Instruction Manual

GARDEN ZONE POLYTUNNEL Instructions Manual

MODEL A2468 6m x 2.05m

Contents Introduction ..................................................................................................... 3 Background ...................................................................................................... 4 Kit Equipment .......................................................................................................4 Key Terms .............................................................................................................4 Required Tools......................................................................................................5 Overview of Assembly ..........................................................................................5 Preparing the Site .................................................................................................5 Instructions ...................................................................................................... 6 1.

Setting the Foundation Tubes and Anchor Plates .......................................6

2.

Assembling the Hoops ..................................................................................8

3.

Assembling the Ridge...................................................................................9

4.

Stabilising the Corners ...............................................................................10

5.

Fitting the Door Frame ...............................................................................11

6.

Digging the Trench ......................................................................................12

7.

Covering the Tunnel....................................................................................13

Optional Extras ............................................................................................... 15 Troubleshooting and Maintenance .................................................................. 15 Contact........................................................................................................... 16

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Introduction Garden World polytunnels are ideal for domestic use. They are spacious and suitable for growing plants, sheltering a clothes line or even storage. If assembled correctly, the polytunnel will be able to withstand the most extreme conditions. Is it essential to read this manual? Yes. Following this manual will help to prevent any errors or damage to the polytunnel. Read the manual fully before beginning in order to plan the process, gather resources and enlist help. Who should build the polytunnel? The process involves some strenuous labour and using many tools competently. The user must have intermediate experience with the required tools. Some steps will require more than one person. When should I build my polytunnel? ⚠️Warning - Build the polytunnel in dry weather. It is unsafe to use electrical tools in wet conditions. Note - Put the polythene cover on in warm, windless conditions. If the weather is not warm, the polythene will need to be heated before covering. How long will it take to build? Two people can build the polytunnel in one day.

Safety Measures ⚠️CAUTION ⚠️WARNING

Pay attention to these signs throughout the manual, in order to avoid injury or damage to the equipment.

Note

This symbol denotes tips and useful advice. This symbol indicates that assistance from a second person is required.

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Background Kit Equipment

Foundation Tubes x10

Tube clamp & bracket x8

Anchor plate x 4

Half hoops x10

Pack of selfdrill screws

Ridge clamp & bracket x5

Ridge pipe x4

Silver protection tape

Stabiliser bars (in 2 parts) x4

Q-clips

P-clips x4

Pre-assembled door frame x2

Anti hot spot tape

Polythene covering

Repair tape

Battens – 2 short & 4 long

Nails (pack)

Nuts (pack)

Hex bolts (pack)

Key Terms Swage

Flattened end 4|Page

Swaged end

Plain end

Required Tools     

1 2 3 4 5

Measuring tape Sledgehammer  String/twine  Spanner  Hammer 

⚠️Warning – -

6  7  8  9  10

Shovel Piece of timber Spirit level Drill Stanley knife

    

11 12   

2 doors (optional) Step ladder (optional)

Follow safety instructions provided with all tools. Do not use electrical tools in wet conditions.

- This symbol indicates what tools and materials are needed in each section.

Overview of Assembly Prepare the site

Set foundation tubes and anchor plates

Assemble the hoop

Assemble the ridge

Cover with polythene

Dig the trench

Fit door frame

Stabilise the corners

Preparing the Site ⚠️CAUTION - Choose a site with a level surface and as much wind protection as

possible. Clear the site of any rocks, branches and debris, as they may damage the polythene.

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Instructions 1. Setting the Foundation Tubes and Anchor Plates - Measuring tape, 10 foundation tubes, shovel, string, spirit level, sledgehammer, piece of timber, 8 tube clamps, 4 anchor plates, 16 nuts

1.1 - Mark out the corners of the polytunnel by pushing foundation tubes approx. 5cm into the ground at the measurements shown in the diagram.

2.05m

6m

Foundation Tubes

6m

Note : Measure from the centre of the foundation tubes.

- Measure the distance from corner to corner along the diagonals (see diagram 1A). The diagonals must be equal in length for the polytunnel to be square.

2.05m 1A Swaged end

1.2 Remove the foundation tubes and dig a square hole (40cmx40cmx40cm) at each corner.

40cm

40cm

40cm

1B

1.3 - Drive a foundation tube into the bottom of each hole, using the sledgehammer, until only the swage remains above ground level. - Check that the tubes are vertical, using a spirit level. ⚠️CAUTION – Cushion the top of the tube with a piece of timber to avoid damaging the tube.

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1.4 - Secure two tube clamps and an anchor plate around the bottom of each tube in the order shown (see diagram 1C). - Refill the holes with the dug out soil up to ground level.

foundation tube tube clamps

anchor plate 1C

1.5 - Push intermediate tubes into the ground (swage up) at 1.5m intervals (see diagram 1D).

- Run a length of string along the side of the tubes to ensure that they are in a straight line and adjust accordingly. - Drive the tubes into the ground (⚠️CAUTION as in step 1.3) until they are level with the corner tubes.

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1D

2. Assembling the Hoops 5 plain half hoops, 5 swaged half hoops, 5 self-drill screws, drill NOTE - Assemble the hoops on an even surface, e.g., on the ground.

2.1 Slot a swaged half hoop into a plain half hoop (See diagram 2A). 2A 2.2 ⚠️Warning – Exercise caution when using

Swaged joint

Self-drill screw

drill.

Screw the half hoops together at the joint, using a drill and a self-drill screw. Section 2 continued on next page.

2.3 - Slot the ends of the hoop into opposite foundation tubes. - Repeat all of section 2 for each hoop.

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2B

3. Assembling the Ridge 5 ridge clamps & brackets, 10 nuts, spanner, 4 ridge pipe, silver protection tape

3.1 Slot a clamp over each hoop at the joint and loosely secure the bracket and nuts (See diagram 3A). 3.2

- Start at one end of the tunnel and place a section of ridge pipe through the clamps on the first and second hoop.

hoop joints ridge

- Continue to add sections of ridge pipe through the clamps, along the tunnel. Note : The swaged ends fit into the plain ends (same as the half hoops in 2.1).

tube clamp bracket

3.3

3A

- Tighten the clamp at one end. - Look down the tunnel at the ridge pipe to ensure it is straight. - Check that the ridge joint and hoop joint are within each clamp (see diagram 3A). - Tighten each clamp.

3.4 Wrap silver protection tape around the ridge tube ends to prevent any damage to the polythene cover.

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3B

4. Stabilising the Corners 8 Q-clips, 4 stabiliser bars (in 2 parts), 8 hex bolts, 8 nuts, spanner

4.1 Fit 2 Q-clips to the first, second, second-last and last hoops. The black squares on the diagram indicate where to place the Q-clips. 4A 4.2 Join the 2 parts of the stabiliser bars together by fitting the swaged end into the plain end (See diagram 2A). Make sure the flattened ends are in line with each other. 4.3

- Fix the Q-clip, on the second hoop, to 20cm above ground. - Secure one end of the bar to this Qclip, using a hex bolt and nut (See diagram 4B). ⚠️CAUTION – Face bolts inwards to avoid damaging the polythene.

4.4

Stabiliser bar hoop Q-clip hex bolt

4B

- Angle the bar upwards to the end hoop and secure it to the Q-clip, as in step 4.3. - Repeat for the other three corners.

4C

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5. Fitting the Door Frame Shovel, measuring tape, 2 pre-assembled door frames, spirit level, 4 P-clips, 8 selfdrill screws, drill

5.1 Dig a trench approx. 30cm deep underneath the centre of the end hoop, to fit the base of the door frame.

end hoop trench 5A

30cm

end hoop

5.2 - Position the frame in the trench. Ensure that the top of the frame meets the hoop and is centralised under the hoop. - Ensure that the post is vertical, using a spirit level.

door frame 5B A

5.3 - Put the P-clips on the end hoop at the 2 points where the frame meets the hoop. - Position the P-clip to the outside so that both prongs run down the front of the door post (See diagram 5C). 5.4 ⚠️Warning – Exercise caution when using the drill.

- Drill 2 self-drilling screws into the Pclips to secure the door frame. - Refill the trench. - Repeat all of section 5 at the other end of the tunnel.

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end hoop

p-clip Self-drill screws

door frame 5C

6. Digging the Trench Shovel, measuring tape

6.1 Dig a trench all around the framework (excluding the doorways) 10cm outside the foundation tubes. The trench must measure 40cm deep and 30cm wide. NOTE – Deposit soil outside the framework. This will be more convenient when refilling the trench.

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trench

tube

6A

7. Covering the Tunnel Anti hot spot tape, stanley knife, polythene covering, pack of nails, hammer, battens ⚠️CAUTION - Apply anti hot spot tape in dry weather. If the metal is wet, the tape will not stick. - Apply the tape immediately before covering the tunnel. - Cover the tunnel on a warm, windless day. If the weather is not warm, NOTE heat the polythene before covering the tunnel.

7.1 Apply anti hot spot tape to any metal that will be touching the polythene. E.g., the outside of the intermediate hoops, clamps, brackets.

Anti hot spot tape

hoop

7A 7.2

- Lay the polythene along the length of the tunnel. - Holding one end each, pull the polythene over the tunnel.

Polythene

NOTE - Centralise the polythene along both the length and width of the tunnel. The polythene should come halfway down both doorways.

7.3

- Nail a short batten onto one door frame, trapping the polythene under the batten. Note - Nail the batten as shown in diagram. Do not nail the full length of the batten yet.

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7B door frame batten

7C

7.4

- At the opposite doorway, pull the polythene tight along the length. - Repeat step 7.3 on this door frame.

door frame Polythene 7D

7.5

- Perforate the polythene along the trenches to prevent the trenches becoming waterlogged. - Lightly tension the polythene at one side of the tunnel. - Start refilling the trench at the centre and work out to the ends and around the corners. - Tightly tension at other side and repeat.

Polythene

trench soil 7E

7.6 Pull the polythene under the doorframe again and nail the full length of the batten. Repeat on other side.

7.7

- Make a diagonal cut in the polythene from the top corners of the door frame (See diagram 7F). - At the side of the doorway, pull the polythene tight and pleat the covering evenly (See diagram 7F). - Nail a long batten to the door frame, trapping the polythene underneath, as shown in diagram. - Repeat this at the other side of the door frame and at the other end of the tunnel. - Trim surplus polythene with a Stanley knife. 14 | P a g e

diagonal cut

pleats batten

7F

The polytunnel is now fully assembled and ready to use.

Optional Extras  

Doors can be fitted on the door frames. To make your tunnel even sturdier, add crop bars to the hoops.

Troubleshooting and Maintenance Problem

Possible Cause

Solution

The hoops seem too wide to fit into the foundation tubes. Difficulty digging the trench Small tears and rips in the polythene

This is normal. The hoops are not the correct shape or width until put into the foundation tubes.

Push the hoop to the correct width, with another person.

The soil is too hard or full of rocks.

Use the base rail method instead of the trench method.

- Wear and tear

Stick repair tape on to clean polythene. Cover any protruding equipment with silver protection tape and repair polythene with repair tape. Loosen or remove the battens at the door frame, tighten the polythene and refit the battens. Clean the inside with a sponge and warm water. Clean the outside with warm, soapy water and a soft sweeping brush.

The polythene has come loose The polythene is turning green.

- Uncovered nuts and bolts protruding into the polythene. Polythene expands with heat. Algae often grows on polythene during the Winter.

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Contact  For more information, please visit our website: www.gardenzone.com.  If you have any queries contact us via telephone or e-mail. Tel: 061 – 123456

E-mail: [email protected]

Image Sources  Image on Pg: 1 https://blog.firsttunnels.co.uk/polytunnel-polythene-types/  1A, 1D: Original  All other graphics: http://www.polytunnels.co.uk/pdf/tr/8tr.pdf Most graphics from this source have been altered to suit this set of instructions.

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