DECK SUPERMARKET Tagged Handrails Caravan Decking Kits Instruction Manual

DECK SUPERMARKET Tagged Handrails Caravan Decking Kits

INTRODUCTION

CONGRATULATIONS

Deck Supermarket Limited would like to congratulate you on the purchase of a high quality verandah/deck kit. You have made the decision to purchase a kit from the market leaders in this field and all that is left to do now is assemble your kit and enjoy.

ITEMS REQUIRED

ITEMS REQUIRED TO FIT

• Safety Gloves, Safety Goggles and Ear Protection as required
• Pencil and Tape Measure, Axle Stands, String Line and Spirit Level
• Drill/Driver and Screw Driver
• Fine Tooth Wood Saw or Power Saw
• Hacksaw
• Appropriate Screws
• *N.B. These instructions are intended as a guide only as all installations vary. All Self Build Deck Kits should be installed by competent persons Deck Supermarket Limited can not be held responsible for mistakes or injury that happen while using this guide.
• *All heights and Building Regulations should be checked with Local Authority prior to installing and correct codes of practice followed by the installer.

KEY TO PARTS

KEY TO PARTS USED IN OUR KITS

BUILDING THE FRAMES

The frames are supplied as flat pack, they will be labeled individually and numbered to correspond with your supplied frame plan. You should first form the outside of the first frame, this will be made up of 2 pairs of equal length timber. The supplied corner brackets should be screwed at either end to a pair of timbers of equal length using the supplied 40mm screws, then attached the second pair of timbers to create your outer frame.
The corners should look like the image on the left, timbers corner to corner and ready to accept the posts when you reach that stage.

The joists can then be added using 70mm screws to secure them, the frames will be marked for there positions and the joists always run in the opposite direction to the deck boards. Once all the joists are all in place the noggins can be cut and fixed, staggering them will make them easier to attach between the joists. Your first frame should now be complete, repeat this until all frames have been built up.

When all the frames have been completed they can be laid out in number order as per the supplied Deck Frame Drawing. Once this step has been done you are ready to set your frame heights and distance.

SETTING FRAME HEIGHT & DISTANCE

• Measure from bottom of door to bottom of home, halve this measurement and deduct the thickness of your chosen deck board and make a note of this.
• Cut 2 blocks/pieces of timber to the measurement you made a note of, be sure they are square. Now cut 2 slightly longer lengths as per the the image to form an “L” shape and screw together.
• These “L” shaped brackets need to be set approximately 70mm from the front of the home to the face of the timber and can now be screwed to the bottom edge of the home.
• Add a screw to the bottom to take a string line
• Both brackets attached
• Now attach your string line between both

LEVELLING FRAMES

• The frame/s can now be set to the string line, we use caravan axle stands to hold the frame/s to the correct level as they are easy to adjust.
• Take your time to make sure your frames are level with the string line that you set.

SETTINGS INSTRUCTIONS

SETTING FRAME FALL

• Allow 15mm fall using an 1800mm spirit level or a 7mm fall if using a 1000mm level away from your van, we use 3 x 5mm packers with the 1800mm level shown. This is to allow for water run off.

SETTING POST HEIGHTS BEFORE FIXING IN PLACE

Each full height post needs to be measured between arrows and marked and cut to make sure all post height/caps line up as the slabs are not always true and level. Once cut the post can only be installed in the position it was measured. The height to mark and cut the post is determined by the length of picket in the handrails.

Picket Length = Measure & Cut at:

• 695mm 920mm
• 795mm 1020mm
• 895mm 1120mm

SETTING POSTS

• Pilot drill using a 6.5mm bit
• Insert coach bolts
• Leaving the bottom loose
• Check level all round
• Use wooden wedge to make level if required
• Now fully tighten all the coach bolts

ADD GATE POST

ADD GATE POST TO CLEAT IF REQUIRED AND SUPPORT POSTS AND ADD BOLTS BETWEEN FRAMES

• The gate post if used can be attached by pilot drilling (using a 6.5mm bit) and fixed in place using 2 x coach bolts which should be fixed diagonally across the post
• The support posts should be cut 5mm below frame height and fixed using 70mm wood screws. Angle the screws up slightly to pull the post downwards.
• Add a coach bolt to either side of centre where the frames join for added support.

NEXT ADD YOUR FASCIA

• The Fascia should be offered to the opening and marked 2mm over size, it should be cut using a fine tooth saw.
• Cut one end at an angle to achieve a perfect snug fit and screw from behind starting at either end before attaching in the centre. If you are adding a Ranch Skirt Kit to your deck ignore this stage.

COMPLETED FRAME SHOULD RESEMBLE

THIS IS WHAT THE COMPLETED FRAME SHOULD RESEMBLE

TIME TO ADD YOUR STEPS

Measure from the top of the frame to the floor and divide this measurement by 3 if using 2 tread steps or by 4 if using 3 tread steps and mark the post. i.e. if the measurement is 600 and it’s 2 tread steps each mark will be at 200mm distance. Use a square to mark the post across, place the top of the “U” bracket to the mark and attach to the post with 32mm stainless steel screws as per the image. Be careful not to over tighten the screws as this could result in splitting or breaking the corner off the bracket. We suggest using a drill/driver with adjustable torque for this.

Transfer bracket height across to outer posts using a spirit level, this will keep the the step treads level if the floor is not. Attach brackets and fit step treads as per images above.. Pilot drill and use 25mm stainless steel screws to fix through the side of each ”U” bracket as marked by the yellow arrow on both sides of the step.

ATTACHING STEP SUPPORT POSTS

• Cut the step support posts to size, make sure they are 1mm oversize so full contact between ground and the step is made and attach with 2 x 25mm stainless steel screws to each galvanized step tray.

ADD BOTTOM STEP RAIL

• Attach bottom stair rail brackets and rail with 32mm stainless steel screws, the same bracket is used for the top but is turn around.
• Again pilot drill and fix with 32mm stainless steel screws through the side of the bracket to secure. Do not attach the top rail yet.

ADDING A RANCH SKIRT?

If you have bought a Ranch Skirt Kit with your Deck Kit then now is the time to install it to the deck area. Access is so much easier before the deck boards have been fitted. Simply screw the supplied u-channel to the inside edge of the posts, the u-channel should start level with the top of the frame and run to the floor.

The top fascia board will then cover the frame, the fascia boards below can then be spaced out equally. You may need to scribe the bottom fascia board if a full board does not fit or the ground is not level. You can then cut to length and screw the supplied pickets to the back of the fascia boards to keep everything in line.

DECK INSTALLATION

START AT THE STEP END OF THE DECK, CUT STARTER TRIM TO SIZE AND ATTACH WITH 40MM WOOD SCREWS

FIT YOUR FIRST DECK BOARD

• Use a square and pencil to mark your boards and cut with a jigsaw for ease, insert a screw at each joist.
• Leave a 2mm gap around posts etc. this will avoid squeaking and noise.

NOW ADD ALL OTHER BOARDS TO COMPLETE

MEASURE, MARK, CUT AND ATTACH U CHANNEL

• The U Channel should only be pushed on and not stuck on, the U Channel is designed to drain water away and may need removing to clean from time to time.

DECK BOARDS & RANCH SKIRT COMPLETED

ATTACHING YOUR HANDRAILS

• Set the height of the bottom rail up to 100mm max from the deck to the bottom of the rail. Only attach the brackets to the 2 outermost posts using 32mm stainless steel screws
• Now string a line between the 2 outside posts level with the top of the brackets, this will make sure the handrails are level all the way through
• Mark where the line touches the centre post
• Transfer across using a square
• Attach your bottom rail brackets to the centre post using 32mm stainless steel screws

LEVELLING RETURN RAILS

• Level up the return rails using a spirit level. Bear in mind because of the fall on the deck the gap under the rail will not be exactly parallel.

ADDING PICKETS AND TOP RAILS

• Angle the top rail slightly when inserting the pickets will make this stage easier.

ATTACHING TOP RAILS

• Next fit your top rail brackets
• Your rails can then be centered with in the width of the post and fixed in place with 32mm stainless steel screws

ADDING TOP HANDRAIL FOR STEPS AND CAPS

• Line up stair bracket with other top rails, attach top bracket first and the bottom will naturally find its place and can be attached with 32mm stainless steel screws
• The caps can now be put in place with a small amount of silicone

ATTACHING THE GATE

• Firstly decide which way your gate will be hung, turn the gate upside down and drill 3 x 5mm drain holes in the centre of the base.
• Next line the gate up with the top rail and then screw the hinges in place. Finally attach your latch and check operation.

FINALLY CLEAN OFF

FINALLY, CLEAN OFF WITH A SOFT WHITE CLOTH AND YOUR INSTALL IS COMPLETE

CLEANING & MAINTENANCE

DECK SUPERMARKET DECK KITS CLEANING & MAINTENANCE

• Please take a moment to read this information
• We would like to thank you for choosing Deck Supermarket for your Deck Kit.
• Please find below a few tips to help maintain your Deck Supermarket Deck Kit for many years to come.
• Cleaning and Maintenance
• To keep the high quality looks and finish of your Deck Supermarket Deck Kit we recommend only the use of soapy water and a soft cleaning cloth or sponge.
• No harsh chemicals, scouring agents or abrasive pads or cloths should be used to clean your decking and handrails as these could lead to a change in finish (shine) or discolouration of your finished product and may invalidate your warranty.
• From time to time it may be necessary to remove the u channel on the outer edge of your decking to clean behind as this acts as a gutter system and may become clogged with dirt and moss.
• Should you find the decking is excessively dirty a power washer can be used, however the end of the lance should not be put too close to the deck and a wide spray rather than a thin jet is recommended as this could also lead to a change in surface finish.
• Deck Supermarket Limited reserves the right to change colours and part shapes and sizes and discontinue products at their discretion.

KITS WARRANTY

DECK SUPERMARKET DECK KITS WARRANTY

Warranty

• All Deck Supermarket Deck Kits come with a 5-year structural Timber warranty and all materials and vinyl are warrantied based on supplier’s recommendations on individual colours, the majority of these carry 3 years against abnormal colour variation, under normal weathering 30 degrees maximum as per Northern Hemisphere testing although the colour on all products will change slightly over time due to UV Rays.
• Warranty on gates are at Deck Supermarkets discretion.
• Any colour or surface variation or dark patches/scorching caused by reflective surfaces, reflective glass, mats, plant pots, furniture or chemicals and excessive temperature over tested parameters are classed as external forces and not material faults so will not be covered under warranty.

FAQ

Frequently Asked Questions

• Q: Can I customize the deck kit with additional components?
  • A: Yes, you can customize your deck kit with additional components based on your requirements. Ensure they are compatible with the existing parts.
• Q: How long does it typically take to assemble the deck kit?
  • A: The assembly time can vary based on individual expertise, but on average, it may take a few hours to a day to complete the assembly process.

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