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Greenhouse Engineering NRAES–33 Greenhouse enGineerinG G R E E N H O U S E S E R I E S Natural Resource, Agriculture, and Engineering Service (NRAES) COOPERATIVE EXTENSION about NRaES NRAES, the Natural Resource, Agriculture, and Engineering Service (formerly the Northeast Regional Agricultural Engineering Service), is an interdisciplinary, issues-oriented program focused on delivering educational materials and training opportunities in support of cooperative extension. The mission of NRAES is to assist faculty and staff at member land grant universities in increasing the availability of research- and experience-based knowledge to (1) improve the competitiveness and sustainability of agriculture and natural resources enterprises, (2) increase understanding of processes that safeguard the food supply, and (3) promote environmental protection and enhancement. All NRAES activities are guided by faculty from member land grant universities (see the map below for a list of cooperating members). NRAES began in 1974 through an agreement among the cooperative extension programs in the Northeast. The program is guided by the NRAES Committee, which consists of a representative from each member university, the NRAES director, and an administrative liaison appointed by the Northeast Cooperative Extension Directors Committee. Administrative support is provided by Cornell University, the host university. Office hours are Monday through Thursday, 8:30a .m. to 4:30 p.m., and Friday, 8:30 a.m. to 2:30 p.m., eastern time. Currently, NRAES has published more than 100 publications and distributes a total of more than 160 publications on the following topics: general agriculture, aquaculture, agrichemical handling, IPM, horticulture, greenhouses, building construction, livestock and poultry, dairy, waste management, composting, farm management, farm safety, forestry and wildlife, and home. Please contact us for a free copy of our publications catalog. NRAES (Natural Resource, Agriculture, and Engineering Service) Phone: (607) 255-7654 Cooperative Extension Fax: (607) 254-8770 PO Box 4557 E-mail: [email protected] Ithaca, New York 14852-4557 Web site: www.nraes.org COOPERATIVE EXTENSION NRAES–33 GREENHOUSE ENGINEERING Written by: Robert A. Aldrich, Emeritus Professor of Agricultural Engineering and John W. Bartok, Jr., Extension Professor of Agricultural Engineering Natural Resources Management and Engineering Department, University of Connecticut, Storrs, CT Technical Editing by Marty Sailus Editing by Chris Napierala Editing and Design by Marcia Sanders NATURAL RESOURCE, AGRICULTURE, AND ENGINEERING SERVICE (NRAES) Cooperative Extension PO Box 4557 Ithaca, NY 14852-4557 The use of trade names is for information only and no discrimination is intended nor endorsement implied. NRAES–33 © 1984, 1989, 1990, 1992, 1994. The Natural Resource, Agriculture, and Engineering Service All rights reserved. Inquiries invited. (607) 255-7654. ISBN 0-935817-57-3 3rd revision August 1994 Reprinted with minor revisions September 1992 Reprint August 1990 2nd revision February 1989 1st edition December 1984 Requests to reprint parts of this publication should be sent to NRAES. In your request, please state which parts of the publication you would like to reprint and describe how you intend to use the reprinted material. Contact NRAES if you have any questions. NRAES—Natural Resource, Agriculture, and Engineering Service Cooperative Extension, PO Box 4557 Ithaca, New York 14852-4557 Phone: (607) 255-7654 • Fax: (607) 254-8770 • E-mail: [email protected] Web site: WWW.NRAES.ORG TABLE OF CONTENTS CHAPTER 1. GREENHOUSE PLANNING 1 Site Selection 1 Plan Layout 1 Utilities 4 Hydroponic Systems 6 Institutional Greenhouses 8 Special Purpose Facilities 15 CHAPTER 2. GREENHOUSE STRUCTURES 22 Design Load 22 Materials and Methods of Construction 24 Construction Costs 37 CHAPTER 3. MATERIALS HANDLING 39 Operations Analysis 39 Materials Handling Basics 42 Equipment Selection Basics 44 Planning the Facilities 44 Equipment 52 Shipping 55 Economics 56 Loading Docks 56 CHAPTER 4. GREENHOUSE ENVIRONMENT 61 Effects of Environment on Plant Growth 61 Environmental Control 63 Energy Conservation 67 Humidity Control 69 Estimating Heating and Cooling Loads 70 Insect Screens 71 CHAPTER 5. EQUIPMENT FOR HEATING AND COOLING 73 Heating Equipment 73 Cooling Equipment 79 Control Systems 83 Controllers and Computers 87 Alarm Systems 88 Standby Generators 90 CHAPTER 6. ENVIRONMENTAL MODIFICATION 92 Lighting 92 Watering 103 Water System Components 106 Carbon Dioxide Enrichment 118 Media Treatment 121 Pesticide Application Equipment 124 Pesticide Storage 132 CHAPTER 7. REMODELING GREENHOUSES 137 Site Criteria 137 Function 138 Structure 138 Environmental Control 139 Energy Conservation Systems and Methods 139 Utilities 140 CHAPTER 8. ENERGY CONSERVATION 141 Thermal Energy Use 141 Alternate Fuels 148 Power Plant Waste Heat 151 Geothermal Heat 151 Estimating Fuel Use 151 Solar Energy Systems 152 Heating System Maintenance 153 Energy Conservation Checklist 155 APPENDIXES Appendix I. References 159 Appendix II. Greenhouse Construction and Supply Companies 160 Appendix III. Plans for Greenhouses 164 Appendix IV. Heating and Cooling Data 166 Appendix V. Container Capacities 168 Appendix VI. Labor Output and Machine Capacities 169 Appendix VII. Electrical Data 171 Appendix VIII. Movable Bench Data 175 Appendix IX. Lighting Conversion Data 176 Appendix X. Hydraulics—Conversions, pipe friction, etc. 179 Appendix XI. Crop Storage and Night Temperatures 183 Appendix XII. Worksheets 188 Appendix XIII. Useful Conversions 208 INDEX 210 CHAPTER 1: GREENHOUSE PLANNING NTRODUCTION away. Subsurface drainage is also important and I may require the digging of test holes to see what problems, if any, may exist or develop. A greenhouse has one purpose: to provide and maintain the environment that will result in Greenhouses need a dependable supply of energy optimum crop production or maximum profit. This in the form of electricity and fuel for heating. An includes an environment for work efficiency as well electric power distribution line adjacent to the as for crop growth. site will reduce the investment needed to bring electricity to the greenhouse. A short access road There are many factors to consider in determining to a public all-weather road should result in fewer the amount of greenhouse space to build. Most problems in maintaining an adequate fuel supply growers start out with one or two houses and then and in transporting supplies to the greenhouse and expand as sales and markets increase. The following plants to market. Telephone service is necessary for should be included as part of the overall plan: successful operation. 1) investment capital available, A dependable supply of high quality water is 2) management skills and training, needed for greenhouse operation. Check with a local 3) type of business—wholesale, retail, well driller or groundwater geologist, if available, 4) crops to be grown and their environmental to determine the potential for an adequate water requirements, source. Zoning regulations control land use in most 5) markets available, communities. Consult the appropriate local or state 6) labor requirements and availability, and agency before planning a facility and work with the 7) personal preferences. officials during planning and construction to keep problems from developing. All new facilities must Generally, a minimum of 2,500 sq. ft. for a retail comply with the Americans with Disabilities Act. business or 5,000 sq. ft. for a wholesale business is needed to provide sufficient gross income for a one- person business. PLAN LAYOUT ITE ELECTION It is best to develop a preliminary layout by first S S considering only major activity areas. Using ovals (goose eggs) avoids the problem of dimension A good building site can make a difference in associated with rectangular-shaped areas and allows the functional and environmental operation of a you to look at alternate arrangements to determine greenhouse. The following discussion may help which should be developed in detail. Figure 1–1 in evaluating potential locations for selection as a on page 2 illustrates this system for a retail grower greenhouse site. operation. Worksheet No. 1 in Appendix XII will assist in layout planning. The following planning Ground slope for drainage and building orientation factors can help in developing a satisfactory layout: are important factors. A south-facing slope is good for winter light and protection from northerly 1) Locate the headhouse to the north of the winds. It should also provide adequate drainage growing area if possible so there will be less of surface water from the site. Swales can be shading. built around greenhouses to direct surface water 1 2) Separate supplier and customer traffic. 3) Locate and arrange retail sales area to keep customers away from the production area. 4) Arrange the layout so traffic moves away from a residence to ensure privacy. 5) Locate windbreaks to the north and west at Service Road least 100 ft. from the nearest building. Supplies In 6) Arrange sales area so that all customers Production Area Headhouse must exit past the cash register. Customer Sales Parking Area Garden centers may differ from retail growers by having a larger assortment of materials available for purchase. They may carry container and ground- Public Road grown nursery products, small equipment items, on East Side and garden supplies. A shade structure and outdoor display area will increase the sales area for a modest
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