GARDEN MODEL

A2468
6m x 2.05m
ZONE
POLYTUNNEL
Instructions Manual
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 Pay attention to these signs throughout the manual, in
⚠️WARNING 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 Tube clamp & Anchor plate x 4 Half hoops x10 Pack of self-
Tubes x10 bracket x8 drill screws

Ridge clamp & Ridge pipe x4 Silver protection Stabiliser bars Q-clips
bracket x5 tape (in 2 parts) x4

P-clips x4 Pre-assembled Anti hot spot tape Polythene Repair tape

door frame x2 covering

Battens – 2 Nails (pack) Nuts (pack) Hex bolts (pack)

short & 4 long

Key Terms

Swage

Flattened end Swaged end Plain end

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 Required Tools
 1 Measuring tape 6  Shovel  11 2 doors (optional)
 2 Sledgehammer  7  Piece of timber  12 Step ladder (optional)
 3 String/twine  8  Spirit level  
 4 Spanner  9  Drill  
 5 Hammer  10 Stanley knife  

⚠️Warning – 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

Set foundation
Prepare the Assemble the Assemble the
tubes and
site hoop ridge
anchor plates

Cover with Stabilise the

Dig the trench Fit door frame
polythene 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 2.05m
polytunnel by pushing foundation
tubes approx. 5cm into the ground at
the measurements shown in the
diagram. Foundation
6m 6m
Note : Measure from the centre of the Tubes
foundation tubes.
- Measure the distance from corner to
corner along the diagonals (see
diagram 1A). The diagonals must be 2.05m
equal in length for the polytunnel to 1A
be square.
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
foundation
- Secure two tube clamps and an
anchor plate around the bottom of tube
each tube in the order shown (see
diagram 1C). tube anchor
- Refill the holes with the dug out soil clamps plate
up to ground level.
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 1D
are level with the corner tubes.

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 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

Swaged joint Self-drill screw

2.2 ⚠️Warning – Exercise caution when using
drill.
Screw the half hoops together at the
joint, using a drill and a self-drill screw. 2B
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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 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 hoop

place a section of ridge pipe through
the clamps on the first and second joints
hoop.
ridge
- Continue to add sections of ridge pipe
through the clamps, along the tunnel.
tube clamp
Note : The swaged ends fit into the plain
ends (same as the half hoops in 2.1).
bracket 3A

3.3 - 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.
3B

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

4.4 - 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 self-
drill 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

30cm 5A

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. door
- Ensure that the post is vertical, using frame
a spirit level.
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).
p-clip
5.4 ⚠️Warning – Exercise caution when using end Self-drill
the drill.
hoop screws
- Drill 2 self-drilling screws into the P-
clips to secure the door frame. door
- Refill the trench. frame
- Repeat all of section 5 at the other
5C
end of the tunnel.

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 6. Digging the Trench
Shovel, measuring tape

6.1 Dig a trench all around the framework trench tube

(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. 6A

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 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.
NOTE - Cover the tunnel on a warm, windless day. If the weather is not warm,
heat the polythene before covering the tunnel.
Anti hot
7.1 Apply anti hot spot tape to any metal hoop
spot tape
that will be touching the polythene. E.g.,
the outside of the intermediate hoops,
clamps, brackets.

7A

Polythene
7.2 - Lay the polythene along the length of
the tunnel.
- Holding one end each, pull the
polythene over the tunnel.
NOTE - Centralise the polythene along
both the length and width of the tunnel. The
polythene should come halfway down both 7B
doorways.

door
7.3 - Nail a short batten onto one door
frame, trapping the polythene under frame
the batten.
batten
Note - Nail the batten as shown in
diagram. Do not nail the full length of the
batten yet. 7C

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7.4 - At the opposite doorway, pull the door
polythene tight along the length.
frame
- Repeat step 7.3 on this 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. Polythene trench soil
- Tightly tension at other side and 7E
repeat.
7.6 Pull the polythene under the doorframe again and nail the full length of the
batten. Repeat on other side.

- Make a diagonal cut in the polythene

diagonal cut pleats
7.7 from the top corners of the door frame
(See diagram 7F). batten
- 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 7F
knife.
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 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 This is normal. The hoops Push the hoop to the correct
too wide to fit are not the correct shape width, with another person.
into the or width until put into the
foundation foundation tubes.
tubes.
Difficulty The soil is too hard or full Use the base rail method instead
digging the of rocks. of the trench method.
trench
Small tears and - Wear and tear Stick repair tape on to clean
rips in the polythene.
polythene - Uncovered nuts and Cover any protruding equipment
bolts protruding into with silver protection tape and
the polythene. repair polythene with repair tape.
The polythene Polythene expands with Loosen or remove the battens at
has come loose heat. the door frame, tighten the
polythene and refit the battens.
The polythene is Algae often grows on Clean the inside with a sponge
turning green. polythene during the and warm water. Clean the
Winter. outside with warm, soapy water
and a soft sweeping brush.

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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: info@gardenzone.com

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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