Robinson Polytunnels 6ft Wide Polytunnel User manual

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 2
CONTENTS
Section Page
1. FOUNDATION TUBES: Option A –Hammered-In Foundation Tubes 3
2. FOUNDATION TUBES: Option B –Ground Anchor Plates 4
3. FOUNDATION TUBES: Option C –Concreted Foundation Tubes 5
4. STEEL FRAME ASSEMBLY & INSTALLATION 6
5. TIMBER END FRAME ASSEMBLY & INSTALLATION 8
6. TIMBER BASE RAIL (OPTION) 9
7. FITTING THE ANTI HOT SPOT TAPE 11
8. FITTING THE POLYTHENE –TRENCHING METHOD 12
9. FITTING THE POLYTHENE –POLYTHENE TO BASE RAIL 14
10. DOOR ASSEMBLY & INSTALLATION 16
PARTS LIST 18
POLYTUNNEL MAINTENANCE 21

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 3
Work Safely
When you tackle a job it is important to work safely. Please consider the following points when building your
Polytunnel.
Keep your work area tidy. A tidy site is a safe site.
Use the correct tools for the job.
Wear gloves where practical. Components may have sharp edges. Timber may have splinters.
Take care when using tools such as hammer, spade, drill, knife, scissors.
Consider other people, particularly children.
Tools Required
You will require a few tools to assemble your Polytunnel which are usually available in most households.
Spade
Hammer
Wood saw
Spirit level
Cordless drill
9mm drill bit
String line (optional)
Staple gun (optional) or stapler
13mm spanners or sockets
Tape measure
Scissors or craft knife
1. FOUNDATION TUBES: Option A –Hammered-In Foundation Tubes (Suitable for trenched polythene only)
1Set two string lines to the width of the polytunnel
(6ft apart). Ensure they are parallel.
Tip! It’s best to put your polytunnel on a flat, level
site. A fall lengthways is easy to accommodate.
A fall sideways should be limited to about 6” over
the width of the polytunnel.
2Set another string line for the end of the
polytunnel. Ensure the “end” string line is
perpendicular to the “length” string lines.
3Hammer the first two corner foundation tubes into the ground.
These will be positioned just outside the “length” string lines and just
touching the “end” string line. Ensure the foundation tubes are
vertical.
Tip! Use a piece of wood on top of the foundation tube
to ensure that the tube does not become
“mushroomed”.
4Hammer in the remaining foundation tubes at 5ft centres until the full length is reached.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 4
2. FOUNDATION TUBES: Option B –Ground Anchor Plates (Suitable for base rail or trenched polythene)
1Set two string lines to the width of the polytunnel
(6ft apart). Ensure they are parallel.
Tip! It’s best to put your polytunnel on a flat, level site.
A fall lengthways is easy to accommodate. A fall
sideways should be limited to about 6” over the
width of the polytunnel.
2Set another string line for the end of the
polytunnel. Ensure the “end” string line is
perpendicular to the “length” string lines.
3Mark the ground at each foundation position, to the outside of the “length” string lines at 5ft centres
until the full length is reached.
4Temporarily remove the string lines so they don’t get in the way whilst digging.
5Dig a hole for each foundation tube, approximately 25cm square x 35cm deep.
6Slot the ground anchor plates onto the bottom end of the
Foundation Tubes. And lock in place with the Starlock
Washers. Starlock Washers are inserted using the short piece
of tube.
a. With the foundation tube upside-down, slot the 6mm
Concrete Tie Bar (steel rod) into the pre-punched
hole in the Foundation Tube.
b. Slot the Ground Anchor Plate onto the bottom end of
the Foundation Tube, to rest on the Concrete Tie Bar.
c. Hold the short piece of tube over the starlock washer
on the bottom end of the Foundation Tube and tap
the short tube with a hammer until the washer is
located on the Foundation Tube, right up to the
Ground Anchor Plate.
7Reinstate the string lines.
8Insert the foundation tube and anchor plate assembly into
the excavated holes, to the outside of the string line. Make sure the foundation tubes are vertical,
touching the string line and spaced at 5ft centres. The foundation tubes should be protruding above
ground by approximately 40cm.
9Backfill the excavated holes, checking that the foundation tubes are still in the correct position. Stamp
on the soil to ensure the soil is well-compacted.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 5
3. FOUNDATION TUBES: Option C –Concreted Foundation Tubes (Suitable for base rail or trenched
polythene)
1Set two string lines to the width of the polytunnel
(6ft apart). Ensure they are parallel.
Tip! It’s best to put your polytunnel on a flat, level site.
A fall lengthways is easy to accommodate. A fall
sideways should be limited to about 6” over the
width of the polytunnel.
2Set another string line for the end of the
polytunnel. Ensure the “end” string line is
perpendicular to the “length” string lines.
3Mark the ground at each foundation position, to the outside of the “length” string lines at 5ft centres
until the full length is reached.
4Temporarily remove the string lines so they don’t get in the way whilst digging.
5Dig a hole for each foundation tube, approximately 25cm square x 35cm deep.
6Reinstate the string lines.
7Fill the excavated holes with freshly-mixed concrete.
8Put a steel rod through the hole in the foundation tube. Slot the foundation tubes into the concrete, to
the outside of the string lines. Make sure the foundation tubes are vertical, touching the string line and
spaced at 5ft centres. The foundation tubes should be protruding above ground by approximately 40cm.
Tip! Allow the concrete to set before you try to install
the framework!

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 6
4. STEEL FRAME ASSEMBLY & INSTALLATION
1Assemble the hoops. Lay the components out on a flat surface with the fittings in the positions shown.
Notice that the bolt heads are facing inwards so as not to protrude into the polythene.
2Fix the two half-hoops together with the E25 fitting.
3Slot a KH20 fitting over the second foundation
tube from each end of the polytunnel. This is
to hold the bottom end of the corner diagonal.
4(OPTION) If you have ordered the Base Rail
Option, slide an M20/25 fitting over each
corner foundation tube.
5Put an A20 fitting onto each foundation tube.
On the corner foundation tubes, set the A20
fitting to about 18cm above ground level. On
the inner foundation tubes, set the A20 fittings
about 5cm lower.
6Slot the assembled hoops onto the foundation tubes.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 7
7Make sure the end hoops are set approximately 5cm higher than the inner hoops. (The inner hoops will
be raised later to tension the polythene.) The end hoops should be approximately 18cm above ground
level. Lock in place with the A20 fittings.
8Slot the ridge tube into the E25 fittings,
starting with the plain-ended ridge tube.
Set the end of the ridge tube flush with the
E25 fitting and tighten the bolt to secure in
place.
9Slot a swaged ridge tube into the end of
the previous ridge tube until you reach the
end of the polytunnel. Tighten the bolts in
the E25 fittings to secure the ridge tubes in
place.
10 Insert a plastic plug into each end of the
ridge tube.
11 Fit the four corner diagonals. Fix to the
KH20 fitting on the foundation tube first
using an M8 x 30 bolt & nylock nut. Then
fix to the KH25 fitting on the end hoop.
Tip! Put the bolts through from the outside so
that the thread of the bolt doesn’t
protrude into the polythene.
12 Set the end hoops so that they are vertical (looking from
the side) by adjusting the position of the KH25 fittings.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 8
5. TIMBER END FRAME ASSEMBLY & INSTALLATION
1For each Timber End Frame you will need:
a. 2 pieces of timber at 89mm x 38mm x
2400mm long (posts)
b. 1 piece of timber at 89mm x 38mm x 1200mm
long (lintel)
c. 2 Corner Joint Plates
d. 1 batten 38mm x 19mm x 900mm long
e. 18 twist nails 30mm long
f. 2 nails 125mm long
2Lay the timber end frames out on a flat surface in the
arrangement shown.
Tip! It’s easier to make the frame of the door first
and then build the End Frame around it.
3Use the 30mm twist nails to fix the corner joint plates (9 nails each) and then nail through the lintel into
the top of the door post with the 125mm nails.
Tip! It’s easier to make the frame of the door first
and then build the End Frame around it.
4Nail a temporary batten across the door posts at 183cm below the lintel. This will rest on the ground
when you are installing the Timber End Frame and set the lintel to the correct height.
5Dig two holes for the door posts at each
end of the polytunnel, approximately 55cm
deep.
6Slot the door posts into the excavated holes
and set the end frame vertical in both
directions.
7Position the D25 fittings on the end hoop to
accept the lintel. Mark the lintel for mitring
if necessary and drilling to bolt to the D25
fittings.
8Fix the Timber End Frame to the D25
fittings with M8 x 50 coach bolts and nuts. Note,
the Timber End Frame is located on the inside face
of the tabs on the D25 fittings.
9Back-fill the excavated holes and remove the
temporary battens.
10 If you are trenching the polythene, create a rebate
around the Timber End Frame for fixing the
polythene. Use battens 38mm x 19mm and 50mm
long nails at about 15cm apart.
View from
outside

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 9
6. TIMBER BASE RAIL (OPTION)
1Set the M20 fittings on the corner foundation tubes so that the holes in the
plate are about 5cm above ground level.
2Start at one end of the polytunnel, at the door post. Place the end of the
timber 89mm x 38mm x 240cm long up to the side of the door post. Mark the
timber to the outside face of the M20 fitting and cut to length.
3Re-position the piece of timber and mark through the
hole on the M20 fitting and drill the timber to accept an
8mm diameter bolt.
Tip! Use the timber offcuts wherever they are long
enough.
4Bolt the timber to the M20 fitting with an
M8 x 50 coach bolt and nut.
5Using a flat nail plate, fix the timber to the
door post with 30mm long twist nails. Nail
through the door post into the end of the
timber with a 125mm long nail.
6Lay the next timber along the side of the
polytunnel, flush with the outside of the timber
base rail on the end of the polytunnel. Mark
through the hole in the M20 fitting and drill to
accept an M8 bolt.
7Bolt the timber to the M20 fitting with an M8 x 50
coach bolt and nut.
8On the next foundation tube, position an SC20 fitting over the
foundation tube and mark through the two holes. Drill to accept an
M8 bolt and fix in place with two M8 x 65 coach bolts and nuts.
9Continue until you reach the end of the polytunnel and trim the last
timber to length.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 10
10 Where the timber rails join end-to-end, connect together with a timber
joint plate and 30mm long twist nails.
11 Check that the timber base rail is straight and adjust the SC20 fittings if necessary.
12 If you are fixing the main cover to the base rail, create a rebate around the Timber End Frame and along
the base rail for fixing the polythene. Use battens 38mm x 19mm and 50mm long nails, about 15cm
apart.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 11
7. FITTING THE ANTI HOT SPOT TAPE
1The Anti Hot Spot Tape is applied to the hoops of the polytunnel where
the polythene would touch.
2Starting just above the A20 fitting on the foundation tube, place the
Anti Hot Spot Tape on the outside face of the hoop. On the inner hoops
the tape should be central on the tube. On the end hoops the tape
should be on the “corner” of the tube.
Tip! Don’t fit the Anti Hot Spot Tape until you’re
ready to sheet –it may get damaged if the
weather is wet and windy.
3Tape over any sharp edges, bolt heads and metal faces that the polythene may come into contact with.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 12
8. FITTING THE POLYTHENE –TRENCHING METHOD
1Dig a trench around the perimeter of the
polytunnel, approximately 15cm away from the
foundation tubes. The trench should be
approximately 30cm wide x 30cm deep.
Tip! Wait for a calm and preferably warm day to
sheet your polytunnel. It will be much easier
and you’ll probably do a better job!
2Unroll and unfold the polythene and drape it over the
polytunnel framework with an equal amount over each side
and each end.
3Carefully slice the polythene diagonally from the top corners
of the doorway. Trim the bottom off the central flap so that it
hangs approximately 30cm below the door lintel.
4Use a full batten to fit in the rebate above the doorway.
5Place the batten underneath the flap of polythene and
roll the batten into the polythene, up to the rebate. Nail
the batten in place. Note, it is preferable to have a
couple of small pleats in the flap of polythene.
6Repeat at the other end, PULLING THE POLYTHENE AS
TIGHT AS POSSIBLE.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 13
7Start back-filling the trench along the sides of the polytunnel,
working from the centre towards each end. Try to get the
polythene tight by pulling on the surplus polythene as you fill
the trench. Continue right up to the door posts, pulling the
polythene towards the doorway.
8Now fix the polythene to the door posts. The polythene
is pulled into the doorway and pleated. Trap the
polythene behind the batten as you nail the batten into
the rebate. Use nails 50mm long at about 10cm apart.
Tip! Pre-nail the battens so they’re ready to fix
the polythene quickly.
Tip! Fold the pleats downwards so that they don’t
collect rainwater.
9Trim off the surplus polythene in the doorway.
Tip! To avoid the back-filled trench becoming
water-logged, prick the polythene at the
bottom of the trench with a garden fork.
10 Raise the inner hoops to tension the polythene.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 14
9. FITTING THE POLYTHENE –POLYTHENE TO BASE RAIL
1Unroll and unfold the polythene and drape it over the polytunnel framework with an equal amount over
each side and each end.
2Carefully slice the polythene diagonally from the top corners
of the doorway. Trim the bottom off the central flap so that it
hangs approximately 30cm below the door lintel.
11 Use a full batten to fit in the rebate above the doorway.
3Place the batten underneath the flap of
polythene and roll the batten into the
polythene, up to the rebate. Nail the batten in
place. Note, it is preferable to have a couple of
small pleats in the flap of polythene.
4Repeat at the other end, PULLING THE
POLYTHENE AS TIGHT AS POSSIBLE.
5Starting at the centre of one side, batten the
polythene to the base rail. Hold the batten
under the edge of the polythene and carefully
cut the polythene in line with the ends of the
batten to create a flap, up to the bottom edge
of the base rail.
6Roll the batten into the polythene up to the
rebate and nail the batten to the base rail with
50mm long nails, approximately 7 nails per
batten.
7Do the same at the opposite side of the polytunnel but try to tension the polythene by levering the edge
of the batten against the rebate.
8Continue towards each end of the polytunnel, alternating between each side.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 15
9Continue around the corners, pulling the polythene towards to doorway.
10 Now fix the polythene to the door posts. The polythene
is pulled into the doorway and pleated. Trap the
polythene behind the batten as you nail the batten into
the rebate. Use nails 50mm long at about 10cm apart.
Tip! Fold the pleats “downwards” so that they
don’t collect rainwater.
Tip! Pre-nail the battens so they’re ready to fix
the polythene quickly.
11 Trim off the surplus polythene in the doorway.
12 Raise the inner hoops to tension the polythene.

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 16
10. DOOR ASSEMBLY & INSTALLATION
1For each door frame you will need:
a. 2 pieces of timber at 42mm x 38mm x 1830mm long
(verticals)
b. 3 pieces of timber at 42mm x 38mm x 770mm long
(horizontals)
c. 2 plywood triangles
d. 4 Corner Joint Plates
e. 46 twist nails 30mm long
f. 6 nails 75mm long
2Lay the door frame out on a flat surface in the arrangement
shown. Note, the visible face of the timber is 38mm wide (not
42mm).
3Using the 30mm twist nails, nail the Corner
Joint Plates over the corners of the door. Nail
the 2 Plywood Triangles over the joints of the
mid-rail to the verticals, 5 nails per triangle.
Set the triangles approximately 5mm from
the edge of the door.
4Stand the door on its side and nail through
the door verticals into the ends of the door
horizontals with the 75mm nails.
5For cladding each door you will need:
a. 3 battens at 38mm x 19mm x 846mm (cut to length)
b. 4 battens at 38mm x 19mm x 858mm (cut to length)
c. Piece of door polythene, 1m x 1m
d. Piece of door net, 1m x 1m
e. 63 nails 50mm long
6Lay the door on its inside face (plywood triangles down). Lay
the polythene over the bottom half of the door and the net
over the top half of the door. The polythene and net will
overlap on the middle door horizontal by the thickness of the
timber (38mm).
7Hold the polythene and net in place with staples using a staple gun or stapler. Try to get the polythene
and net tight when stapling to the door frame.
Tip! Pre-nail the battens before you clad the door
to get the job done quicker!

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 17
8Starting with the mid-rail, nail a batten over the
polythene and net. Use 50mm long nails, 9 nails per
batten. Next nail on the end battens and finally the side
battens.
9Trim off the surplus polythene and net.
10 Screw the hinges onto the front face of the door,
ensuring that the door is hinged on the side which
you want.
11 Position the door with the end frame, resting
on packing pieces to set the gap around the
door. Screw the hinges to the door post.
12 Screw the auto gate latch and latching bar to
the door post and door vertical, respectively.
13 Drill a hole through the door post for the pull-
string. The polyester cord (pull-string) is tied
around the sneck of the gate latch, threaded
through the hole and a loop tied on the end.
This operates the latch from the inside of the
Polytunnel.
If you are unsure about any part of the assembly procedure you can contact our office
between 8:30am and 5:00pm, Monday to Friday on 01282 501252

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 18
PARTS LIST

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 19
PARTS LIST (continued)

6ft Wide Polytunnel Assembly Instructions
Copyright © Robinson Polytunnels 2009 - 2018 20
PARTS LIST (continued)