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Simple Space Assembly Instructions

  • EXPOL Emperor wall panels are marked on the top of the panel, starting at #1, each has a rectangle diagram indicating its position in the base channel.
  • Ensure both tongue and grooved edges of the panel are clean and clear of debris before joining the following panels, and the weather conditions are fine.
  • All beads of sealant caulked into the wall panel joints and wall base channel should be an even 5-7mm thick, and applied to a clean, dry surface.
  • Methylated spirits and a lint free cloth will clean any bead accidentally smeared or pushed out from the base channel when placing the panel into the base channel.
  • Wipe any excess sealant that may push out the predrilled holes in the channel, so as not to clog up your drill end.
  • When applying sealant in the channel, only apply sealant into the channel at 1200mm increments to seal the sheet you are installing at that time.
  • Apply the sealant immediately prior to lifting the wall into place, so have the panel moved nearby and ready to be installed.
  • When installing the flashings and trims, place into the correct position, drill through the pre-drill holes of the trim into the panel, then, remove the flashing or trim, to clear out the metal filings, then place back.
  • Click here for a full list of kiset components and tools / PPE required for assembly. 

STEP BY STEP GUIDE

Assembly Instructions for Simple Space with a Steel Base
Assembly Instructions for Simple Space with a Wooden Subfloor
Steel Base

STEP BY STEP GUIDE

Step 1
Place Steel Base (Component A) bearers onto piles, ensuring the structure is level. If you are using wood 125mm H5 piles, fix a H3.2, 90x45mm timber to the sides of the bases steel bearers, mechanically fixing with a 180mm M12 engineered bolt/nut and washer, then fix a sub-floor kit, or dog tie (6 or12kn) as per manufacturer’s instructions. Ensure the joist side marked DOOR-WAY, is the orientation you desire.

Example of a pile to bearer connection

Step 2
Install UnderFloor Insulation Joist Saddles (Component D) over the steel floor joist, 200mm from the end of each joist, to support the insulation. The end joist, (where a Joist Saddle will not fit) can be secured by cutting the insulation snug and applying a thin bead of Styro-FIX (Component E), along the edge joists.
Step 3
Measure, cut and install Underfloor Insulation Panels (Component C) between all steel floor joists. Use Styro-FIX on the insulation ends, where they meet. If you accidentally break a panel, simply glue it together, before putting back in the joist space.
Step 4
Place a polythene DPM sheet over the base structure, to hold it in place, prior to laying ply floor with tape, at the corners, or simply place under the floor on the ground, weighing it down and taping it around the piles, to mitigate ground moisture ingress, up into to the Simple Space.
Step 5
Install the plywood floor (Component B), flush with the inside edge of the base channel, and over the joist. Marks over the joist have been marked, screw (Component AI) at 150mm centres, 12mm from sheet edge, on all four sides and the intermediate middle joist, an indication mark has been marked on the ply flooring. Some screws may snap and require predrilling. ONLY PUT 2 SCREWS IN THE PLY SHEET MARKED FLOOR, AS THIS MAY NEED TO BE LIFTED TO INSTALL THE #1 (DOOR PANEL), OR LEAVE IT OUT, UNTILL THE #1 (DOOR PANEL) IS INSTALLED.
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Step 1
Starting with the door wall panel #1 (Components H + M), apply Sikisil C Silicone Sealant (Component AC) to the inside, upward edges of base channel where it will go, as wide as where the sheet will go, (marking 1.2m intervals may help).
Step 2
Lift the High Wall Panel with Door (Components H + M) into the channel, pushing the mitred corner hard to the channels corner edge.
Step 3
Place a level vertically along the panel groove edge fold (the panel joint), when its plumb, drill through the base channel holes and fix in plain rivets (Component AE) to secure it in a plumb position, if it requires slight adjustment to make plumb, place a small plastic packer under the side you wish to lift, thus adjusting its plumbness, or having one person holding the level and panel keeping it plumb, while the other person drills and rivets the panel to the base channel.

Before drilling into the panel through the base channel predrilled holes and securing the plain rivets. It should be within the allowable tolerance if the piles are level with each other.
Step 4
Next install the side wall panel #2 (Component J) , applying sealant to the base channel again, creating a right-angle wall with the panels, then moving the two panels mitred corners together, ensuring it is completely down inside the base of the channel, and the mitred corners are together.

If there is a slight gap between the long or short points of the mitred corners, this can be sealed/filled (with Gorilla Foam), before the external flashing and internal corner trim are installed.

Step 5
Place a gusset (Component AJ) 50mm from the top of the corner, fixing it to one panel(with a plian rivert - Component AE) , then when both faces of the mitred corner are plumb, place another plain rivet in the other side of the gusset.

With 2 rivets in both sides of the gusset, the corner should stay secure plumb both ways now.

Ensure the first corner is secure and stable, in a plumb position, both ways.

Again, If it requires slight adjustment to make plumb, place a small plastic packer under the side you wish to lift, thus adjusting its plumbness, or having one person holding the level and panel keeping it plumb, while the other person drills and rivets the panel to the base channel.
Step 6
Repeat the process of caulking sealant to both inside edges of the base channel, where the window wall panel will sit, as in Step 1.
Step 7
Chalk with Sikasil C Silicone Sealant (Component AC) the inside edge of the folded groove, with a 5mm bead of sealant, using a steady and smooth action, for an even bead.
Step 8
Lift and place the window panel (Components I and Q) next, placing into the channel and pushing the tongue edge into door’s groove edge with pressure, so that the panels are firmly into each other.
Step 9
When the panels are firmly into each other, check the plumb of the window panel, before vice gripping the top of the joining panels and drill and rivet to temporary hold the top of the panels together, while you are installing the walls, (this step is repeated for ALL panel joins, and the rivet is removed prior to installing the external, 40x40 titania flashing).
Step 10
Continue sequentially installing the panels, repeating the previous steps, noting the last one can be tricky, as you must get the tongue & groove joined, THEN slot down into the channel, before gusseting the mitre closed.
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The method for joining the roof panels is the same, as joining the walls panels, in relation to sealing the joins, joining them, and riveting the end of the panels, to temporarily hold them together, before the roof edge trim is installed.



1
Place Roof Panel #1 (Component K), over the door panel side of the Simple Space, positioning the roof panel with a 300mm overhang to the side wall, and a 300mm overhang to the front high side of the unit, ensure the male edge is the side out, overhanging, and the groove edge over the inside, for so the next roof panel #2 tongue edge pushed into roof panel #1 groove edge.
2
Rivet 2 gussets provided to the top of the side wall 2 &3 and at the front or back of the unit, as so the roof panel 1 does not move when inserting roof panel 1 into 2.

Example of a pile to bearer connection

3
Bead the upper facing female groove with sealant, before joining both roof panels 1 and 2, securing with a rivet at both ends 10mm from the edge.
4
Repeat until all roof panels are on, the last being the 600mm end roof panel #4.
5
Check the plumbness of all the walls, while maintaining the correct overhangs. If a wall needs to be adjusted out to make it plumb, in turn lessens the amount of overhang, so you may need to move the roofs panels again, a gusset will hold the junction plumb while holding the correct overhang distance.
6
Now mask the sides of the joins on all the panels joins on the top of the roof, apply a 10mm bead of the roof and gutter silicone into the joins channel profile, and trowel off flush with top of the roof, peel off tape before silicone dries.
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  1. Install the roof trims, starting at the back. 1 underlap fold has been folded already, so put it on, mark the other end, and repeat the cut & fold. [pic]
  2. Drill the trim flashing, then remove to clear all metal filings before beading sealant along the top inside edge, and the fold, before putting back on, and riveting in place with the sealed plain rivets.
  3. On one side place a side trim, with the pre-folded end at the front and square end over the back trim fold. As in step 2, pre-drill, take offside trim, clear all the filings, apply a bead of sealant to the inside top edge, put back and rivet.
  4. Repeat step 3 on the other side of the roof edge.
  5. Dry fit the front eave roof trim, drilling, and clearing the metal filings, applying sealant on the inside top edge of the trim and two folds, before fixing off with the sealed rivets.
  1. Place the 2 x longer flashings on the front corners and shorter ones on the back corners of the external walls, hold in place while you drill the panel through the flashing.
  2. Remove and clear the filings before applying a 5mm bead along both inside crush folds. [pic]
  3. Before placing back on, apply a 10mm bead of sealant down the tips of the mitre’s long points and trowel/smear flat.
  4. Rivet with the grey friars’ rivets.
  5. Repeat on the other three corners.
  1. With the flashing off-cut provided (2 mitred corner), place on a side wall, align the front Titania flashing’s external corner mitre in place, with it [pic], and mark the front flashings non cut side, with the opposing inside edge other side wall, and mark.
  2. Cut with the saw. (If you are using a hack saw, you will need to mark the external mitre from the initial plumb mark.)
  3. Cut and drill through the flashing & panel and put two temporary rivets at each end.
  4. Progressively work around each side of the Simple Space, repeating step 2 & 3.
  5. When you are happy with the flashings positioning remove the flashing and remove any filings, then apply a 10mm bead of silicone to the wall/Eave junction, and trowel in.
  6. Apply 5mm bead of sealant to the flashing inside face that goes against the roof.
  7. Rivet in position with the Titania rivets.
  1. Measure the inside to inside of the 2 side walls, where the Titania trim will go, one side has been precut so cut the other side.
  2. Progressively work around the walls, drilling through the trim and panel, temporarily riveting, before moving to the next walls side.
  3. Once all the flashings are in, remove each one, apply a 10mm bead to the wall/ceiling junction, trowel in.
  4. Put back trim into position and rivet off with the titania rivets.
  1. Position each trim to place and predrill, through the trim into the panel.
  2. Remove, clear the metal filings.
  3. Apply a 10mm bead of sealant to the internal junction of the Wall/wall internal corner, trowel smooth.
  4. Position back in and rivet in.
Wooden Subfloor

STEP BY STEP GUIDE

1
Construct bearers. Leave as long as possible for easier Hiab lifting points.

2
Construct sub floor, on bearers..

3
Install underfloor insulation...

4
Install ply floor...

5
Install SIP channel to boundary joist..

6
Predrill 5mm holes @ 200mm centres, allowing for SIP sheet joins.

7
Drill weep holes, & zinc spray base of channel @ 400m centres.
8

Screw down through channel to the boundary joist.

Previous slide
Next slide
Step 1
Starting with the door wall panel #1 (Components H + M), apply Sikisil C Silicone Sealant (Component AC) to the inside, upward edges of base channel where it will go, as wide as where the sheet will go, (marking 1.2m intervals may help).
Step 2
Lift the High Wall Panel with Door (Components H + M) into the channel, pushing the mitred corner hard to the channels corner edge.
Step 3
Place a level vertically along the panel groove edge fold (the panel joint), when its plumb, drill through the base channel holes and fix in plain rivets (Component AE) to secure it in a plumb position, if it requires slight adjustment to make plumb, place a small plastic packer under the side you wish to lift, thus adjusting its plumbness, or having one person holding the level and panel keeping it plumb, while the other person drills and rivets the panel to the base channel.

Before drilling into the panel through the base channel predrilled holes and securing the plain rivets. It should be within the allowable tolerance if the piles are level with each other.
Step 4
Next install the side wall panel #2 (Component J) , applying sealant to the base channel again, creating a right-angle wall with the panels, then moving the two panels mitred corners together, ensuring it is completely down inside the base of the channel, and the mitred corners are together.

If there is a slight gap between the long or short points of the mitred corners, this can be sealed/filled (with Gorilla Foam), before the external flashing and internal corner trim are installed.

Step 5
Place a gusset (Component AJ) 50mm from the top of the corner, fixing it to one panel(with a plian rivert - Component AE) , then when both faces of the mitred corner are plumb, place another plain rivet in the other side of the gusset.

With 2 rivets in both sides of the gusset, the corner should stay secure plumb both ways now.

Ensure the first corner is secure and stable, in a plumb position, both ways.

Again, If it requires slight adjustment to make plumb, place a small plastic packer under the side you wish to lift, thus adjusting its plumbness, or having one person holding the level and panel keeping it plumb, while the other person drills and rivets the panel to the base channel.
Step 6
Repeat the process of caulking sealant to both inside edges of the base channel, where the window wall panel will sit, as in Step 1.
Step 7
Chalk with Sikasil C Silicone Sealant (Component AC) the inside edge of the folded groove, with a 5mm bead of sealant, using a steady and smooth action, for an even bead.
Step 8
Lift and place the window panel (Components I and Q) next, placing into the channel and pushing the tongue edge into door’s groove edge with pressure, so that the panels are firmly into each other.
Step 9
When the panels are firmly into each other, check the plumb of the window panel, before vice gripping the top of the joining panels and drill and rivet to temporary hold the top of the panels together, while you are installing the walls, (this step is repeated for ALL panel joins, and the rivet is removed prior to installing the external, 40x40 titania flashing).
Step 10
Continue sequentially installing the panels, repeating the previous steps, noting the last one can be tricky, as you must get the tongue & groove joined, THEN slot down into the channel, before gusseting the mitre closed.
Previous slide
Next slide

The method for joining the roof panels is the same, as joining the walls panels, in relation to sealing the joins, joining them, and riveting the end of the panels, to temporarily hold them together, before the roof edge trim is installed.



1
Place Roof Panel #1 (Component K), over the door panel side of the Simple Space, positioning the roof panel with a 300mm overhang to the side wall, and a 300mm overhang to the front high side of the unit, ensure the male edge is the side out, overhanging, and the groove edge over the inside, for so the next roof panel #2 tongue edge pushed into roof panel #1 groove edge.
2
Rivet 2 gussets provided to the top of the side wall 2 &3 and at the front or back of the unit, as so the roof panel 1 does not move when inserting roof panel 1 into 2.

Example of a pile to bearer connection

3
Bead the upper facing female groove with sealant, before joining both roof panels 1 and 2, securing with a rivet at both ends 10mm from the edge.
4
Repeat until all roof panels are on, the last being the 600mm end roof panel #4.
5
Check the plumbness of all the walls, while maintaining the correct overhangs. If a wall needs to be adjusted out to make it plumb, in turn lessens the amount of overhang, so you may need to move the roofs panels again, a gusset will hold the junction plumb while holding the correct overhang distance.
6
Now mask the sides of the joins on all the panels joins on the top of the roof, apply a 10mm bead of the roof and gutter silicone into the joins channel profile, and trowel off flush with top of the roof, peel off tape before silicone dries.
Previous slide
Next slide
  1. Install the roof trims, starting at the back. 1 underlap fold has been folded already, so put it on, mark the other end, and repeat the cut & fold. [pic]
  2. Drill the trim flashing, then remove to clear all metal filings before beading sealant along the top inside edge, and the fold, before putting back on, and riveting in place with the sealed plain rivets.
  3. On one side place a side trim, with the pre-folded end at the front and square end over the back trim fold. As in step 2, pre-drill, take offside trim, clear all the filings, apply a bead of sealant to the inside top edge, put back and rivet.
  4. Repeat step 3 on the other side of the roof edge.
  5. Dry fit the front eave roof trim, drilling, and clearing the metal filings, applying sealant on the inside top edge of the trim and two folds, before fixing off with the sealed rivets.
  1. Place the 2 x longer flashings on the front corners and shorter ones on the back corners of the external walls, hold in place while you drill the panel through the flashing.
  2. Remove and clear the filings before applying a 5mm bead along both inside crush folds. [pic]
  3. Before placing back on, apply a 10mm bead of sealant down the tips of the mitre’s long points and trowel/smear flat.
  4. Rivet with the grey friars’ rivets.
  5. Repeat on the other three corners.
  1. With the flashing off-cut provided (2 mitred corner), place on a side wall, align the front Titania flashing’s external corner mitre in place, with it [pic], and mark the front flashings non cut side, with the opposing inside edge other side wall, and mark.
  2. Cut with the saw. (If you are using a hack saw, you will need to mark the external mitre from the initial plumb mark.)
  3. Cut and drill through the flashing & panel and put two temporary rivets at each end.
  4. Progressively work around each side of the Simple Space, repeating step 2 & 3.
  5. When you are happy with the flashings positioning remove the flashing and remove any filings, then apply a 10mm bead of silicone to the wall/Eave junction, and trowel in.
  6. Apply 5mm bead of sealant to the flashing inside face that goes against the roof.
  7. Rivet in position with the Titania rivets.
  1. Measure the inside to inside of the 2 side walls, where the Titania trim will go, one side has been precut so cut the other side.
  2. Progressively work around the walls, drilling through the trim and panel, temporarily riveting, before moving to the next walls side.
  3. Once all the flashings are in, remove each one, apply a 10mm bead to the wall/ceiling junction, trowel in.
  4. Put back trim into position and rivet off with the titania rivets.
  1. Position each trim to place and predrill, through the trim into the panel.
  2. Remove, clear the metal filings.
  3. Apply a 10mm bead of sealant to the internal junction of the Wall/wall internal corner, trowel smooth.
  4. Position back in and rivet in.

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