The Accidental Smallholder Forum
Smallholding => Buildings & planning => Topic started by: County Dangler on April 04, 2014, 03:22:29 pm
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I thought that some folk might find it useful for me to post my experiences of building a polytunnel and give folk the inspiration to do it themselves.
After much research and negotiations with the usual suspects we plumped for a commercial tunnel from Premier polytunnels. We went for a 24' x 72' and spec'd an upgraded cover, anchor plates, crop bars, storm strengthening kit, timber bases rails and triple ridge kit.
I'm certainly not a professional. I'd class my DIY skill level as 'a confident bodger' (I'm not scared of any job but i don't always get it right!) and have no trade skills. If i managed to do it with minimal help then anyone can.
So the anchor plate option saved having to use concrete and as far as i can see, are just as good but would be far, far easier to dig up should the need arise.
I had a machine on site for something else so too that opportunity to dig 2 2'x2'x75' trenches ready for the anchor plates and foundation tubes.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2143.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2143.jpg.html)
One of only 2 days that i had help was putting the foundation tubes in as i wanted to get the bit right, so i had a build mate come to see that all of them went in correctly and were square. Back filling those trenches was a hard days graft and it rained all day! To save my back i got a machine back in to finish off the back filling.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2436.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2436.jpg.html)
and the foundation tubes in
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2440.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2440.jpg.html)
Then the hoops. The main problem we found here was that ideally, you need a perfectly flat surface to put the 4 hoop pieces together on. hands up who has got that right next to where they want there tunnel? All that this meant was that the hoops wern't perfectly straight but that didn't really matter. We also learned at the point that no matter how perfectly you put your foundation tubes in they would need a good boot to fit the hoop over. Perhaps next time i wouldn't have back filled the trenches right to the top.
The first 3 hoops, crop bars starting from the 2nd and the top ridge in place.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2441.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2441.jpg.html)
That picture also remind me of 1 thing that i would say is essential-a good ladder. for the first day i used the rickety old 6' ladder in the picture. By the time it had sunk in 6'', reaching the 11' ridge to fit the p clip (the clips used to join 1 piece to another) was a nightmare as they are bloody awkward at a sensible height, never mind 20 stone balancing on my tip toes on top of a precarious ladder. I went out and bought a 10' A frame ladder after that and that made life a million times easier and safer.
A couple more hoops up
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2444.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2444.jpg.html)
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2456.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2456.jpg.html)
and after 3 weekends we had the framework up, all of the supports in and the tripe ridges on.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2470.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2470.jpg.html)
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2472.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2472.jpg.html)
To be continued when i have a little more time..........
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wow, that looks like a great tunnel! Thank you for the pictures, sometimes it is easier to know what you need to do when you see the pictures rather than reading instructions. Looks like it was a lot of hard graft to get a tunnel that size to that point.
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Compared to what I'm looking at, that's a tunnel and a half - then another tunnel. Awesome.
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it looks huge. looking forward to the next instalment...
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Great share, I'm also looking forward to next set of pics, thanks
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Then it was time to start work on the ends. The bit i was dreading most as i never seem to be able to cut straight or get measurements right. I was seriously tempted to pay someone to do it due to this but after reading through the instructions it seemed pretty straight forward so i gave it a go, and I'm glad i did.
First up was to build the doors. They came in packs with pre cut timber so it was just a case of using little 90deg anglers to screw the shape together then drilling 6mm pilot holes to hammer in some serious 6" nails. Then use a staple gun to cover in the supplied polythene panel and nail in batten over the top of that to cover the panel sand stiff up the door. The quality of the timer supplied all round was second to none.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2492.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2492.jpg.html)
Then onto the verticals, lintels and door posts. Again, easy to follow instructions. Basically, measure, dig a hole, cut post to size, re measure and back fill. Once this post is solid then you've got a datum. Then affix the 3.6m lintel with more massive screws and nail joining panels then do the same on the other side.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2497.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2497.jpg.html)
Next was the door posts, again measured, dug in, nailed and nail paneled. Offered the doors up and put in the other door post. Then just hang the doors. (the doors are open inwards on the first pic)
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2502.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2502.jpg.html)
Then repeat on the other side
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2507.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2507.jpg.html)
and fill in the panels. Then use the batton to secure and st regthen which also forms a rebate to trap the cover when it comes to that.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2518.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2518.jpg.html)
Then the hotspot tape to protect the cover from rubbing against the hoops. Maneuvering the ladder between hoops was a ball ache but my Mrs CA did a sterling job of it.
Next onto the timber base rail. This was essentially lengths of 3x2 joined together and clamped onto every post, with a batten nailed along the top to form a rebate.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2521.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2521.jpg.html)
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2522.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2522.jpg.html)
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2520.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2520.jpg.html)
The worst job of the lot next....self tapping screws to hold the job lot together. If i never see a self tapping screw again it will be far too soon. The screws supplied were good, strong screws as they have to take a bit of weight but due to this they were quite thick and a real pain to get in. Now bear in mind the often they were going through 3 walls of aluminium, starting on a curved surface, at ever place a tube met a tube or a clip, on top of a ladder, always bearing in mind where the cover will go so often in an awkward location and you will begin to feel my pain. It was an awful job but it had to be done. 300 or so screws, 1 dead drill, 1 new drill and lots of holes in my hands later it was done, aside from the ones that secured the hoops to the foundation tubes as the would have gotten in the way of the bail rail clamps.
I was really lucky to have some expert help with the cover. A mate from my fishing club has a big farm and nursery and has skinned at least 1 commercial tunnel every year since being knee high to a grass hopper. He also kindly brought along his head farm worker to help too. Also Harry, a chap I'd met on a bee keeping course and at cornwall smallholders came along with his wife to lend a hand and see how it was done.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2535.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2535.jpg.html)
and 3 hours later it was done!
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2529.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2529.jpg.html)
I can't imagine how much more awkward it would have been without help but they made it easy for us. I didn't get any pics of the base rails being done as i was busy supervising but basically the cover was pulled tight, rolled around a length of batten, this then sat under the top batten and was nailed in place.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2530.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2530.jpg.html)
(http://i168.photobucket.com/albums/u170/thebigmansphotos/IMG_2533.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/IMG_2533.jpg.html)
We are really please with it. I can't remember exactly how much it cost but I think it was in the region of £3k which seemed like a lot at the time but it looks like very good value now. It's rock solid and very well manufactured. Everything it came with was spot on, even down to the nails and screws.
The instruction lacked a bit of detail in certain places but on the 3 occasions i called to ask, my questions were quickly answered by the lady that answered the phone. We were also 3 packs of P clips short and these were sent out first class in the same days post. Superb service.
I wouldn't hesitate to recommend premier tunnels and also saving yourself the circa £1.5k we got quoted to build it.
I hope this help a few folks and feel free to ask if you have any questions.
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Cracking tunnel. You must be well chuffed with it. Some photos of the fixtures & fittings would be great as the project progresses.
Got to say; £1.5k to build it seems a bit steep. No satisfaction in paying somebody either, not when you've done such a brilliant job yourself (plus helpers).
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Thanks for taking the time to write up.....great post :thumbsup:
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Yes a brilliant post, thank you so much for putting that on.
We had to deconstruct ours a couple of years back and will be building it up again - we didn't build it first time round so that was great to see. We have 2 actually, one we are covering in mesh to use as a fruit tunnel, will have to put some things on to stop wee birds getting tangled though.
Loved that last picture with the rain clouds rolling in. Once the good weather comes you'll be pleased as punch and pulling it all together will seem ages ago.
Well done, great job. :thumbsup:
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Great post, thanks for sharing all this enlightening progress info.
And what a fantastic result you got!
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Very impressive job County Angler and brilliant pictures and explanations with it. Definitely a reference source for years to come. Makes our 'big' polytunnel look absolutely tiny!
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Thanks folks.
Many forums are often take, take, take. I know I have had a few questions to ask and I'm sure to have many more, so it's nice to give a little back.
I'll keep the thread updated with how things progress.
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its really helpful to know how its done for when we eventually have ours.
its huge. what are your plans for it?
:thumbsup:
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its really helpful to know how its done for when we eventually have ours.
its huge. what are your plans for it?
:thumbsup:
Mrs CA resigned from her job last term and is now setting up as a flower grower. And we also plan to sell produce on a small scale to local chefs and hotels. Small scale, high quality and unusual varieties is the plan. Also we have several campsites within a mile or two and thousands of tourists pass our place everyday so a roadside stall with honesty box is another possibility. It's really a case of suck it and see. Who knows which road we will end up going down.
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well good luck to you both, a friend from years back made quite a successful business growing lillies in a big polytunnel like that.
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An older thread but worth resurrecting to show you the following.....
A car issue last Tuesday meant i had the day off work and was greeted with this nightmare.....
(http://i168.photobucket.com/albums/u170/thebigmansphotos/BA7D7E1E-50CB-4E03-8155-46367B3E42BE.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/BA7D7E1E-50CB-4E03-8155-46367B3E42BE.jpg.html)
I couldn't believe it. It was windy the previous night but not horrendous and certainly no windier then some of the winter storm that it had made it through. Kind of my own fault though as the day previous mrs CA had pointed out to me that the rail that holds the cover in the recess was a touch loose. As it happened it didn't have any of my tools with me and it was on the sheltered side of the tunnel so i just said that i'd sort it in the week. BIG mistake. Massive mistake. You could see it had somehow come loose and had ripped the sheet vertically up towards the apex of the tunnel and then each of the recess rails had popped off down the full length of it. And this was despite double nailing it.
In no way do i blame the manufacturer but....there instructions were quite specific in using nails rather then screws but I'm 100% certain the if the rails were screwed in the wouldn't have just popped off. I've mentioned this to them and they said that they say that because it makes it much easier to remove the rail should you want to re skin them-I would counter that by saying that if you are planning on leaving your cover on over winter then the sheet should last 5 years give or take-after that time you would also need to replace the timber for the rail and thus screws wouldn't make any difference. Either way I've learned a lesson the hard way.
Anyway, despite the 40 knots winds we managed to raise the base rail from the ground up to about 5ft and managed to loosely trap the sheet it the recess (with screws!) so as not to do any more damage to the sheet and try and salvage it, in the hope of a reasonably calm day in the near future to see if we can make it right. That day came on Thursday. We managed to get the cover pretty much back to where it was and just about as tight as it was with the only visible damage being the tears at either end and a tear of about 2' in the middle.
(http://i168.photobucket.com/albums/u170/thebigmansphotos/BB9902F9-89E2-47DA-A555-72614CDDA9CB.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/BB9902F9-89E2-47DA-A555-72614CDDA9CB.jpg.html)
I was happy that the sheet was secure but the tunnel (full of flowers that mrs CA had nursed through winter) was now open to the hoard of rabbits so as soon i could we had to finish it off. The plan was to make another base rail (£100 in timber and fixings) and attach wind proof netting between the 2. It went remarkably well and it looks pretty good now if i may say so myself
(http://i168.photobucket.com/albums/u170/thebigmansphotos/D65CC01A-29C0-427E-871A-493B5B7D9E60.jpg) (http://s168.photobucket.com/user/thebigmansphotos/media/D65CC01A-29C0-427E-871A-493B5B7D9E60.jpg.html)
I wouldn't go as far as saying it's a blessing in disguise but it was far too hot in there in the summer with regular temps well over 40deg with both doors open.. In the heat of the hot days you couldn't stand being in the for more then a couple of minutes at a time, so maybe it might just be a better tunnel for better ventilation.
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Oh dear, what a nightmare! It's looks like you've done a great job salvaging everything though, fingers crossed it doesn't happen again