CHEMICAL SHED 2.4M X 2.4M PROCEDURE.

- Prepare material on list

Material Length (mm) Quantity Notes
75x50x3 RHS 2500 2

75x50x3 RHS 2300 2

50x1.6 SHS 3145 6 Bend for Down

tubes

50x1.6 SHS 2670 1

50x1.6 SHS 2300 6

50x1.6 SHS 1100 3 Bend for Nose

50x50x3 Angle 2300 1

50x50x3 Angle 1270 2

50x50x3 Angle 1125 1

2.1 Checker Plate 1200x3020 2

2.1 Checker Plate 430x1148 2

2.1 Checker Plate 358x2298 1

Trim clad 2800 4

Trim clad 2500 4

Trim clad 2400 4

Vent Mesh 400x2500 2

Vent Mesh 400x2400 1

Vent Mesh 200x2500 2

Vent Mesh 200x2400 1

Roller Door Rails 2080 2

Roller Door Bracket N/A 2

3/4” Tube 90 1

Swage Pegs N/A 7

Tank 1170x660 1

¾ 20nb gal pipe 1200 1

¾ 20nb gal pipe 100 1

roller door N/A 1

Roof flashing 4200 2

Flashing 2200 4

Flashing 1020 2

Manifest holder with caps and brackets N/A 1

Locking bracket N/A 2

Ball valve N/A 1

¾ M to F elbow ¾ 1

Shower handle N/A 1

Shower rose N/A 1

Emergency shower sign N/A 1

Hazardous Chemical Sticker N/A 1

Sheeting screw 10x16mm hex 380

Frame screws 12x20mm hex 120

- Assemble RHS for base (drill tugger holes in side pieces first) pic 1
(14mm hole 75mm in from ends and on centreline) refer to drawing

- weld out base pic 2

- Fit and weld in drain pipe/tube (refer to drawing) pic 3

- Sheet floor and sides of bund (ensure joins of floor sheets are on centre of floor joist and leave a
5mm gap to weld between them to ensure penetration) pic 4

- Fold up checker plate step and fit up (refer to drawing) pic 5

- Fit 50 x 50 RHS and angle support frame (30mm down from top of step) pic 6

- Weld out bund and frame (stitch weld under side of floor pan first) pic 7

- Fit swaged 50x50 pegs to frame using setting tool and weld out pic 8
- Clean spatter and remove any sharp edged ready for paint
- Cut floor mesh to suit and fit hold down brackets/screws pic 8

- Remove floor mesh, brackets and screws

- vacuum out and wipe down with thinners rag and paint the bund/base pic 9

-assemble portals on jig table (ensure to mark top centre on noses whilst on jig) Refer to drawing pic
10

- Once bund has dried, set up bund on stands and make level (must have level base to start)
- Fit portals to base and level up portals and fit temporary 30x30 braces pic 11
- Clamp 75x50RHS to side of portal uprights to ensure sides are straight in line pic 12
- Screw off portals to pegs
- Fit first 2 roof sheets together on ground, then lift up and fit to top of portals (ensure the join is
centred in portals and there is 150 mm of overhang on front and back) pic 13
- Remove temporary bracing
- Fit roller door tracks/guide (cut roller door tracks 50mm lower to topside of rubber bump stop than
the door opening) eg- if door opening is 2000mm, cut track at 1950 from bump stop.

- Fit roller door bracket (1910mm to underside of bracket and centred on post) pic 14
- Fit roller door -REFER TO Roller door PROCEDURE
- fit locking mechanism too door, metal stops and plastic guide inserts.
- Transfer marks from plastic guide to tracks while door is in a closed position.
Mark out holes, then drill out and finish off with die grinder.
- Attach locking arms. Ensure door locks and unlocks with keys at least 3 times.
- Hang keys on inside of shed on a screw so they won’t be lost
- trim excess pipe from roller door axle
- finish roof sheets and screw off
- Fit gable sheets to rear and front of shed (they should be cut first using the templates and nibbler) pic
15

- screw them off

- Fit wall sheets and screw off
- Cut vent mesh to size and fit/screw off pic 16
- Fit tank and plumb off (mark hole in vent mesh for shower pipe to pass through)
(silicon base of tank to angle to prevent vibration)

- Flash roof edging front and back

(start from middle and work your way to the outside cutting and screwing as you go)
- Flash rear corners then front corners
- Touch up paint any marks/scratches inside bund and fit floor mesh (screw down)
- Fit signs to front gable and under emergency shower outlet
- Fit manifest holder and shed ID sticker
- Fabricate shower handle and paint
- Engrave blue compliance plate and record all details (details to be given to Shannon so can be added
to a register)
- Fit compliance plate to bund
- Remove plastic coating from ball valve handle and drill 6.5mm hole in bottom centre of lever for
handle to pass through
- package shower head, handle, ball valve and rear drain lockable ball valve together and zip tie to floor
mesh inside for transport
- lock roller door and put key in manifest holder
-Ensure quality assurance checklist is completed.