30 flanged purlin bolts. Do not tighten fully d) Lift complete portal into position and bolt the portal into the haunch barackets using M12x30 flanged purlin bolts. e) Using a temporary prop adjust the height of the portal and sight along the ridge using a string line so the portal rafters and the end trusses are all level. (Fig 11) (Fig 11) 15 P a g e

h) Fix (1) x 12-14x20 teks next to each purlin bolt in the brackets to ensure there is no 'slip' when roof is loaded with roof sheeting and top hats. Then remove the temporary bracing.

16 CONSTRUCTION GUIDE f) Check the side walls are still plumb. Using a ratched tie or temporary brace (Fig 12) pull/push the side walls into plumb. (Fig 12) g) When portals are level with end trusses and the side walls are plumb use a impact drill with a socket drive to tighten all the bolts in the haunches, apex and collar tie. h) Fix (1) x 12-14x20 teks next to each purlin bolt in the brackets to ensure there is no 'slip' when roof is loaded with roof sheeting and top hats. Then remove the temporary bracing. STEP 4 - INSTALLING TOP HATS a) To fit the apex top hats first mark 140mm down from the apex to bottom flange of top hat (Fig 14) and place temporary teks in both end trusses and all portals to stop from sliding, let the tophat rest above this tek. At the gable ends the top hats should be flush with outside of gable frame. (Fig 13) (Fig 13) 16 P a g e

17 CONSTRUCTION GUIDE b) Fit the eaves top hats flush along external walls and have the remaining tophats spaced evenly between apex and eaves. (Fig 14) (Fig 14) c) Using (2) x 12-14x20 teks fix tophats to trusses and portals in both sides of the top hat in the flanges. d) Where top hats are lapped fix (4) x 12-14x20 teks to both ends of the lap and into both sides. e) Fit strap bracing to end bays starting from apex going to opposite diagonal corners of bays using 12-14x20 teks. f) If required the supplied bracing tensioners can be installed to tension up the stap and also to fine tune the building into square and plumb. STEP 5 - FINISHING THE FRAME a) The bottoms of rolladoor/sliding glass door and PA door opens will still have the bottom framing plates attached, these can now be removed with a hacksaw or tinsnips. b) Windows and sliding glass doors need to be installed at this stage. Place the pre-assembled windows or sliding glass doors into the openings from the outside and fix to the frame at the sides using wafer teks. c) Ensure the windows or sliding glass doors are level and even in the openings. 17 P a g e

STEP 6 - INSTALLING THE ROLLADOORS CONSTRUCTION GUIDE a) Install rolladoor fixing plates to rolladoor frames both sides using 12-14x20 teks (Fig 15).

b) Please use the installation instructions provided by your rolladoor manufacturer that comes with your rolladoors to ensure all warranties are protected.

(Fig 15) STEP 7 - INSTALLING HEAD FLASHINGS a) Before sheeting the walls all the rolladoor/window/pa door and sliding glass door head flashings must be installed.

18 STEP 6 - INSTALLING THE ROLLADOORS CONSTRUCTION GUIDE a) Install rolladoor fixing plates to rolladoor frames both sides using 12-14x20 teks (Fig 15). These are the backing plates to support the rollador angle brackets. b) Please use the installation instructions provided by your rolladoor manufacturer that comes with your rolladoors to ensure all warranties are protected. This is a propriety item and must be installed correctly or by a professional installer. (Fig 15) STEP 7 - INSTALLING HEAD FLASHINGS a) Before sheeting the walls all the rolladoor/window/pa door and sliding glass door head flashings must be installed. b) Head flashings need to trimmed to size, add the depth of the side flashings for the appropriate openings + 5mm + the opening width and cut to this length. c) Install the flashing flush with the bottom of top plate of the frame using wafer teks. (Fig 16), wall sheeting will be cut/slit around the head flashings when sheeting is installed. Section 2.8 will identify the appropriate flashings for your openings. (Fig 16) 18 P a g e

GENERAL NOTES Roof and wall sheets are best cut using tin snips or electric nibblers.

19 CONSTRUCTION GUIDE STEP 8 - ROOF AND WALL SHEETING SAFTEY NOTES Always wear saftey gloves when handling any type of metal sheeting. Never attempt to install metal sheeting in windy conditions. GENERAL NOTES Roof and wall sheets are best cut using tin snips or electric nibblers. NEVER USE ABRASIVE CUTTING DISCS as they will damage the coating and promote corrosion. Where possible cut sheets on the ground and always clean off any swarf and metal filings. Wall and roof sheets should be fixed at the recommended supported spacings. (Fig 17 & 18) (Fig 17) (Fig 18) 19 P a g e

20 CONSTRUCTION GUIDE Teks with neoprene washers should never be under or over tightened. (Fig 19) (Fig 19) All Roof sheeting should be turned up at the apex and turned down at the gutter using a shifting spanner, turnup tool or a piece of 4"x2" wood with a saw cut 25mm deep into the end along the 4" direction. (Fig 20) Turning up Trimclad Turning up Corodek (Fig 20) Roof and wall sheets are always laid into the prevailing wind and weather. (Fig 21) (Fig 21) 20 P a g e

CONSTRUCTION GUIDE WALL SHEETING a) Ensure the first and second sheet is plumb to the frame by using a long spirit level, then check every 2-3 sheets as you progress along the wall.

21 CONSTRUCTION GUIDE WALL SHEETING a) Ensure the first and second sheet is plumb to the frame by using a long spirit level, then check every 2-3 sheets as you progress along the wall. b) Ensure the wall sheet is at the right height under the roof sheet and passes the slab by 40mm. You may want to flick a chalk line along the slab to assist you in keeping the right height. c) Remembering that wall sheeting is valley fixed with 10x16 Hex Teks, fix at top, bottom and all center noggings using the method to suit your sheet profile (Fig 17 & 18). d) Using tin snips or electric nibbler cut in the openings and trim back the rake on the gable ends. (Fig 22) (Fig 22) ROOF SHEETING a) Ensure your first sheet is square to the gable and positioned 50mm past wall sheet into the gutter. b) Remembering that roof sheeting is rib fixed with M6-50 roof zips, fix at eaves and the center top hats using the method to suit your sheet profile (Fig 17 & 18). c) DO NOT fix the roof sheet to the apex tophats as these will be fixed when installing the ridge cap. 21 P a g e

STEP 9 - BARGE AND CORNER FLASHINGS CONSTRUCTION GUIDE a) Place the first barge capping along one side of the roof where the bottom end of the barge capping should finish level with the bottom end of

22 STEP 9 - BARGE AND CORNER FLASHINGS CONSTRUCTION GUIDE a) Place the first barge capping along one side of the roof where the bottom end of the barge capping should finish level with the bottom end of the roof sheets. b) At the ridge, place a plumb line from the apex of the shed and mark the barge cap along the line with a marker. Cut the barge capping along this line as shown in (Fig 23). (Fig 23) c) Place the retuning barge from the apex underneather the first to produce a lap. (Fig 24) (Fig 24) d) Trim returning barge capping to the same length as the roof sheeting. e) Start fixing the barge capping from the bottom gutter end of the gable (Fig 25) on to wall and roof sheeting using 10x16 Teks. Use pop rivets provided to fix the apex lap. (Fig 25) 22 P a g e

23 CONSTRUCTION GUIDE f) Fit corner flashings up behind the barge capping (Fig 25) using 10x16 wall teks provided making sure to fit along the same screw line as wall sheets. STEP 10 - INSTALLING THE PA DOOR a) You can set door to open either to the left or right side. b) Fit hinges to door frame 200mm from top and bottom of PA door. c) Ensure even and adequate gap to top, bottom and sides of door. d) Door should be flush with outside of frame with pins of the hinges on the outside of frame opening. e) Fit side flashing to frame and cut to length, fix using pops provided. f) Swing the door closed, fit the lock and mark latch holes, then drill latch hole in frame through side flashing. g) Install the striker plate provided with the lockset, use fixings proved or 4mm pop rivets (not included in kit). h) Fix the PA Door jamb flashing to the door panel when the door is closed so the jamb flashing stops the door at the right position flush with frame (flashing type 1), use pop rivets or 12-14x20 teks. STEP 11 - INSTALLING THE GUTTER a) Cut holes for downpipe dropper at the desired location. b) Fix concealed gutter brackets at both ends of the shed and ensure there a fall of approx 10mm over the length of the shed, use the wafter teks privided. c) Run a string line along the bottom edge of the brackets and install the remaining gutter brackets on the ribs of the sheeting between 900mm mm apart. d) Avoid placing brackets at downpipe drops or within 300mm of gutter joins. e) Install the gutter drops and gutter stop ends to the gutter using pop rivets and roof and gutter silicon. f) Where gutter joins allow 200mm over lap and place two beads of roof and gutter silicon and join using pop rivets provided. g) Gutter length should be flush with outside of both ends of barge capping. h) Remove all plastic and lift the gutter onto the roll of the concealed gutter brackets. 23 P a g e

24 CONSTRUCTION GUIDE i) Carefully roll the gutter towards the rear of the bracket until it clips into place at the same time ensuring the gutter fits neatly against the barge capping at either end of the building. j) Snip/notch barge capping to produce a lap over the gutter ends and use pop rivets to fix to gutter stop ends. (Fig 25) STEP 12 - INSTALLING THE RIDGE CAPPING a) Fit the ridge capping in the direction of the prevailing wind. b) Seal the joints using roof and gutter silicon. c) Screw down ridge capping through roof sheeting into top hats using M6x50 hex roof zips with neoprene seals. STEP 13 - CLEANING UP a) Clear entire site of all loose screws, sheeting/flashing off cuts and rubbish. b) Use vacuum cleaner to rid bottom of stud frames of all debris. c) Wash down all roof and wall sheeting to remove all swarf and chalk marks. d) Sweep entire slab area and wash down and allow to dry. When dry use an appropriate silicon sealant to seal bottom of stud frame to concrete slab and allow to cure. 24 P a g e

25 GALLERY FINISHED PROJECTS SOME FINISHED PROJECTS 6.00m x x Gable Entry with 6m Garaport 9.00m x x Gable Entry 25 P a g e

shed. (Notice downpipe dropper is back from corner)

26 GALLERY FINISHED PROJECTS Shows rolladoor - head flashing/side flashing and gutter for a side entry shed. (Notice downpipe dropper is back from corner) Shows how barge is notched and fixed to gutter 26 P a g e

GALLERY FINISHED PROJECTS Internal studs

27 GALLERY FINISHED PROJECTS Internal studs are useful for running electrical conduit. Shows internal sheet flashing neatly finishes against roof top hats. (Notice how corner flashing and gable skirt is notched against eaves fascia purlin) 27 P a g e

GABLE ROOF CARPORT RECOMMENDED INSTRUCTION MANUAL

GABLE ROOF CARPORT RECOMMENDED INSTRUCTION MANUAL Table of Contents Introduction 2 Components 3 Step 1a Marking out the Perimeter of the Carport with Footing only 3 Step 2a Footing Set-Out for Concrete