Redpath Tunnelhouse User manual

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Tools suggested: Step ladder, Saw-stools, Hammer, Rubber Mallet, Secateurs, Scissors, Hacksaw, Square, Tape measure,
Cordless or Electric drill, Level, String-line, Marker pen, Safety gear (as needed).
Select a site:
Choose a level site that offers some protection for the Tunnelhouse from strong wind. Face the door away from the pre-dominant
wind. We suggest you take your time and allow yourself a weekend to erect the frame and then fit the covering on a warm calm day.
For standard sites, place a 50x50mm x 450-600mm length ground peg at approximately 1m apart around the inside base rail of the
building. You can then screw the base rail to these pegs. See below Foundation and base rail(s)
If you wish to build an additional base frame:
The tunnelhouse is already supplied with alloy base rails, however if your ground is undulating you may wish to build an additional
base from 4 x 2 or 6 x 2 timber or some other material. The dimensions for the base are shown on page 2.
The dimensions shown are the inside measurements enabling the interior base rail of the tunnelhouse to match the inner edges of
your frame base. Check the level using a builder’s spirit level. Screw or use a bracket to secure the alloy base to your timber base.
Redpath Pacific Ltd
PO Box 9058
16 Bounty Place
Palmerston North 4414
Free Ph 0508-733-728

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(Pic GP1) Ground peg connection to base rail (Pic GP2) Ground peg spacing
INTERIOR MEASUREMENTS –if making your own timber base (use 4 x 2 or 6 x 2 timber)

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MODEL: Nominal frame size
A(actual internal base size width)
B(actual internal base size length)
C(actual internal diagonal –check)
2.36m x 1.5m
2300mm
1532mm
2764mm
2.36m x 3m
2300mm
3032mm
3806mm
2.36m x 4.5m
2300mm
4532mm
5082mm
2.36m x 6m
2300mm
6032mm
6456mm
2.36m x 7.5m
2300mm
7532mm
7875mm
2.36m x 9m
2300mm
9032mm
9320mm
2.36m x 10.5m
2300mm
10532mm
10780mm
2.36m x 12m
2300mm
12032mm
12250mm
2.36m x 15m
2300mm
15032mm
15207mm
2.36m x 18m
2300mm
18032mm
18178mm
2.36m x 21m
2300mm
21032mm
21157mm
2.36m x 24m
2300mm
24032mm
24142mm
Stage 1: Assemble the side base rails and stand up the door end and the louvre end walls.
* On longer tunnels –Join the various length of side base rail sections so that they are both of equal length. Use two 16mm self-
drilling screws on the inside face to connect each joint/sleeve.
* The groove in the side base rail will face to the outside.
* The groove in the base rail at the door end base rail faces to the inside, This is so that the sliding door has clearance from the end
wall cladding when the door slides open.
* The groove for the rear wall base rail faces to the outside.
* Stand the pre-assembled end walls vertical with the brackets facing to the inside. The endwall base rails finish flush with the ends
of the side rails.(See Pic BR1 page 4)
* Stand up the pre-made end frames and attach them to the side base rails using three screws. (See Pic BR2 and BR1 page 4).
Note, the door end base rail
has the Duralock cover
clipping groove facing to the
inside
The door slider guide is to the
outside

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The end wall finishes flush with the side base rails (Pic BR1)Internal corner brackets with screws fitted (Pic BR2)
Stage 2: Position the internal hoop(s).
*For the 15m, 18m 21m & 24m models fit the horizontal collar tie to each central hoop. See image below.
NOTE: Select and position the correct hoops for where the roof vent (if any) is to be positioned See below.
Position the internal hoops into the pre-fitted saddles on side base rails, do not screw them into place at this stage see Pic Page 5
IMPORTANT: *If there is a roof vent - those hoops that will have the roof vent located between them will have a gap in the Polyguard
protection soft tape at their apex. And they should also be positioned so that their smooth/flat side faces, - face toward each other.
NOTE 1: We suggest not securing the internal hoops with the two screw(s) at their base saddles until after the covering has been
fitted. This allows the hoops to be lifted ‘upward’ slightly after the covering is in place to help with tensioning of the covering.
Door End wall
base rail,
groove faces
to INSIDE
Side base, groove to
OUTSIDE
Louvre end
base rail.
Groove faces to
OUTSIDE

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(Secure the internal hoop screws after the cover installed) (Pic POL1) Polyguard on internal hoops, Purlins & end dwangs
Stage 3: Assemble and position the five lengthways purlins. (and high wind collar tie brace for “X” models)
* Join the various sections of purlins together so that they are all of equal length and so that the white Polyguard tape is all on the
same side for the full length.
* Use two 16mm self-drilling screws to secure the joints/sleeve and place screws to the inside face
* The five purlins are positioned as shown below, with the Polyguard soft white felt tape facing to the outside.
* If you have a 15m or longer tunnel, fit the collar tie high wind braces as shown in the drawing below
NOTE: If an optional sidewall or end wall shelf unit is to be fitted, the lowest purlin should be placed above the shelf bracket height
position to provide clearance.
NOTE: If a roof vent is to be fitted The ridge purlin for that 1.5m section will need to be cut out and removed . (Redpath has not
removed this ridge purlin section as it does not know what section you plan to place the roof vent)

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Wrap two layers of Polyguard tape around
Purlin ends (P1) purlin ends to prevent wear on covering (P2) Saddle holding side purlin in place (P3)
Ridge purlin Polyguard faces up (P4) Interior purlin fitted, polyguard faces out(P5)
Wall bracing
Position the side and end wall angle bracing as shown in Pic B1, 2 & 3 and fasten to the inside face of the base rail and inside face
of the end hoop using one screw. The top end of the brace must stop short of the end hoop otherwise it will damage the end wall
covering.
TIPS & TRICKS: It can be helpful when you come to fitting the roof/side cover, to release one end of the sidewall bracing
temporarily. Then re-attach after the roof/side cover has been fitted. (This can assist in adding tension to the covering)
Note: End & Side wall angle brace may require subtle re-positioning or shortening if you have chosen an optional shelf unit.
(Pic B1) (Pic B2) Secure the side wall brace (Pic B3) Top of brace stops short of end wall

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Stage 4 –A) Identify the two types of cover clipping systems. B) The fitting of the covers
Type 1:Lockstrip
Lockstrip is used on the end hoops, and also a 200mm piece is used at the apex of internal hoops where the roof vent ends.
Lockstrip is a green coloured continuous strip “insert”and a small grey coloured “L” shaped locking “clip”.
IMPORTANT The insert and the clip parts must be positioned in the direction shown below (otherwise the cover will not be held)
The pre-cut 200mm length pieces of Lockstrip insert are only used on the front face of the curved part of each end hoop
The rest of the Lockstrip insert is supplied in full 1.5 lengths (trim these to length to suit). Also watch the video on the Redpath web
site for Lockstrip assembly http://www.redpath.co.nz/commercial-greenhouse-accessories/greenhouse-film-clipping-systems.html
(1) The sequence below shows the Lockstrip assembly. - Whilst pulling the cover tight, position the insert strip at a slight angle.
(2). Press down and forward on the insert strip WHILST releasing the tension from the tail of the film behind, (3). Seat the insert
and pull it ‘back’ into the groove. (4). Locate and seat the small 1cm x 1cm Lockstrip clip.
(Pic L1): Use the 200mm green inserts in the front (Pic L2): Shows the positioning of the covering (red), Insert (green)
face of the curved part at each end hoop only and Lockstrip clip on the end hoops. Note the direction of the parts
Type 2:Duralock
The Duralock groove inserts are made up of 1.5m white ‘channel shaped’ inserts and a rectangular white ‘bead’ insert. These are
inserted into the Duralock aluminium grooves used on base rails, door, and end studs / lintels.
How to assemble Duralock:
See video link web site http://www.redpath.co.nz/commercial-greenhouse-accessories/greenhouse-film-clipping-systems.html
1. Pull the cover and tension it over the jaw of aluminium.
2. Face the channel strip as shown below and Insert it by tilting it slightly and pressing it down and into the groove WHILST you
releasing the tension from the tail of the film. ‘Seat’ the channel into the alloy groove. Use secateurs to trim the Duralock parts
to length.
3. Tap the rectangular locking bead into place with the rounded edge facing down as shown
(A) Locking Lug Forward (B)Tilt Channel Insert (C) Fully Seat Channel Insert, then fit Bead
(Fig 1)
Lockstrip Clip

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Below picture shows all parts of Duralock assembled
FITTING THE COVERS TO THE TUNNELHOUSE
The covering is supplied in separate pieces. 1 for the door(s), 1 for each end, and 1 for the roof/side.
Install the covers on a warm, calm day.
The printing on the cover (if applicable) faces to the inside.
When trimming off the covers leave a 100mm ‘tail’ in place initially and when satisfied with the tension on the various parts , you
can trim the tail to 20mm for a tidy appearance
DOOR COVER –select the Duralock white channel and bead.
Lay the door frame on the ground with Duralock groove facing upward and lay the 2m x 1m door cover in approximate position
You will need to cut the clipping inserts (channel and bead) with a pair of secateurs to suit the length of the frame work grooves.
The clipping inserts should be cut to length finish approximately 25mm short of each corner.
You will begin by fitting the clipping insert to the top door rail firstly, - then the bottom door rail (pulling the cover tight as you do
so). Then install the inserts into the side door edges. (begin in the middle and work toward the corners)
ROOF/SIDE COVER, Select the correct type of inserts for the alloy grooves that are used on the end hoops & base rail
If your Tunnelhouse includes a roof vent please install the roof vent kit before-hand (see instruction below), You will need to cut
and remove the section of ridge purlin where you intend to locate the roof vent. The two internal hoops where the roof vent is to
be placed should have their flat faces facing toward each other and also have a 200mm gap in the Polyguard tape at the apex.
Before fitting the roof cover remove the cap vent part plus the aluminium pivot arms and handle
(leaving the two vent rails and upstand in place ( See Pics on page 10)
NOTE: If your Tunnelhouse has a roof vent take care not to catch the cover on the vent rail, Unfold the cover and lay it out over
the Tunnelhouse so that it rests in approximate position with an equal amount of excess film draping over each end hoop and to
each side base rail.
Begin at the apex at one end of the Tunnelhouse and install the 200mm Lockstrip holding system parts into the top curved face
working your way down to the left and right. Use a 1m length of Lockstrip for the straight part of the hoop.
Go to the other end and pull the cover tight along the length of the ridge, and repeat the process
Now move to the side base rails. These use the Duralock clipping system.
TIP: Sometimes it is simpler to lift the entire side of the Tunnelhouse up in the air and rest it on blocks or sawstools –this can make
it more convenient to insert the Duralock clip.
TIP: Read the Duralock clipping instructions above and also view the assembly video http://www.redpath.co.nz/commercial-
greenhouse-accessories/greenhouse-film-clipping-systems.html
Begin at the center & start inserting the U shaped Duralock channel insert + bead whilst tensioning the cover as much as
possible. Work your way to the left and right toward the ends of the building.
TIP: If the weather is cold, you can place a small heater inside the greenhouse after the ends and doors have been clad to warm the
tunnelhouse, and the covering to make it easier to stretch tight.
Cover
Bead
Channel
Alloy
channel
Base Rail
Channel
Bead

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END WALLS:
You will fit the end wall covers in one large piece, and cut out the door and the louvre openings afterwards.
Use the 200mm short pieces of Lockstrip insert for the curved part of each end wall face only.
Start at the top and position a piece of the 200mm Lockstrip + clips. Then position a piece at to your left and right where the
curvature of the end stops and the sidewall begins (9 o’clock and 3 o’clock)
Then pull the cover flat and position another 200mm piece of Lockstrip + clips midway in-between these two.
If satisfied with the cover flatness and tension, begin to fill in the gaps in-between these inserts and also the rest of the end wall
edges and base rail parts. NOTE: At the door end the base rail groove is on the INSIDE of the tunnelhouse, - this is so that there
is sufficient clearance between the end wall covering and the sliding door.
At the door end you will cut an “X” from corner to corner where the door will eventually be and also the same at the rear wall for
louvre window openings (if included). You can then clip the edges of these panels around the door end wall studs/lintel, and
louvre lintels/stud parts pulling it as tight as you can as you go. The clipping inserts should be cut to length finish approximately
25mm short of any corner.
ROOF VENT: If the roof vent option is included with your model, you will complete this section before fitting the roof and
sidewall cover (disregard this section if you have no vent)
If the roof vent option is included in your design then it will be partially installed prior to fitting the roof / side piece of covers.
NOTE: The roof vent may be positioned in any of the Tunnelhouse 1.5m sections; however, you cannot fit the roof vent in a section
directly beside another section that might already have a roof vent. The two hoops that will have the roof vent fitted in-between
should have their flat side faces, - facing toward each other.
When you have decided which section to place the roof vent in, you will need to cut and remove the ridge purlin in that section.
1. Before fitting the roof and side covering - Lift the roof vent complete into place at the centre/apex of the Tunnelhouse. The
ends of the steel vent rails will rest approximately halfway across the top face of the hoops.
2. Use four 22mm at each end into the pre-drilled holes to secure the two steel vent rails to the top face of the central hoops
3. Before you fit the cover onto the building stage 4. - You will need to disconnect the galvanized steel sheet roof cap by
undoing the four bolts at the end of the alloy arms. (this will be re-fitted later after the roof cover has been fitted.)
4. With the vent removed, you can now proceed to fit the main roof cover.
2 x 25mm screws at end of vent rails Remove cap vent part before Use the M6 bolt, Nylock nut, Nylon packer as shown below
fitting roof cover (re-fit after) to attach the cap vent to the ends of the 4 lever arms.
After the main roof and sidewall covering has been fitted, - you can re-fit the cap vent
1. In the section where the vent is to be fitted –Use a knife or scissors to slice the cover along at the center apex for to 100mm
short of the length of the roof vent rails, then slice the cover toward the corners of each vent rail.
2. Insert the Duralock holding system into each along each side of the steel 1.5m vent rails
3. Insert a 150mm piece of Lockstrip insert + clip into the top edge of the hoops at each end of the roof vent
4. Secure the edge of the cover onto the top edge of the steel upstand using the white Omega clips
5. Trim the excess film behind the Omega clip to 25mm and also at the end of the roof vent
6. Re-install the vent roof cap.
7. Test the roof vent for open / close action and adjust tension on pivot bolts if needed.
150mm Lockstrip insert
Duralock Insert

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Cut cover along center and into corners Insert Duralock into vent rails + Omega clips, Trim tail of cover
Auto solar-vent positioning (if an included option)
Stage 5. Fitting the louvre window (rear or sidewall option)
After the tunnel has had its covers fitted - slide the three polycarbonate sheets into place. Remove the backing tape from the 570mm
aluminium strong-back angles and adhere one across the center of each blade to stiffen them.
Fit the strongback alloy angle across center of
each louvre blade to stiffen the polycarbonate
(double sided tape is included)
Louvre mechanism is already fitted
150mm Lockstrip insert + clip
1.5m of Duralock Insert
Omega clip
Omega clip

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Stage 6. Door
Note: Do not fit the door track or the door itself to the building until after the door end wall cover has been fitted.
Fitting the door and door track
1. Rest the door on top of the end base rail and slide the door track onto the two door rollers
2. Note that the door guide and its corresponding slider is already pre-fitted to the base rail and the underside of the door.
3. Lift up the door track with door attached into approximate position so that the weight of the door is suspended on the track, and
the base of the door is clear of the base rail. (the door guide should be still within the base rail door guide slot)
4. Screw through the mount plate of the door track at one end to secure, then repeat this at the opposite end. see pic page 12
5. Screw three more screws (evenly spaced) through to the door lintel to fully support the track/ Place one longer screw into the
end hoop to support that end of the door track - Check the door sliding action.
6. Place a screw through each end of the door track where the door rollers slide to act as a stop for the door rollers so that the door
cannot slide off the track at its ends.
Note: If you have ordered the extra wide door option, there will be a 30mm x 30mm x 1.6m door track support stay included. The
stay is attached to the end wall hoop and extends up to the height of the door track to help support the end of the track with the wider
door fitted
Exterior view of door track (Pic D1) Door guide and door guide “slot” (Pic D3)
(Pic D4) (Pic D5)
Screw into end hoop

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OPTIONAL ACCESSORY “Throw-over” temporary shadecloth cover for temporary summertime protection:
The throw-over shadecloth cover is an option that can be very useful in reducing internal temperatures by up to 8-10deg C. The throw-
over shade cover is 6m wide so that it fits up-and-over’ the tunnel shape. Redpath includes ropes with this option which pull-over and
secure the throw-over cover in place.
Throw-over Shadecloth for summertime cooling:
Drawing below shows approximate retaining rope positions and saddles to be screwed to the base rail or base timber.
Use one rope beside each hoop, and place the rope approximatley 200-300mm in from each end.
If a roof vent is fitted place the rope to the side of the vent.
Tension the rope so that it is not slack –but do not over-tension.

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Sidewall louvre system fitted
You can assemble and fit the sidewall louvre option (if included) after the main roof cover has been installed. Fit the 4 x aluminium
parts and 8 x triangle brackets as shown below. Cut an “X” in the opening where the blade mechanism is to be fitted, and use the
Duralock clip system around the perimeter of the blade area only.
Optional Aluminium shelf units (if selected)
The shelf bracket is fitted to the vertical section and side face of the arch hoops.
Ensure that the buildings purlins are above the position of the shelf. This is so that you have space on
the arch hoops to locate the shelf brackets.
The end wall angle brace may require shortening and repositioning so that it clears the end shelf
bracket (depends on your choice of shelf height)
If your shelf is longer than 3 metres, the aluminium shelf slats may have joins and sleeves. You will
need to join the parts with the sleeves and screws supplied to make the correct length shelf slats.
INSTALLATION:
There is one shelf bracket per arch hoop, (and end studs if a rear wall shelf)
1. Position a shelf bracket at each end using three screws into the side face of the uprights. Set them
at the same height with their top folded edges facing inwards and level. see Fig (1)
Position a string line between the two brackets and pull it tight.
2. Position the center shelf bracket(s) at the string line height, and also level.
3. There are five aluminium 25mm shelf slats. The slats finishes flush with the outer edge of the shelf
bracket of the end. (approximately 30mm short of the end wall covering) see Fig (3)
4. Fit the front and rear shelf slats using the screws provided and screw through the pre-drilled shelf
bracket holes from the underside, see Fig (2). Fit the remaining three slats and space them evenly
(they will be an approximatley 36mm gap between each of them)

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Fig (1) Fold faces inwards Fig (2) Position rear and front slat Fig (3)Slats finish 30mm from end Fig (4) General view
Photo image file –for reference

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Rear wall shelf example
Image gallery below is for reference from archives: Note your model may differ in length and options shown, Also see on-
line images at www.redpath.co.nz
Base pad prepared ready for construction Dual door option fitted one end

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General view 7.5m model, single front door, 1 x roof vent, high wind kit.
General view interior 6m model, high wind kit, interior

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General view –3m model with high wind kit fitted, internal raised gardens included
General views Louvre. Roof vent

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Roof vent internal view
Internal end wall view Sidewall shelf option
Door systems

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Sidewall Louvre images (optional extra)
Tunnel Maintenance:
Clean your greenhouse once per year to remove algae / pollen / dirt. Use dishwashing liquid and a soft broom. There is also a product
brand name “Surrender” – available from Fruifed/Wrightsons supplies NZ, spray this on 24hours prior to rainfall.
Wash and wipe down the interior of the tunnel house to prevent any fertilizer or chemical degradation of the covers or alloy.
Patch any holes or tears in the cover as they happen with Redpath’s All-weather repair tape or Patchbond tape.
Check annually that foundations are secure, all bracket screws are tight, replace any missing or broken screws, check that door rollers
and vent mechanisms are operating smoothly.
Replacement tunnelhouse parts are held in stock by Redpath
Replacement cover kit may be purchased on-line www.redpath.co.nz for all sizes of tunnel kits.
Call us on Free Ph 0508 733 728 if you have any questions during assembly. Our office hours are 8am –5pm
Monday to Friday