NRAES 33 - Greenhouse Engineering Textbook

NRAES-33 Greenhouse Engineeering
By R. Aldrich and J. Bartok

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About NRAES
COOPERATIVE EXTENSION
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
NRAES–33
NRAES–33
© 1984, 1989, 1990, 1992, 1994. The Natural Resource, Agriculture, and Engineering Service
All rights reserved. Inquiries invited. (607) 255-7654.
The use of trade names is for information only and no discrimination is intended nor endorsement
implied.
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
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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
Introduction
A greenhouse has one purpose: to provide and
maintain the environment that will result in
optimum crop production or maximum profit. This
includes an environment for work efficiency as well
as for crop growth.
There are many factors to consider in determining
the amount of greenhouse space to build. Most
growers start out with one or two houses and then
expand as sales and markets increase. The following
should be included as part of the overall plan:
1) investment capital available,
2) management skills and training,
3) type of business—wholesale, retail,
4) crops to be grown and their environmental
requirements,
5) markets available,
6) labor requirements and availability, and
7) personal preferences.
Generally, a minimum of 2,500 sq. ft. for a retail
business or 5,000 sq. ft. for a wholesale business is
needed to provide sufficient gross income for a oneperson
business.
Site Selection
A good building site can make a difference in
the functional and environmental operation of a
greenhouse. The following discussion may help
in evaluating potential locations for selection as a
greenhouse site.
Ground slope for drainage and building orientation
are important factors. A south-facing slope is good
for winter light and protection from northerly
winds. It should also provide adequate drainage
of surface water from the site. Swales can be
built around greenhouses to direct surface water
away. Subsurface drainage is also important and
may require the digging of test holes to see what
problems, if any, may exist or develop.
Greenhouses need a dependable supply of energy
in the form of electricity and fuel for heating. An
electric power distribution line adjacent to the
site will reduce the investment needed to bring
electricity to the greenhouse. A short access road
to a public all-weather road should result in fewer
problems in maintaining an adequate fuel supply
and in transporting supplies to the greenhouse and
plants to market. Telephone service is necessary for
successful operation.
A dependable supply of high quality water is
needed for greenhouse operation. Check with a local
well driller or groundwater geologist, if available,
to determine the potential for an adequate water
source. Zoning regulations control land use in most
communities. Consult the appropriate local or state
agency before planning a facility and work with the
officials during planning and construction to keep
problems from developing. All new facilities must
comply with the Americans with Disabilities Act.
Plan Layout
It is best to develop a preliminary layout by first
considering only major activity areas. Using ovals
(goose eggs) avoids the problem of dimension
associated with rectangular-shaped areas and allows
you to look at alternate arrangements to determine
which should be developed in detail. Figure 1–1
on page 2 illustrates this system for a retail grower
operation. Worksheet No. 1 in Appendix XII will
assist in layout planning. The following planning
factors can help in developing a satisfactory layout:
1) Locate the headhouse to the north of the
growing area if possible so there will be less
shading.
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2
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
least 100 ft. from the nearest building.
6) Arrange sales area so that all customers
must exit past the cash register.
Garden centers may differ from retail growers by
having a larger assortment of materials available for
purchase. They may carry container and groundgrown
nursery products, small equipment items,
and garden supplies. A shade structure and outdoor
display area will increase the sales area for a modest
investment. Checkout location is important for
controlling customer traffic. A suggested garden
center layout is shown in Figure 1–2 on the opposite
page.
Wholesale growers need order assembly and
shipping work areas that are accessible to both their
own and customers’ vehicles. Covered loading
docks protect crops and personnel from weather
and increase materials handling efficiency. The
area should be arranged to keep cross traffic to
a minimum and prevent contamination of clean
plants.
As spring advances and weather gets mild, it is
possible to get double use of a greenhouse by
moving plants outside during the day and inside
the greenhouse at night. This can be done using
movable tray benches, traveling on rails, which set
either over or under benches inside the greenhouse.
Plants on the lower bench must be short to allow the
lower bench to move freely under the upper bench.
Outdoor space must be available and the
greenhouse wall must be constructed to permit
benches to be passed through it. Movable benches
reduce the labor needed to move the plants twice
daily.
The layout of the greenhouse range will depend to
some extent on the crop or crops being grown, with
two basic systems in use. The first system consists
of separate, relatively small greenhouses served
by a central headhouse, as shown in Figure 1–3 on
the opposite page. The second system consists of a
Figure 1–1. General layout for a retail grower for three
locations off a public road.
Public Road North Side
Service
Road
Customer
Parking
Head
house Sales Area
Production
Area
Supplies
In
Wind Break
Production
Area
Supplies
In
Service Road
Customer
Sales Parking
Area
Headhouse
Public Road
on East Side
Public Road on South Side
Customer
Parking
Sales
Area
Head
house Supplies
Production In
Area
3
gutter-connected greenhouse with the headhouse
attached to one side, also shown in Figure 1–3. Each
system has advantages and disadvantages.
For example, the individual greenhouses may be
easily constructed, so expansion or contraction of
the operation can be accomplished easily by placing
them into or out of production as needed. Species
with unique environmental requirements can be
grown without interference. One disadvantage
may be that individual houses in total require more
heat per unit of floor area than a gutter-connected
greenhouse because of the larger ratio of surface
area to floor area. Another disadvantage may be
that plants and personnel have to be outside while
moving between headhouse and greenhouse or
between greenhouses.
Figure 1–3. Plan layouts for 40,000 flat capacity bedding plant production.
Figure 1–2. Garden center layout.
Services
Employee
Parking
Service
Road
Greenhouses
Shade
Structure
Outdoor
Display
Customer
Parking
Retail
Store
Public Road
Cash
Register
Locations
A. Individual greenhouses with separate headhouse.
PARKING
BULK STORAGE
12' ROADWAY
50' x 120'
HEADHOUSE
10' min. between greenhouse
12 @ 28' x 144' =
48,384 sq.ft.
B. Gutter connected greenhouse with attached headhouse.
PARKING
50' x 120' BULK STORAGE
HEADHOUSE
Service aisle
144' x 336' =
48,384 sq.ft.
Each aisle
serves 2 bays
4
Figure 1–4. Two possible headhouse plans to serve a
40,000 flat capacity bedding plant operation.
Each is 56 ft. x 73 ft. = 4,032 sq. ft.
The gutter-connected range keeps all activities
inside one building, and a central heating plant can
easily serve all areas. A minimum area of 20,000 sq.
ft. should be provided to efficiently use materials
and equipment. It may not be as easy to expand or
contract space use as with the individual greenhouse.
For greenhouses above 40° North latitude, the ridge
in either an individual greenhouse or a gutterconnected
range should run east-west to transmit
maximum winter sunlight to the plants. Gutters
shading the same area each day may cause uneven
growth in some plants. The potential for uneven
growth must be balanced against general reduction
in winter light if ridges run north-south.
The choice between production on the ground (floor)
or on benches depends on crop and production
schedule. It may be easier to supply bottom heat to
benches, but the investment in benches is not needed
in a floor operation. A movable bench system can
result in a floor use factor as high as that from a floor
system. It may be easier to justify a bench system
for a pot plant operation than for bedding plant
production, because the work required on potted
plants is easier when performed at waist level.
A good headhouse layout will help the system
operate smoothly and efficiently. Material flow
should be such that there is a minimum of handling
or cross traffic in moving the components through
the system. Examples are shown in Figure 1–4.
When planning a greenhouse system, allow space
for expansion. Most growers who start out small will
add one or two greenhouses each year. Figure 1–5 on
the opposite page shows a layout with an expansion
area indicated.
Utilities
ELECTRICITY
An adequate electric power supply and
distribution system should be provided to serve the
environmental control and mechanization needs of
the greenhouse. Early in plan development, contact
the local supplier to determine availability and cost
of power and the best service drop location. Once
this is done, a plan for the distribution system can be
developed.
To determine service drop size, the size and number
of motors and other electrical components should be
known. Unless special equipment or plant lighting is
to be used, the size given in Table 1–1 on the opposite
page should be adequate.
The distribution system within the greenhouse/
headhouse area will have to meet the National
Electric Code and any local codes. Watertight boxes,
UF wire, and ground fault interrupters may be
required.
H and I
12' x 12'
A
10' X 12'
B
10' X 12'
C
12' X 12'
D
12' X 12'
E
20' X 20'
F
34' X 20'
G
To ghse.
From ghse.
Supplies in To market
6'
H
16' x 16'
E
20' x 16'
A
20' x 16'
F
20' x 28'
I
20' x 28'
G
To ghse.
From ghse.
To market
Supplies in
12' X 10'
6' D
12' X 10'
C
12' X 10'
B
KEY
A HEAT & SERVICE
B MEN'S ROOM
C WOMEN'S ROOM
D LUNCH ROOM
E OFFICE
F GERMINATION
G TRANSPLANT
H ORDER ASSEMBLY
I FLAT FILLING
5
Figure 1–5. Central headhouse with individual greenhouses and room for expansion. Initial total greenhouse area =
12,096 ft.2.
GREENHOUSE SIZE ELECTRICAL SERVICE ENTRANCE SIZE (a)
(amp/volts)
<5000 60/240
5,000 – 20,000 100/240
20,000 – 30,000 150/240
30,000 – 40,000 200/240
40,000 – 80,000 400/240
80,000 – 120,000 600/240
120,000 – 160,000 400/440
160,000 – 200,000 600/440
200,000 – 300,000 800/440
Table 1–1. Sizing the electrical system.
Excluding plant lighting and heavy machinery
(a)
To Market
Order
Assembly
Dry
Storage
Overhead
Supplies In
Expansion
Area
36' x 104' Headhouse
10' min. space
10' min. space
6' Aisle
6' Aisle
6' Aisle
28' x 144' 6' Aisle
Greenhouse
28' x 144'
Greenhouse
28' x 144'
Greenhouse
12' x 16'
Office
16' x 16'
Heat
&
Service
16' x 16'
Transplant
12' x 16'
Seed &
Germinate
Toilets
8' x 12'
12' x 24'
Flat
Filling
Media
Mixing
8' x 12'
6
Provisions should also be made for an alarm system
which indicates when a power interruption has
occurred or an environmental control system has
failed. Control systems range in complexity from
simply activating alarm bells to dialing a phone
number to alert an owner. Along with the alarm,
an auxiliary generating system should be installed
with the proper transfer switch to prevent power
feedback to utility lines.
WATER
Plants require an adequate supply of moisture
for optimum growth and maximum flower
production. Water is the medium by which plants
absorb nutrients. Water absorbed by the root
system moves through the roots and xylem into the
branches and leaves. Water vapor then transpires
through stomates in the leaves into the atmosphere
surrounding the plant. For each ounce of dry matter
produced, as much as two gallons of water moves
through the plant.
Moisture is also needed by the plant for several
other functions:
1) Cell division—Turgid cells reproduce faster,
2) Photosynthesis—Where moisture is deficient,
stomates are closed and carbon dioxide
movement is limited,
3) Rooting of cuttings—Moisture is needed to keep
stem from drying,
4) Germination of seeds—Uniform moisture will
give a higher percentage of germination, and
5) Soil air supply—Amount of moisture regulates
the air supply.
By supplying an adequate but regulated amount
of moisture, it is possible to control the growth and
flowering of plants.
Water Supply
A correctly designed water system will satisfy daily
water requirements. The volume of water required
will depend on the area to be watered, crop grown,
weather conditions, time of year, and whether the
heating or ventilating system is operating. The
maximum requirement is about 500 gal/1,000 sq.
ft. per watering. During a summer dry spell, this
might be applied on an alternate day basis. Table 6–5
(page 104) gives estimated maximum daily water
requirements for greenhouse and nursery crops.
These amounts can be reduced somewhat for crops
that are watered by hand or by trickle irrigation
systems.
Hydroponic Systems
Hydroponics, in its most basic definition, is a
production method by which plants are grown
in a nutrient solution rather than in soil. Recent
research and advances have developed a number
of variations on the basic system. Although it is
possible to use hydroponics on outdoor crops,
most hydroponic production in the U.S. today is in
greenhouses.
The greenhouse and its environmental control
system are the same whether plants are grown
conventionally or with hydroponics. The difference
comes from the support system and method of
supplying water and nutrients.
ADVANTAGES
1) Greater plant density—Use of a growth room for
germination and seedling production and the
spacing of certain crops in the greenhouse
decreases the average area needed per plant as
compared to conventional soil production.
2) Higher yields—Reports of higher yields and
better quality are common, although equal
yields should be obtainable from conventional
soil production.
3) Less water consumption—In methods where the
root system is contained in a closed trough or
tube, evaporation is eliminated and less water
consumed.
4) Less disease and fewer insects—Hydroponic
greenhouses tend to be better maintained than
many conventional greenhouses, resulting in a
reduction of disease and insects. However, if a
waterborne disease is introduced, it can be
transmitted rapidly to all of the plants.
7
DISADVANTAGES
1) Increased initial investment—Pumps, tanks,
controls, and support systems increase costs by
several dollars per square foot. If supplemental
lighting or a growth room is included, a large
additional cost will be incurred.
2) H igher energy costs—Pumps, lights, and
additional controls will require additional
energy.
3) More technical skills needed—A grower needs
both a good plant science and chemistry
background.
CROPS
Although almost any crop can be grown
hydroponically, the most common are leaf lettuce,
tomatoes, cucumbers, strawberries, watercress,
celery, and some herbs. One key factor in system
design for a particular crop is how it is supported in
the nutrient solution.
GROWING SYSTEMS
During the past few years, many innovative systems
have been developed to replace the traditional
gravel-filled bed. When evaluating the type of
system to install, consideration should be given
to such factors as types of crops grown, space
requirements, growing time, support system, and
economics.
Growing systems can be set up in either a
greenhouse or a growth room. Some growers use
both: the growth room for germination and seedling
production, and the greenhouse for growing the
crop to maturity. Extra heat from the growth room
lights may be used to heat the greenhouse. Several
soilless growing systems are shown in Figure 1–6.
Sand/Stone Culture
This technique for growing almost any type of plant
consists of a deep bed (18–24 in.) of sand, pea stone,
or trap rock placed in a plastic-lined trough or bed
Figure 1–6. Soilless growing systems: a) Sand/Stone Culture; b) Pipe System; c) Tray System; d) Bed system with
polystyrene flats for plant support; e) NFT System; and f) Bag System.
f. Bag System
Drip Tube
Polyethylene bag
Rockwool, Foam, or
Peat-Vermiculite mix
d. Bed system with polystyrene flats
Polystyrene flat
PVC Liner
Nutrient Solution
b. Pipe System
Nutrient Supply Line
3" PVC pipe sloped to
drain nutrients
Chain Support and
Conveyor System
a. Sand/Stone Culture
Concrete Bed and Aisle
Sand or Stone Support Medium
Polyethylene or Polyvinyl Liner
c. Tray System
Direction
of Travel
Track
Shelf Nutrient Solution
Growth Tape
Slat
Air Duct
e. NFT System
Starter Block Nutrient
Polyethylene Channel
8
which slopes to one point to drain off excess nutrient
solution (a minimum slope of 2% is recommended
for most systems). Seedlings are set directly into this
medium and watered several times per day with the
nutrient solution.
Troughs and Pipes
Open and closed troughs are commonly used for
lettuce, tomatoes, and cucumbers. Troughs and
pipes may contain just the nutrient solution or may
be filled with peat moss, vermiculite, or perlite.
Some are mounted on rollers or movable racks for
spacing the plants as they grow. PVC pipes (2–3 in.
diameter) with holes 6 in. on center are being used
for leaf lettuce production. Carts may be used to
move pipes from the growing area to the packing
room.
Trays
Periodically, flooded trays are used for growing
lettuce. Plants grown in 1–2 in.2 growth blocks may
be spaced manually as the plants grow. Trays are
made from molded plastic, waterproof plywood, or
flake board. Plastic is used as a liner.
Beds
Bed systems are composed of a plastic-lined ground
bed with nutrient solution pumped in at one
end and removed at the other. Lettuce plants are
supported in foam polystyrene flats which float on
the solution.
Nutrient Film Technique (NFT)
This system uses channels formed of thin plastic film
which are placed on the floor and slope the length
or width of the greenhouse. Nutrients are supplied
to one end of the channel through plastic tubing and
drain into a below-ground reservoir at the other end.
Seedlings are usually grown in pots, poly bags, or
growth blocks in the channel.
Bags
A modified hydroponic system uses polyethylene
film bags, filled with a peat-vermiculite mix, foam,
or rockwool placed end-to-end. Drip tubes or soaker
hoses supply the nutrient solution.
Aeroponics
For this modified system, plants are supported
through a plastic cover to a closed tank. Nutrients
are supplied to the roots as a fine mist or fog.
Other Components
Besides the plant support system, tanks, pumps,
and controls are needed. Tanks of concrete, plastic,
or wood are common. Submersible pumps made for
chemical solutions should be used because fertilizer
salts corrode pumps made for use with water.
Controls can be simple time clocks and manual
switches or complex computers which automatically
adjust the chemical content of the nutrient solution.
Institutional Greenhouses
Greenhouses for academic units, retirement
homes, rehabilitation centers, or public parks and
gardens have unique requirements. The objective
of a commercial greenhouse operation is to
realize a financial profit. Institutional greenhouses
such as those in schools, retirement homes,
rehabilitation centers, and public areas all have
different objectives. School greenhouses teach basic
knowledge and develop skills, while retirement
home greenhouses provide an environment for
relaxed enjoyment of growing plants. Rehabilitation
centers use greenhouses as therapy to assist persons
in living fulfilling lives. Public parks and gardens
provide enjoyment and education for the general
public. There may be highly structured programs
carried out in school and rehabilitation center
greenhouses but very little formal programming in a
retirement home greenhouse.
The institutional greenhouse can be of standard
commercial construction unless there is a
unique architectural need to satisfy aesthetics.
Environmental control systems can be the same as
those used in commercial greenhouses, although hot
water heat can provide more accurate temperature
control. The system should be automated to ensure
acceptable control in the absence of personnel.
Equipment, including benches, watering devices,
lighting, etc., may require modification to fit
particular situations. Equipment noise should be as
low as possible. Additional doors may be needed to
satisfy safety requirements because of occupancy.
9
Site selection should be based on the same factors
considered for siting a commercial greenhouse.
In some areas, the need for public access may
require a site which is less than optimum for factors
considered critical in commercial production. An
example would be a public garden greenhouse
having relatively inefficient materials handling
facilities because of the need for public access and
aesthetic considerations. Acceptable orientation for
sun, protection from prevailing winds, and drainage
are still very important in site selection, although
wind breaks can be created.
Functional layout of the institutional greenhouse
will depend on the clientele to be served. For
example, a high school program has different needs
than a rehabilitation program. Convenient access is
essential for all persons, including the handicapped,
singly or in groups. The benches or floor growing
areas should be arranged to permit several persons
to have access without crowding.
GREENHOUSES FOR TEACHING
A greenhouse for teaching in elementary or
secondary schools should be organized to provide
experience through both individual and group
projects. It should provide for student participation
in all phases of plant production, from propagation
to harvest of commercially important species and
cultivars. Figure 1–7 shows suggested layouts for a
secondary school teaching greenhouse.
Figure 1–7. Suggested layouts for a secondary school teaching greenhouse.
Wheelchair Access
Ground Bed or
Container Areas
Sink
A. In-line Layout
Potting
Mixing
Storage
Warm Section Cool Section
4' x 12' Benches
2' Aisles
Work
Table
20' 32' 32'
30'
Chem.
Storage
Display
Cooler
Work
Table
B. T Layout
Potting Chemicals
24'
Classroom
Demonstration
Display
Cooler
Work
Tables
32'
32' 32'
70'
6'
Ground Bed or
Container Area Cool Section
Warm Section Sliding Doors
4' x 12' Benches
2' Aisles
10
A separate but attached room should be used for
such activities as medium mixing, seeding, pot or
tray filling, transplanting, and some demonstrations.
Containers, seeds, chemicals, equipment, and other
supplies should be stored adjacent to the workroom
and greenhouse. A small display cooler should be
available in the workroom for storage of fresh plant
material. A two-section greenhouse is desirable to
provide separate warm and cool environments.
The environmental control system should be
automated to ensure acceptable conditions when the
greenhouse is unattended. Distribution systems for
heating and cooling should be arranged to permit
changes in the operation to satisfy instructional
needs. An alarm system should be installed to alert
those responsible when environmental control
equipment malfunctions.
The electrical system should provide circuits for
general lighting, special purpose lighting, special
purpose heating, special equipment operation, and
general cooling. All convenience outlets should be
waterproof and mounted above bench height. The
water distribution system should permit changes
as instructional needs require. Suggested utility
distribution systems are shown in Figure 1–8.
Benches should be built to permit changes in layout
or benching system. The use of rolling benches,
trays, or pallets should be possible alternatives in
the instruction program.
Figure 1–8. Environmental control for teaching greenhouses.
CROSS SECTION
Perforated
PE Tube
General Lighting
Duplex Outlet
Sidewall
Vent
Finned Tube
Valved outlet
for root zone heating
Hose
Valve
Aspirated box
for Thermostat
Bench Top
PLAN
Sidewall vents full
length each section
Duplex
Outlet
Valved outlet
for root zone
heating
Container
Area
Hose
Valve
General
Motorized Lighting
Louver
Fan and
perforated
PE tube for
mild weather
cooling
Finned tube
space heating
Partition Wall
COOL SECTION
WARM SECTION
Exhaust fan
Aspirated
box for
Thermostats
Bench
Area
Valved
outlet
for root
zone
heating
Classroom
11
RETIREMENT CENTER GREENHOUSE
A retirement center greenhouse should provide
convenient access for able-bodied persons and
those confined to wheelchairs or assisted by
walkers. Hard-surfaced, non-skid aisles are
necessary, and benches should be at heights which
accommodate persons both standing and sitting.
The greenhouse should have ample open space to
facilitate movement and promote fellowship among
residents. Separate areas should be provided for
storage of greenhouse supplies and for pot filling,
transplanting, and other service activities. There
should be a floor drain in the service area. Fan noise
levels should be as low as possible, so belt-driven
units should be used for ventilating. Separate cool
and warm sections are desirable if conditions permit.
Figure 1–9 shows possible layouts for retirement
center greenhouses.
Figure 1–9. Suggested layouts for retirement center greenhouses.
B. Attached Gable Greenhouse
24'
32'
8'
Access to living unit
Access to outside
Service Area
Drain
Storage
3' Aisle for Wheelchair
2' Aisles
4' Benches
Fintube
Heater
A. Lean-to Greenhouse
10' 30'
16'
6'
Access
to
outside
Access to living unit
Service
Area
Drain
Work
Bench
Storage
3' Aisles
4' Benches
Fintube
Heater
12
REHABILITATION CENTER
GREENHOUSES
A rehabilitation center greenhouse should be
arranged to accommodate a variety of programs.
When designing space for use by the physically
handicapped, consider space for wheelchairs,
as well as the height of equipment and controls.
Space arranged for wheelchair operation will also
accommodate persons supported by crutches
or braces. Figure 1–10 shows recommended
dimensions for men and women operating from
wheelchairs.
Figure 1–10. Anthropometrics for wheelchair-bound men and women.
Access walks to the greenhouse should be at least
48 in. wide, have a smooth surface, and a maximum
grade of 5% (6 in. every 10 ft.). The greenhouse
entrance should have a level platform on either side
of the door. Dimensions are shown in Figure 1–11
on the opposite page. If space is so limited that a 5%
grade would not provide the necessary elevation, a
ramp with side rails must be installed. The surface
should be non-slip and must have a maximum grade
of 8.3% (10 in. every 10 ft.). Ramp length should not
exceed 30 ft. between level platforms. Dimensions
are shown in Figure 1–12 on the opposite page.
Mean 5'¾"
Anthropometrics: Wheelchair-bound men
+ = maximum reach
– = minimum reach
+4'9¼"
mean 4'4½" head height
–3'11¾"
mean 3'5" shoulder
+3'9¼"
–3'¾"
mean 2'3¼" elbow
+2'6"
–2'½"
Eye level mean 4'¼"
+4'4¾"
–3'7¾"
Mean forward reach
1'9¾" over high table
1'2" over low table
–1'5¾"
–8"
mean 1'11¾" knee level
+2'2½"
+8½"
Foot height
Thigh level at point
of obstruction
Anthropometrics: Wheelchair-bound women
+ = maximum reach
– = minimum reach
+4'6¼"
mean 4'1½" head height
–3'8¼"
mean 3'3" shoulder
+3'7½"
–2'10¾"
+2'6"
–2'½"
mean 2'3¼" elbow
Eye level mean 3'7½"
+4'2"
–3'5"
1'7" over high table
11½" over low table
–1'3½"
–5½"
Thigh level at point
of obstruction
mean 1'11½"
+2'2¼"
+8¾"
Foot height
knee level
mean 6½"
Anthropometrics: Wheelchair-bound men
+ = maximum reach
– = minimum reach
mean 5'7½" vertical reach
–5'2¼"
Knuckle height
mean 1'3"
+1'4¼"
+8¾"
mean 7¼"
Front edge of chair 1'7"
mean 1'4½" +1'6½"
+2'4¾"
+2'1¾"
mean
1'11½"
2'2½"
Sitting
erect
Back
Toe
projection
vertical reach
Forward mean 4'7½"
–4'3½"
Oblique
vertical reach mean 5'2¾"
–4'10¼"
Anthropometrics: Wheelchair-bound women
+ = maximum reach
– = minimum reach
mean 5'2" vertical reach
–4'8¾" Oblique
vertical reach mean 4'9¾"
–4'5½"
vertical reach
Forward mean 4'3"
–3'11"
Toe
projection
+2'2"
+1'11"
mean
1'9"
2'0"
Sitting
erect
Back
mean 1'2½"
+1'4½"
Front edge of chair 1'7"
+7"
mean 5¾"
Knuckle height
mean 1'4½"
+1'5½"
13
Figure 1–11. Suggested greenhouse layouts for handicapped persons.
Figure 1–12. Ramps for handicapped access.
B. 21' Greenhouse
58'
42' 16'
21' inside
5' x 5' Conc. Slab
8'
5'
8'
A. 30' Greenhouse
8'
8'
5'
5'
4'
4'6" 4'6"
4' x 8' Benches
4' x 12' 4' x 12'
4' Aisle
42' 16'
58'
5' x 5' Conc. Slab
30' inside
2'8"
2" O.D. Met. Railings
Slope not to exceed
1" vertical to
12" horizontal.
ELEVATION
PLAN
1/8" Met. Platform
2" x 4" Curb
2" x 4" slats 3/8" apart
or Broomed Concrete
Single run access ramp
2'5"
4"
4"
2" x 4"
Curb
ELEVATION
Slope not to exceed
1" vertical to
12" horizontal.
2'
12"
4"
PLAN
6'0" 12'0" 6'0"
5'10"
2'5"
Double run access ramp
14
Special identification should be used for sightand
hearing-impaired persons. Raised letters
and numbers should be used for bench or table
identification and should be placed on both ends of
benches or on the ends next to the aisle. Place raisedletter
signs 4.5–5.5 ft. high at the sides of doorways.
All hazardous openings should be identified with
knurled hardware, a change in flooring material,
and audible signals. Visible signals should be placed
as warnings for the hearing-impaired.
The watering system should be installed so that the
handicapped can easily operate it. Easy-to-operate
water taps should be located at each bench. Leveraction
fittings are preferred for people with limited
hand function. Screw-type fittings should allow
a firm grip. Provide a clearance of 1 in. between
handles and any surface.
Electrical switches should be placed for easy access
by the handicapped person. Switches should have
simple and positive action with no more than
two switches together on one plate. Time clocks,
thermostats, and other control devices should be
conveniently placed. Adjustment knobs, etc., may
require modification to permit the handicapped
person to operate equipment easily.
Bench supports should be placed back 6–12 in. from
the outer edges to provide knee room for seated
persons. Bench height should be from 30–36 in. for
comfortable working. An adjustable height bench is
shown in Figure 1–13.
PUBLIC PARK OR GARDEN
GREENHOUSE
A public garden greenhouse or conservatory should
be organized to display plants and/or plantings
Figure 1–13. Adjustable height bench.
Length to Fit
3 to 5 feet
2" x 4" on Edge
2" x 4" Flat for Pipe
Flange
1" Dia. Galv.
Steel Pipe
1" x 1" x 1"
Split Tee
1¼" Dia. Steel Pipe
1¼" Pipe Flange
1¼" x 1¼" x 1"
Split Tee
¼" Dia. x 2" Machine Bolt
5/6" Dia. Holes 1½"
on Center
1" Dia. Galv.
Steel Pipe
1" Pipe Flange
Notes:
1. Legs spaced 4' O.C. maximum
2. Set legs on level half patio
blocks on sand
3. Use pressure treated lumber for frame
4. Top can be welded wire, pressure
treated lumber, redwood or cypress
boards
5. Add sides for bench crops
15
to their best advantage. The interior should be
open to promote creativity in arrangements and
to provide control of visitor movement without
undue restriction. Some efficiency in plant care may
be sacrificed in order to develop pleasing displays.
Clear heights of 30–40 ft. or more are needed in
some areas to allow display of tall specimen plants
or unique arrangements.
Environmental control may be more difficult in
public greenhouses because of periodical changes in
plant arrangement. It may be necessary to move or
modify equipment to maintain acceptable control.
Water and electricity supply lines should be installed
to permit alternative design arrangements without
major reworking.
A classroom or laboratory for lectures and
demonstrations should be attached to the
greenhouse. Adequate workroom space is necessary
for preparing plant material, along with a storage
area for general supplies. The workroom and
storage area should be located where public access is
discouraged or prevented.
Special Purpose Facilities

SHADE STRUCTURES
Shade structures are used to provide minimal
protection against wind and solar radiation for
nursery crops such as shrubs and ground cover.
They are also used in garden center retail sales areas.
They provide from 60–80% shade, depending on
slat size and spacing. Because they are permeable
to wind, the structures may be framed somewhat
lighter than a greenhouse; however, snow will
bridge the slats, so the frames must be strong
enough to carry expected snow loads. A typical
shade structure is shown in Figure 1–14 on page 16.
Shading can be used on greenhouses to reduce
light and heat load on plants. Commercial shading
compounds can be sprayed on the outer surface of a
greenhouse. Such compounds gradually wear off as
the summer advances, and any remainder is washed
off in late summer or early fall. Manufacturer’s
directions should be followed when applying such
materials. Any shading compound still on the
greenhouse surface in mid-September should be
removed to ensure adequate light transmission.
The following is a recipe for shade remover:
Into one gallon of hot water, mix 4-1/2 lb. sodium
carbonate (water softener) and 1 lb. trisodium
phosphate (detergent); stir until it is dissolved. Add
one gallon of 52% hydrofluoric acid and stir. Add
the mixture to 23 gal. cold water and stir. Use a soft
bristle brush to scrub the glazing. Rinse.
Shade materials that will provide from 20–90%
shade are also available. Most are made of
polypropylene, polyethylene, or polyester. They
can be supported internally from thermal blanket
systems or secured to the exterior glazing surface.
External shading fabrics must be secured to resist
wind forces.
OVERWINTERING STRUCTURES
Overwintering structures are temporary structures
used to provide protection from wind and
temperature to container-grown nursery stock. They
are generally framed with pipe or conduit (steel or
aluminum) bent to form an arch and covered with
white polyethylene film. A-frames of wood are
also used, but inside space is somewhat restricted.
Figures 1–15 and 1–16 on page 17 show typical
structures. Most overwintering structures are kept
with temperatures below freezing but above 25°F
to prevent damage, which can result from excessive
moisture loss due to wind or high temperature if the
ground is dry or frozen. Irrigation may be necessary
for some species to maintain quality.
Plant containers are set against each other during
overwintering and spaced apart in the spring;
therefore, overwintering structures are separated to
provide the needed summer growing area. Irrigation
is generally provided by overhead sprinklers, but
this practice wastes water and can produce pollution
problems if fertilizer is applied through the watering
system.
Facilities should be available for accumulating
orders to be shipped. Containers can be set on
pallets to be picked up by a forklift or set on wagons
to be transported to the loading area. See Chapter 3
for additional information on materials handling.
COLD FRAMES AND HOTBEDS
Cold frames are used to start or harden-off seedlings
in the spring or extend the growing season in the
16
Figure 1–14. A permanent shade structure using prefabricated shade fence on a timber frame. The building is
constructed
in 12 ft. x 12 ft. modules.
Shade Fence or
2"x6" 2'-0" O.C. Furring Strips
2 - 2"x10" 12'-0" O.C.
2"x4" Braces Each Column
4"x4" Wine Braces Each Column
4"x4" Pressure Treated Columns
12" O.C. Each Direction
12'-0"
9'-0"
3'-6"
Grade
2'-0"
2'-0"
CROSS SECTION
PLAN LAYOUT
12'-0"
12'-0"
2 2"x10" Beams 12'-0" O.C.
4"x4" Pressure Treated Posts
12'-0" O.C. Each Dir.
2"x6"
Rafters
2'-0" O.C.
Shade
Fence
17
Figure 1–15. Typical overwintering hoop house of steel conduit or fence pipe.
Figure 1–16. A-frame overwintering structure.
1" x 4" wind brace.
Fasten wind brace
and ridge board to
hoops with U-bolts.
Anchor timbers with
steel pins 4' O.C.
ELEVATION
1" x 4" Ridge board
Hoops spaced
4' O.C. set in
holes in timber
Length of
house to suit−
generally 96' or
144'
CROSS SECTION
12'0"
Film
Battens
Film
buried
6" x 6" Pressure
Treated Timber
1" dia. steel conduit
or fence pipe. Ends
can be framed or
plastic can be draped
across ends.
6' radius
White polyethylene
film either buried or
secured to timbers
with battens.
1" x 4" Ridge Boards
1" x 6" Collar Tie
2" x 4" x 10'
6" x 6" Pressure Treated
Timber Sill
4" x 4" Pressure
Treated Sill
Frame End View
3'0"
Secure 4"x4" to Doorway
6"x 6" with framing anchor
12'1"
13'0"
Frame Side View
1" x 4" Wind Brace
each side, each
end of the
buildinig
Anchor sills with
3'0" steel stakes 6' O.C.
Framing anchor to
secure frame to sill
Cover frame
with 6 mil white
polyethylene.
Fasten to sill with
1" x 2" battens.
3'0" 3'0" Multiples of 3'
18
fall. Cold frames are heated only by the sun. If
heated artificially, they are called hotbeds. Orient
cold frames to the south and set them on welldrained
soil. If possible, set them into the ground to
take advantage of ground heat. Figure 1–17 shows
typical cold frame construction. Construct the frame
to permit tray or pallet handling of plants.
Ventilation prevents temperatures from rising
too high on sunny days. Although it is possible
to automate the ventilation system, it may not be
practical because of the short lengths of time cold
frames are in use each year. Heat, if desired, can be
supplied from electric cable, hot water, steam, or
warm air. Supply 50–60 Btu/hr./ft.2 of ground area.
REFRIGERATED STORAGE FOR
GREENHOUSE AND NURSERY CROPS
Refrigerated storage is necessary to maintain
the quality of the harvested crop prior to use or
marketing. Precooling and rooting rooms can extend
the flowering period for forcers of spring flower
bulbs. The recommended storage temperature is
crop and use dependent, varying from 32°F for
most cut flowers to 40°F and above for some bulbs.
Relative humidity should be held above 90% for cut
flowers and fresh vegetables, above 80% for nursery
stock, and from 70–75% for bulbs. Appendix XI
gives recommended storage conditions for several
commodities.
Figure 1–17. Cold frame construction system.
4'0" 4'0"
6'0"
Pipe Rail
Pipe can be used
for warm water
heat supply
Trays rolled into cold
frame from either end
Rafter
Top constructed
in 8" units
PLAN PIPE FRAME
4'0" 4'0"
6'0"
PLAN
Drop Front
Rafter
Pipe Rail
Pipe can be used
for warm water
heat supply
CONCRETE FRAME
Cross Section
a. Roll-up cover with drop front for fork lift loading
6'0"
6" Gravel
6" Sand Sill
2'0"
1'0"
Hinge for
drop front
PE film roller pipe
hand cranked
Film rolled part way
for ventilation
Batten for
film
6" Conc. or
Concrete
Masonry
Wall
12"
6"
3'0"
Tray
Flats
2" x 4" Rafter
4'0" O.C.
1½" x 3" Butt hinge 4' O.C.
2" x 4" Plate
Eye Bolt
18" O.C.
2" x 2" x 6' cover
support bar
Gate Hook
Eye Bolt
Screw Eye
Eye Bolt
Rafter
b. Hinge cover with end loading of trays
Section & Details
2" x 4" Top rail
3'0"
1'0"
6" Gravel
6" Sand
Tray
Flats
2" x 4" Rafter
2" x 4" Rail
Pipe
1¼" Dia.
Pipe 4' O .C.
2" Pressure
Treated T&G Lumber
19
Water loss from stored material is reduced
by lowering the product temperature and by
maintaining a high relative humidity in the storage
area. Water vapor is lost from the storage air through
air exchange with the outside and by condensation
on coils of refrigeration equipment. The minimum
relative humidity in the storage is determined by
the temperature difference between the evaporator
inlet and outlet. Table 1–2 on page 20 shows
the relationship between temperature drop and
resulting relative humidity. It is important that the
Figure 1–19. Layout for storage and rooting rooms for 100,000 bulb capacity.
Figure 1–18. Packing room layout for cut flower
operation. Example: 100,000 sq. ft. for rose house.
refrigeration system be matched to the anticipated
load so that relative humidity can be held at the
desired level.
Most retail outlets will use a walk-in cooler with
glass doors so that customers can view materials.
Coolers for wholesale cut flower producers should
be large enough to store the harvest for at least two
days. Placement of coolers with respect to harvest
area and the packing room is important. Figure 1–18
shows a plan for a wholesale cut flower operation.
Bulbs to be stored for periods of longer than
three weeks should be placed in shallow, wirebottomed
trays that can be stacked in the cooler to
permit adequate ventilation. The use of a rooting
room extends the flower production period. Since
temperature and time sequences vary depending
on flower period, a compartmentalized rooting
room with proper controls is desirable. Ventilation
is necessary to maintain air quality, and water must
be available for easy application. Provide enough
artificial lighting for worker activity (20 foot-candles
at plant levels), but exclude all natural light. Bulb
storage and rooting rooms should be located and
arranged for easy movement in and out of the
facilities. Figure 1–19 shows a plan for a bulb forcing
operation.
Office
12' x 16'
Cooler
16' x 16'
4' x 16'
Grading and Packaging
Personnel
Area
8' x 8'
M
8' x 8'
W
Sorting—3' x 16'
To Market
Deliveries
Dry Storage
48' Greenhouses
ROOTING
ROOM
20' x 24'
½ hp Refrigeration
4,320 cu. ft.
ROOTING
ROOM
20' x 24'
½ hp Refrigeration
4' Pallet
3' Aisle
6' Doorway
1' for air
circulation
3' Aisle
6"
for
air
circulation
TRAY
STORAGE
12' x 24'
1/3 hp Refrig.
2,592 cu. ft.
WORKROOM
16' X 52'
Media Storage
Receiving/Inspection
Dry Storage
to market
Order Assembly
tray filling, potting
to greenhouse
Table 1–2. Minimum relative humidity levels developed at storage temperature and for temperature drop across the
evaporator.(a)
AIR TEMPERATURE DROP MINIMUM RELATIVE HUMIDITY AT
ACROSS EVAPORATOR STORAGE TEMPERATURES
(°F) 32°F 38°F
1 95.8 96.1
3 87.1 88.8
5 79.4 82.0
10 62.7 65.3
15 49.3 51.6
(a) From Bartsch, J.A. and G.D. Blanpied. 1990. Refrigeration and Controlled Atmosphere Storage for Horticultural
Crops.
NRAES–22. Natural Resource, Agriculture, and Engineering Service, Cornell University, Ithaca, NY.
20
21
References
Joiner, J.N. (Editor). 1981. Foliage Plant Production.
Prentice-Hall, Inc.: Englewood Cliffs, NJ 07632.
Langhans, R.W. 1983. Greenhouse Management.
Halcyon Press of Ithaca: Ithaca, NY.
Laurie, A., D.C. Kiplinger and K.E. Nelson. 1979.
Commercial Flower Forcing. Florists Publishing
Co., 310 S. Michigan Ave., Chicago, IL 60604.
Nelson, P.V. 1991. Greenhouse Operation and
Management. Reston Publishing Co., Inc.:
Prentice Hall, Englewood Cliffs, NJ 07632.
Special Purpose Facilities
Bartsch, J.A. and G.D. Blanpied. 1990. Refrigeration
and Controlled Atmosphere Storage for Horticultural
Crops. NRAES–22. Natural Resource,
Agriculture, and Engineering Service: Cornell
Univ., Ithaca, NY.
DeHertogh, A. 1985. Holland Bulb Forcer’s Guide.
Third Edition. International Flower-Bulb Center:
Hillagom, The Netherlands.
Havis, I.R. and R.D. Fitzgerald. 1976. Winter Storage
of Nursery Plants. Publ. 125. Univ. of Mass.:
Amherst, MA.
Huseby, K. 1973. A Tree Seedling Greenhouse: Design
and Cost. USDA Forest Service: Missoula, MT.
Hardenburg, R.E., A.E. Watada, and C.Y. Wang.
1986. The Commercial Storage of Fruits, Vegetables
and Florist and Nursery Stocks. Agric. Handbook
No. 66.: U. S. Dept. of Agric.
McGuire, J.J. 1972. Growing Ornamental Plants in
Containers: A Handbook for the Nurseryman. Bul.
197. Univ. of Rhode Island: Kingston, RI.
Privetto, C.U. 1976. Greenhouse Design for the
Handicapped. Paper No. 76-4004. Am. Soc. of
Agric. Engr., St. Joseph, MI.
Hydroponics
Cooper, A. 1979. The ABC of NFT. ISBS, Inc., 2130
Pacific Ave., Forest Grove, OR 97166.
Reikels, J.W. Hydroponics. Ontario Ministry of
Agriculture & Food Fact Sheet Agolex 200/24.
Edifice Sir John Carling Bldg., 930 Carling Ave.,
Ottawa, Ontario, Canada K1A 0C7.
Rush, H.M. 1985. Hydroponic Food Production. Third
Edition. Woodbridge Press Publ. Co., P.O. Box
6189, Santa Barbara, CA 93160.
22
Chapter 2:
Greenhouse Structures
(1) In many states, agricultural buildings are either exempt
from the code requirements or are treated as special use
structures.
Introduction
Many construction systems are being used
successfully for greenhouses. Some may have
advantages over others for particular applications,
but there is no one best greenhouse.
The structural design of a greenhouse must provide
safety from wind, snow, or crop load damage
while permitting maximum light transmission.
Therefore, opaque framing members should be of
minimum size while providing adequate strength
to resist expected loads over the planned life of the
greenhouse.
Each U.S. state has a basic building code(1) that
is designed to ensure public safety, health, and
welfare insofar as they are affected by building
construction. Local political subdivisions within
each state may adopt basic building codes that are
not in conflict with the state code. The code may set
design loads and material specifications that may
limit the construction options of the owner. Design
loads and mechanical properties of materials are
either prescribed within the code or in accepted
engineering practice. The accepted engineering
practice refers to such things as method of structural
analysis, working stresses for particular materials,
and load distribution characteristics. Buildings are
designed for future performance based on past
experience with an acceptable probability of success.
Design Load
Design loads include the weight of the structure
(dead load), loads brought on because of building
use (live loads), and loads from snow and wind.
Dead load depends on the framing, glazing system,
and the amount of permanent equipment carried
by the frame. For example, a pipe frame greenhouse
covered with double polyethylene (PE) will have
a much lighter dead load than a lapped glass
greenhouse. Heating and ventilating equipment,
water lines, etc., may add dead weight to the frame.
Live loads may be people working on the roof,
hanging plants (if in place for less than 30 days), or
other items carried by the frame for short periods
of time. The National Greenhouse Manufacturers
Association (NGMA) gives a method for estimating
the minimum live load and recommends a
maximum live load of 15 lb./ft.2 of ground area
covered. Figure 2–1 on the following page shows
how loads act on greenhouse frames.
Greenhouses should be designed to resist an 80
mph wind from the direction that will produce
the greatest wind load. The actual load depends
on wind angle, greenhouse shape and size, and
presence or absence of openings and wind breaks.
Snow load is based on expected ground
accumulation, roof slope, whether the greenhouses
are individual or gutter-connected, and whether
they are heated or unheated. The NGMA has used
a minimum value of 15 lb./ft.2 of covered area
for snow load. Even if snow loads for the area are
greater, heat is usually provided to melt snow since
the minimum greenhouse temperature is about
50°F. Figure 2–
2 on page 24 shows water equivalents
of very wet or dry snow. Table 2–
1 on page 24
summarizes minimum design values for loads on
greenhouses.
In the design of greenhouse frames, use the
combination of the loads from Table 2–
1 that results
in the most unfavorable effect on the structure.
Table 2–1 is included to indicate minimum values
only. Actual design values depend on greenhouse
shape, construction material, location, and use.
23
Figure 2–1. Loads on greenhouse frames.
A. Gravity loads act downward and include
dead load (the weight of the greenhouse),
live loads (the weight of suspended crops,
equipiment, workers, etc.), and snow load.
B. The length and direction of arrows
indicate relative size of wind loads and how
they act on greenhouses.
GABLE GABLE
Wind
ARCH
Dead, live, snow
Dead, live
Dead, live, snow
Dead, live
HOOP
Dead, live, snow
Dead, live
ARCH
Wind
½
¼¼
30'
HOOP
Wind
½
¼¼
24
An 80 mph wind can produce a pressure of
16 lb./ft.2. An 80 mph wind striking a typical 28-ft.
span pipe frame greenhouse can produce an uplift
force of 220 lb./ft. of greenhouse length. Since the
dead weight of the building is very small, there
is little to counteract the wind. Anchorage to the
ground must be secure enough to resist winds.
Materials and Methods

of Construction
FOUNDATIONS
The foundation is the link between the building
and the ground. It must transfer gravity, uplift, and
overturning loads, such as those from crop, snow,
and wind, safely to the ground.
If the primary greenhouse frame consists of
members spaced greater than 4 ft. apart, pier
foundations are adequate and may be less costly
than a continuous wall. A curtain wall can be used
to close the area between piers. If primary frame
members are spaced four feet or less, a continuous
masonry or poured concrete wall is best.
The footing should be set below frost or to a
minimum depth of 24 in. below ground surface. It
should rest on level, undisturbed soil, not on fill.
Individual pier footings should be sized to fit load
and soil conditions. The pier can be of reinforced
concrete, galvanized steel, treated wood, or concrete
masonry. The wall between piers can be poured
or precast concrete, masonry, or any moisture and
decay resistant material. A continuous foundation
Figure 2–2. The depths of wet or dry snow equal to one
inch of rain—one inch of water produces a force of
5 lbs./ft.2 on a horizontal surface.
Table 2–1. Minimum design loads for greenhouse main frames. (For more complete information and
recommendations,
consult references.)
LOAD DESCRIPTION
MINIMUM VALUE
(lb/ft.2)
Dead (a)
Pipe frame, double PE 2
Truss frame, lapped glass 5
Hanging basket crops (in place more than 30 days)
such as tomatoes or cucumbers 4
Live (b) 2
Snow (greenhouse continuously heated to 50°F) 15
Wind (c)
(a) For special construction, equipment support, etc., use estimated weights.
(b) Includes distributed weight of workers and assembly or repair materials or other short time loads.
(c) Wind loads act perpendicularly on surfaces. All other loads act on areas equal to ground covered.
5 lb. per sq. ft.
3 inches of wet snow
5 inches of dry snow
25
wall should be set on a poured concrete footing.
The wall can be concrete or masonry. A 6-in. wall is
sufficient for building spans up to 24 ft. Use an 8-in.
wall for wider building spans. Typical foundation
construction details are shown in Figure 2–
3 on the
next page; pier footing dimensions are given in
Table 2–2 below. Pipes driven into the ground do
not have enough resistance to prevent uplift failures
from high winds, so such methods should be used
only for temporary structures to be used for less
than one year.
FLOORS
A gravel floor with concrete traffic aisles will
provide drainage and weed control. Porous concrete
makes a very good floor surface for greenhouses
because it allows water to pass through and avoids
the puddles or standing water common to floors of
regular concrete, sand, or gravel. Porous concrete
is made from a uniformly graded aggregate and a
cement water paste.
The most satisfactory porous concrete mix contains
one cubic yard (2,800 lbs.) of 3/8-inch diameter
stone that is free of dust and uniform in size,
5.5 sacks of standard Portland cement, and 4.25 gal.
of water per sack of cement. There is no sand in the
mix, which is placed on a well-drained base of sand
or gravel. A 4-in. thick floor will carry personnel and
light vehicle traffic.
The concrete should be moved as little as possible
during placing and screeded to the final grade with
no tamping, as tamping would consolidate the mix
and close the pores. Use an overhead bucket, twowheel
buggy, or wheelbarrow to move concrete to
the floor location.
The surface is not trowel-finished. The final surface
will be rough compared with regular concrete, but it
is comfortable for walking and easily maneuverable
for vehicles. When the floor has been screeded to the
final level, cover it with a polyethylene film to keep
evaporation loss to a minimum; allow the concrete
to cure for at least one week before using the floor.
Roll over the PE film with a lawn roller to produce a
relatively smooth surface.
The final product should have a load carrying
capacity of about 600 lbs./in.2 of surface. Average
Portland cement concrete (regular concrete) can
carry about 2,500 lbs/in.2 of surface; therefore, the
use of porous concrete should be restricted to areas
where personnel or light vehicles such as garden
or utility tractors operate. Porous concrete should
not be used in soil mixing areas or where large
quantities of small particles can fall onto the floor.
Particles will clog the pores and prevent downward
water movement.
Table 2–2. Pier footing diameters for sandy loam soil. (a)
GREENHOUSE
SPAN
(ft.)
PIER SPACING (ft.)
4 6 8 10 12 15
PIER DIAMETER
(in.)
20 6 9 12 12 12 15
24 9 9 12 12 15 15
28 9 12 12 15 15 18
32 9 12 12 15 15 18
36 9 12 15 15 18 (b)
40 12 12 15 15 18 (b)
46 12 15 15 18 18 (b)
60 12 18 18 18 (b) (b)
(a) The average soil is assumed to have a bearing capacity of approximately 4,000 psf.
(b) Requires special design.
26
Figure 2–3. Typical foundations for greenhouses.
A. PIPE FOUNDATION
Greenhouse frame fastened to sill
with anchor
Bolt sill to bearing plate
Weld bearing plate to pipe
Galvanized steel pipe
Pressure treated skirt board
2" Foamed
polystyrene
board or
equiv. in
ground 12"
9" Dia. Poured concrete
Below
frost
24" min
12"
B. CONCRETE PIER FOUNDATION
Greenhouse frame
Frame anchor
2" Foamed
polystyrene board or
equiv. in ground 12"
3/8" Dia. Steel
reinf. rod
Concrete pier
Conc. footing
Below
frost
24" min
12"
8" min.
C. CONCRETE MASONRY WALL ON POURED CONCRETE FOOTING
Frame anchor
2" insulation board
Two coats of hot
bituminous material or
Portland cement plaster
Gravel backfill
Drain tile around footing
Greenhouse frame
Bolt sill to conc. block foundation
Top of block wall
12" above grade
Below frost
24" min
16"
Concrete
footing 8"
Note: All greenhouse footings
should be below frost or 24"
minimum depth. Consult local
building codes if they apply.
D. ALTERNATE POST FOUNDATIONS FOR PIPE FRAME GREENHOUSES
Board
insulation Coupling
Pressure treated
skirt board
Drive to min.
depth of 30"
Post
Grade
Note: A driven post provides
limited resistance to uplift.
Post
anchor
Frame
anchor
Pressure
treated wood
post
Poured concrete or 2" x 4" x 8"
pressure treated lumber spiked
to post.
Board
insulation
Coupling
Pressure
treated skirt
board
6"
1/4" steel plate
or 2 1-1/2" x 1-1/2" x 1/8"
steel angles welded to pipe
27
FRAME
Materials
Wood, steel, aluminum, and reinforced concrete
have been used to build frames for greenhouses.
Some frames use combinations of these materials.
Wood must be painted to protect against decay and
to improve light conditions within the buildings.
Preservatives should be used to protect any wood
in contact with soil against decay, but they must be
free of chemicals that are toxic to plants or humans.
Creosote and pentachlorophenol-treated wood
should not be used in greenhouses. Chromated
copper arsenate (CCA) and ammoniacal copper
arsenate (ACA) are waterborne preservatives that
are safe to use where plants are grown. Redwood
or cypress heartwood has natural decay resistance
but is becoming more difficult to obtain at prices
competitive with other materials.
Wood frames include post, beam, and rafter systems,
posts and trusses, glued laminated arches, and rigid
frames. Steel and aluminum are used for posts,
beams, purlins, trusses, and arches. Frames may
be entirely aluminum or steel or a combination
of the two materials. Aluminum is comparatively
maintenance free, as is hot dipped galvanized steel.
White paint on either material will improve the light
conditions in a greenhouse. Both materials must be
protected from direct contact with the ground to
prevent corrosion. The rate of heat loss through
steel or aluminum is much higher than through
wood, so metal frames may need special
insulation.
Composite materials are sometimes used, such as a
trussed beam of wood and steel or a member made
of glass fiber-reinforced plastic. The use of reinforced
concrete is limited to foundations and low walls. The
large size of available reinforced concrete framing
members limits use in such elements as beams and
arches.
Structural Form
The greenhouse with a straight sidewall and a gable
roof is the most common shape and has advantages
in framing and in space utilization. Post and beam,
post and truss, and arches are used to form the gable
structure. Some typical structures are shown in
Figure 2–4 below. Figure 2–5 on the next page shows
a jig and roller that can be used for bending pipe
conduit to form arches.
The part circle arch or quonset-type frame is easily
formed from rolled sections of steel or aluminum
or from glue-laminated wood. It makes better
structural use of frame material than a gable
building but, in some applications, there is unused
space because of sidewall curvature.
The gothic arch frame can be formed from metal
sections or glue-laminated wood. With proper
design, it can provide adequate sidewall height
without loss of strength. Any of the forms can be
used to build a single greenhouse or a large range of
gutter-connected units.
Detailed plans for greenhouse structures incorporate
support systems for movable thermal blankets as a
part of the frame. The support system contributes
Figure 2–4. Some typical greenhouse frames.
Arch Roof
Gable Roof
Hoop Gable Frame
Trussed Roof
28
to the strength of the frame and may be installed if
economically feasible.
Structural Joints
A structural frame is only as strong as its weakest
joint. There must be adequate fasteners at sill, plate,
and ridge to ensure a safe building. Fasteners must
resist loads from any direction—a snow load acts
downward, but a wind load can act in any direction.
Sills should be bolted to the foundation and metal
connectors used to secure the wall frame to the sill.
Use metal connectors at the plate and ridge, also. Do
not rely on nails for structural joints in wood.
GUTTERS AND DOWNSPOUTS
Most greenhouse gutters for multiple span structures
are designed to provide a safe walkway for roof
erection and maintenance. Some gutters also act as
beams to transfer roof loads to columns. They are
generally more than adequate for carrying rainwater
and snow melt.
The downspout should be sized first. Once the
downspout is sized to adequately handle expected
rainfall intensity, calculate the size of gutter and
drain pipe needed to handle rainwater runoff.
Figure 2–5. Jig and roller for bending conduit and pipe for greenhouse arches.
20' length 1" dia. thick
wall conduit
2" x 4" x 6" long
hardwood blocks
secure to floor
7'0" radius
13'6"
6"
1'3"
1. Set up jig on wood floor
2. Make end bends with pipe bender
3. Use 3' length of steel rod or pipe to
make final bend.
A. JIG FOR MAKING CONDUIT ARCH
B. ROLLER PIPE BENDER
36"
18"
1/2" 6" 3"
drill
Weld
7" x 12.25 lb/ft
steel channel 2" x 11" x 1/4"
steel strap
3/4" Machine bolt
1-5/8"
3-3/4"
1. As set will bend 21' length of 3/4" Dia.
steel pipe to form 14' wide frame.
2. Use pipe bender to form straight end
sections.
3. Adjust center wheel for other frame spans.
4" Dia. x 1-3/4" wide
steel caster wheel
3/4" bore
29
One rule of thumb for sizing downspouts and
gutters is 1 in.2 of downspout cross section for
each 100 ft.2 of covered area to be drained, and a
gutter diameter 1.5 in. larger than the downspout
diameter. These sizes should safely handle a rainfall
intensity of 3 in./hr. The duration of a storm of that
intensity will vary with return period and location.
For example, at Hartford, CT, an 11-minute storm
expected to be experienced once in 2 yrs. (a return
period of 2 yrs.) would have an intensity of 3 in./hr.
A 26-minute storm in Hartford with a return period
of 10 yrs. would also have an intensity of 3 in./hr. In
St. Louis, MO, a 22-minute storm with a 2 yr. return
period, or a 40-minute storm with a 10 yr. return
period, would have an intensity of 3 in./hr.
A 1-in. rainstorm on a 1-acre greenhouse will
produce 1 acre-in. of water (3,630 ft.3 or 27,154
gal. water). As much as 95% of the water will run
off the roof (the rest will evaporate) and must be
disposed of in a safe manner. If irrigation water is
expensive, it may be worthwhile to collect rainwater
in a storage tank or small pond. The drain pipe
size needed to carry rainwater away from the
greenhouse depends on the area drained, the slope
of the pipe, and the pipe material. Figure 2–6 on the
next page gives the carrying capacities for smooth
PVC and corrugated PE drain pipe.
Gutters can be level but usually have a slope of
8 in./100 ft. or less. Within the greenhouse, the drain
pipe should slope from 8–12 in./100 ft. Outside the
greenhouse a steeper slope can be used, depending
on the topography. Drain pipes are seldom laid on
slopes greater than 3 ft./100 ft. (0.03 ft./ft.).
The following example greenhouse, which will be
referred to throughout the book, is 96 ft. x 192 ft.,
with a ground area of 18,432 ft2. Each gable roof
spans 24 ft., so each gutter serves a ground area
of 4,608 ft2. Using the rule above, the downspouts
should have a cross sectional area of 23 in.2 (a
circular section with a 5.5-in. diameter) if located at
each end. The gutter should be a semi-circle with
a 7-in. diameter or any other shape with a cross
sectional area of 19 in.2. Another option would be to
have four downspouts, each serving 1,152 ft.2. The
downspouts would then have an area of 11.5 in.2 (a
4-in. diameter). The gutter would be a semi-circle
with a 5.5-in. diameter or a 12 in.2 cross sectional
area. If downspouts are placed at the ends of the
gutter, they can be connected to a buried drain line
along each gable wall. If this pipe runs the length of
the greenhouse, it will have to be large enough to
carry the rainwater from one-half the surface area
(48 ft. x 192 ft. = 9,216 ft.2). A PVC pipe installed at a
slope of 8 in./100 ft. would need an 8-in. diameter.
A 10-in. diameter pipe would be needed to carry the
water away from the total greenhouse area.
COVERING
Materials
The light transmittance of greenhouse glazing
materials should be considered when selecting the
covering material. Figures 2–7 and 2–8 on page
31 show the spectral transmittance of several rigid
and film glazing materials. The solar spectrum is
included for comparison.
Glass is still a common glazing material, and use of
large panes has reduced the shading from glazing
bars. Panes 30" x 36" are in use; Dutch houses
have panes extending from valley to ridge. Dutch
houses have the advantages of few parts and easy
construction. Large panes, bar caps, and strip
caulking have reduced labor required for installation.
Three plastic film materials are in use as greenhouse
covers. Polyethylene (PE) film has been used in
large quantities for several years. It has high light
transmittance, except in the ultraviolet region of
the spectrum, and is transparent to infrared or long
wave radiation. Its chief disadvantage is its lack of
durability—it will last about nine months if put on
in October, but may not last until the fall if put on in
the spring. There are ultraviolet-inhibited (UVI or
weatherable) PEs that will last longer, but in general
they will fail after less than 18 months of exposure.
Copolymer films will last two to four years. Infrared
transparency can result in significant radiation
cooling if there is no condensation on the film. The
latest PE film introduced is infrared-blocking and,
thus, has a lower rate of heat loss to clear skies. The
majority of greenhouses constructed recently have
used copolymer films. Some plastics have a wetting
agent that keeps moisture droplets from forming.
30
Figure 2–6. Sizing drain pipe for rainwater and snow melt removal. Flow rate (
gpm)
10,000
9,000
8,000
7,000
6,000
5,000
4,000
3,000
2,500
2,000
1,000
1,500
900
800
700
600
500
400
300
200
150
100
60
80
40
30
20
10
0.001
1.25
0.002
2.5
0.004
3.5
0.005
6
0.007
8
0.01
12
0.02
24
0.03
36
Slope (ft./ft.)
Slope (in./100 ft.)
Greenhouse ground area (sq.ft.)
Total
greenhouse
area
1/2
greenhouse
area
PVC
Corrugated PE
320,820
288,940
256,655
224,575
192,495
160,410
128,330
96,246
80,250
64,165
32,080
48,125
28,875
25,665
22,460
19,250
16,040
12,830
9,625
6,415
4,810
3,210
1,925
2,565
1,280
960
31
Figure 2–8. Spectral transmittance of selected film greenhouse covering materials.
ULTRAVIOLET
GLASS SUN'S RADIATION
FIBERGLASS
RIGID P.V.C.
ACRYLIC
POLYCARBONATE
WAVELENGTH, NANOMETERS (NM)
RELATIVE ENERGY
VIOLET
100
90
80
70
60
50
40
30
20
10
0
300 350 400 450 500 550 600 650 700 750 800
BLUE GREEN YEL. ORAN. RED
Figure 2–7. Spectral transmittance of selected rigid greenhouse covering materials.
100 POLYVINYL
90
80
70
60
50
40
30
20
10
0
ULTRAVIOLET VIOLET BLUE GREEN YEL. ORAN. RED
POLYETHYLENE
POLYVINYL FLUORIDE
U.V.
POLYETHYLENE
RELATIVE ENERGY
WAVELENGTH, NANOMETERS (NM)
300 350 400 450 500 550 600 650 700 750 800
32
PE film is available in thicknesses of 1–8 mil. (1 mil.
= 0.001 in.) and in widths up to 50 ft. folded or 16 ft.
unfolded. For a double layer application, use 4 mil.
PE on the inside and 4 or 6 mil. PE on the outside.
Use 6 mil. for single layer applications. Use only
unfolded PE if possible because film will fail first
at the folds. It may be desirable to replace PE film
annually on greenhouses where high light-requiring
plants are grown.
Polyvinyl chloride (PVC) is available as a film or
as a rigid panel. Present PVC films will last more
than two years if carefully applied. PVC with an
ultraviolet inhibitor has lasted up to four years.
One disadvantage of PVC film is the difficulty in
keeping it clean to maintain light transmittance. The
static electricity developed tends to attract dust. It
is available in 4–8 mil. thicknesses and in widths
of 36–72 in. The narrow width of vinyl film is a
disadvantage in covering large areas.
Rigid panels of PVC are inexpensive, easy to apply,
and, when new, have high light transmissivity.
Their light stability is affected by heat build-up in
the panel. If they are carefully applied and partially
shaded during hot weather to prevent heat build-up,
they will provide good service. They are available in
24–36 in. widths and in lengths up to 24 ft.
Fiberglass-reinforced plastic (FRP) panels have been
used for years. They have transmissivities equal to
glass and are easy to apply. Problems with surface
erosion and discoloration, with resulting loss in light
transmission, have limited their use in areas of low
winter light. They are available in 24–57 in. widths
and in lengths limited only by transportation.
Structural panels of double wall glass or plastic
are available for energy conservation. Double wall
“thermal insulating” glass panels have not been
used to any great extent in greenhouse construction
because of cost and the difficulty of sealing panels.
Extruded structural panels of acrylic and
polycarbonate are being used for greenhouse
glazing. They are available in widths to 96 in. for
some products and lengths to 39 ft. Because of
thermal expansion, these panels require special
framing details to maintain edge seals. Some
suppliers have specific architectural extrusions
for mounting panels. The second layer of glazing
reduces heat loss from the greenhouse and also
reduces light transmission into the greenhouse. Each
layer will reduce light transmission by about 10%.
Table 2–3 on pages 33–34 gives general
characteristics and price ranges for the more
commonly used glazing materials.
Application Systems
Rigid plastic panels are easily applied to any
conventional gable frame with the addition of
horizontal supports (purlins) across the top of the
glazing bars. Less framing is required for a fiberglass
or double wall plastic panel covering than for glass
because the panels are much stronger in bending
than glass. The panels should be held away from
purlins to prevent condensate drip. Follow the
manufacturer’s directions for best results. Typical
glazing systems are shown in Figure 2–9.
Figure 2–9. Typical glazing systems for greenhouses.
Bar Cap
Glass Pane
Caulk Sealant
Roof Bar
Roof Bar to
Purlin Bolt
Condensate
Gutter
Typical Glass Glazing on
Aluminum Roof Bar
Corrugated
Polycarbonate
Glazing
Spacer
Tek Screw or Ring Nail
Purlin
Fiberglass or Polycarbonate Glazing
on Wood Purin
Top Film
(double sheet)
Lock ring
in place
Outside
of frame
Hex head
bolt & nut
Baseboard
Acrylic or Polycarbonate
Structured Sheet
Two Piece Aluminum
Extrusion Connector
Support Frame
Structured Sheet Glazing System
33
Table 2–3. Transmittance of solar and thermal radiation through greenhouse glazing material. (a)
GENERAL TYPE COMMENTS

TYPICAL
TRADE
NAMES
LIGHT (PAR)
TRANSMITTANCE
(%)
THERMAL
TRANSMITTANCE
(%)
ESTIMATED
LIFETIME
(YEARS)
$/FT.2 (b)
GLASS Advantages
Excellent transmittance
Superior resistance to
heat, U.V., abrasion
Low thermal
expansioncontraction
Readily available
Transparent
Disadvantages
Low impact resistance
unless tempered
High cost
Heavy
Double strength
Insulated units
Solatex
88
75–80
91–94
3
<3
<3
25+
25+
25+
0.75–2.00
3.50–7.00
1.25–3.50
ACRYLIC Advantages
Excellent transmittance
Superior U.V. &
weather resistance
Will not yellow
Lightweight
Easy to fabricate on
site
Disadvantages
Easily scratched
High expansioncontraction
Slight embrittlement
with age
High cost
Relatively low service
temperatures
Flammability
Single wall
Plexiglass
Double wall
Exolite
93
87
<5
<3
20+
20+
1.50–2.00
2.00–3.50
POLYCARBONATE Advantages
Excellent service
temperatures
High impact resistance
Low flammability
Disadvantages
Scratches easily
High expansioncontraction
Single Wall
Dynaglas
Lexan
Corrugated
Macrolux
Corrugated
Double wall
Macrolux
PolyGal
Lexan Dripgard
91–94
83
<3
23
10–15
10–15
1.25–1.50
1.75–2.50
(a) Solar radiation wavelength from 0.38–2.5 microns. Thermal radiation at approximately 10 microns, the wavelength at
maximum radiation from surfaces at 70°F. Data are for thicknesses used for greenhouse glazing.
(b) Includes support extrusions and attachments but not installation labor.
Adapted from manufacturers' data. Local prices may differ. No endorsement is implied where trade names are given.
34
GENERAL TYPE COMMENTS
TYPICAL
TRADE
NAMES
LIGHT (PAR)
TRANSMITTANCE
(%)
THERMAL
TRANSMITTANCE
(%)
ESTIMATED
LIFETIME
(YEARS)
$/FT.2 (a)
FIBERGLASS
REINFORCED
POLYESTER
Advantages
Low cost
Strong
Easy to fabricate and
install
Disadvantages
Susceptible to U.V.,
dust, and pollution
degradation
High flammability
Lascolite
Excelite
Filon
Double wall roof
panels
90
60–80
< 3 10–15
7–12
0.85–1.25
5.00
POLYETHYLENE
FILM (PE)
Advantages
Inexpensive
Easy to install
Readily available in
large sheets
Disadvantages
Short life
Low service
temperature
Tufflite III 603
Standard UV
Tufflite Dripless
703 Fog Bloc
Sun Saver
Cloud 9 Tufflite
Infrared
Dura- Therm
< 85 50
50
< 20
3
3
3
0.06
0.07
0.09
POLYVINYL
CHLORIDE (PVC)
CORRUGATED
Advantages
Durable
Good fire rating
High impact strength
IR inhibitor
Disadvantages
Lower light
High expansion
Yellows with age
Only 4 ft. widths
Bio 2 84 < 25 10+ 1.00–1.25
(Table 2–3 continued)
* All plastics described will burn, so fire safety should be emphasized in greenhouses covered with such materials.
(a) Includes support extrusions and attachments but not installation labor.
transmittance
available
35
The load carrying capacity of fiberglass or double
wall plastic panels can be increased by applying
them to a curved roof frame such as a quonset
or gothic arch. This allows arch or shell action
to contribute to the strength of the system.
Correct design as an arch or shell will permit safe
construction with a minimum of frame.
There have been many systems developed to
apply and fasten single and double layers of film
plastics. Rafter lengths that fit available widths
of layflat or unfolded film should result in fewer
problems during the life of the film. Batten strips
can be used with wood rafters or arches. Covered
cables or wire can be used with pipe or extruded
metal frames. Fans used to pull a partial vacuum or
create positive pressure in the house can be used to
reduce “flapping” from wind. Figure 2–10 shows
the use of a front end loader or fork lift for placing
polyethylene film on greenhouses.
Double layers of film reduce conductive heat loss
and condensate on the inside surface. Double
battens can be used to apply two layers to the
outside of a frame. The second layer can also
be applied to the inside of the frame, but this is
generally more difficult and, if applied to the ceiling,
may negate insurance coverage.
The air supported “bubble” house has been used
generally as a temporary structure. It has advantages
of low cost and fast erection, but problems with
openings, warm weather ventilation, and possible
power loss have prevented it from becoming a
permanent greenhouse. A more popular system is
the two-layer air inflation method, a combination
of structural frame and film that results in a double
film cover with the air gap exceeding four inches
in some areas. This is the maximum gap suggested
for heat flow control, but the ease of application
and stability of the resulting structure more than
offset the slight increase in heat loss. The system is
illustrated in Figure 2–11 on the next page.
The equipment needed to inflate and separate the
film layers using this method includes a squirrel
cage blower with a capacity of 100–150 ft.3/min. at
0.5 in. of water column pressure, a damper to adjust
blower pressure, and flexible tubes to transfer air
between building sections. Blowers with lower
Figure 2–10. Polyethylene film roll handling device for roof application.
Safety chain
Fork Mounting Wood bearing
blocks
Length to fit polyethylene steel pipe
Welded steel channel frame
Bolt to bucket
Bucket Mounting
36
volume output can be used but do not have the
capacity to keep the plastic inflated when holes
develop.
A damper is needed on the blower intake to adjust
the inflation pressure. This can be a 4-in. diameter
electric box cover or piece of sheet metal. A piece of
4-in. dryer-vent tubing is used to connect the blower
exhaust to the plastic. An adapter made from a piece
of wood may be needed on the blower. Support
plates with dimensions of 6-in.2 and a 4-in. diameter
hole in the center are cut from 3/8-inch plywood and
used to attach the duct to the plastic. The plastic is
sandwiched between two of these plates. Screws or
stove bolts hold the plates together.
Fire safety is important in the planning and
operation of any facility, and becomes even more
important if plastic glazing materials are used. All
organic plastics will burn, some at a much faster
rate than others. Three properties are generally used
to rate the fire potential of materials: flame spread,
burning rate, and smoke generation. Standard tests
which determine these characteristics have been
developed by Underwriters Laboratories (UL) and
the American Society for Testing and Materials
(ASTM). When comparing materials with respect to
fire safety, it is important to know whether the same
testing procedure was used for each. For example,
ASTM Test No. D-635 tests for burning rate, and
both ASTM E-162 and E-84 test for flame spread.
UL-94HB tests for horizontal burn, and ASTM E-662
for smoke generation. Building codes specify those
tests considered to provide most useful results. One
state building code lists ASTM E-84 as the standard
for determining surface burning characteristics of
building materials; therefore, to satisfy that code,
the material in question must have been tested by
an independent laboratory and the results made
available to the public.
Figure 2–11. Details of an air-inflated polyethylene-covered greenhouse.
Polyethylene
Plastic
Flower Pot
Clothes Dryer
Duct
Fan Installation
Squirrel Cage
fan draws
in outside
Install adjustable air
damper to control
maximum air pressure
between film layers
Polyethylene
Fastening
Grade
Frame
Member
Post
Skirt Plank
Double Layer
Polyethylene
1x2
6d nails
every 12"
37
Construction Costs
Greenhouse construction costs vary considerably,
and cost comparisons should not be made unless
detailed knowledge of services and materials
provided is available. Comparing the costs of a glass
glazed house with that of a PE film house is of no
value unless all the specifications for each house
are compared and related to the intended use of the
greenhouse.
Costs are often quoted on the basis of dollars
per square foot of covered area. Cost per square
foot of bench or bed area might be more useful,
since it would reflect more closely the production
potential of the house. Comparisons on the basis
of net growing area will also emphasize bench
arrangement for maximum use of enclosed space.
The type of structure that should be purchased
depends on factors such as the crops to be grown,
the length of service the grower desires for the
structure, the seasons the greenhouse will be used,
and the amount of growing space needed. The
grower should also consider economic factors such
as interest, tax rates, and maintenance costs.
Environmental control systems cost about the
same for all types of structures. The systems
described herein are automatic and have remote
sensing devices, with values based on an average
installation. Table 2–4 on the next page gives a brief
summary of construction costs, including costs for
environmental control.
Reference
NMGA. 1981. Greenhouse Design Standards. National
Greenhouse Manufacturers Association.
38
CONSTRUCTION COSTS
Materials
$ / ft.2
Erection
Labor Cost
$ / ft.2
Total
$ / ft.2
Conventional Glass Greenhouse
Concrete foundation—galvanized
frame—truss roof
7.00–9.00 3.00–4.00 10.00–13.00
Ridge & Furrow Greenhouse
Concrete piers—galvanized steel frame—
double poly covering
2.50–4.50 1.50–2.00 4.00–6.50
Steel Pipe Arch Greenhouse
Pipe foundation—1¼" galvanized
pipe—polycarbonate structured
sheet glazing
4.50–6.50 0.70–0.90 5.20–7.40
Steel Pipe Arch Greenhouse
Poly cover—pipe foundation—
1¼" galvanized pipe
1.50–2.50 0.50–0.70 2.00–3.20
Rigid Frame Wood Greenhouse
Poly cover—wood post foundation—
clear span
1.00–1.50 0.50–0.75 1.50–2.25
(Site preparation will cost $0.75–1.00 / ft.2; driveway and parking area, $0.35–1.00 / ft.2; 3" concrete floor,
$1.00–1.25 / ft.2; and benches, $1.50–$4.50 / ft.2of
floor area.)
ENVIRONMENTAL CONTROL
($ / ft.2 of Greenhouse Floor Area, including labor)
Ventilation
Fans with shutter, thermostat, and housing 0.95–1.35
Heating
Oil- or gas-fired hot air
Oil- or gas-fired steam or hot water
1.00–1.75
1.50–2.50
Electric
Supply; materials and labor 1.00–1.50
Water
Materials and labor 0.75–1.25
Heat Retention System
Manual
Motorized
0.50–1.00
1.25–3.00
Fog System 0.50–1.00
Environmental Control Computer 0.75–1.25
(a) 1994 prices; accurate cost estimates are possible only if a detailed plan of the greenhouse is available.
Table 2–4. Greenhouse construction costs. (a)
39
Chapter 3:
Materials Handling
Introduction
The production of most greenhouse crops is highly
labor intensive. For example, in a bedding plant
production system, the medium and containers
used to grow plants may be handled a dozen times
from initial delivery to drop off at the garden center.
In a recent survey, bedding plant growers attributed
approximately 25% of plant production costs to
labor.
The use of labor and equipment for greenhouse
production must be examined as part of a system
rather than as unrelated elements. Each task,
whether performed by hand or by machine, is
related to other tasks in the growing process.
Operation size, container type, production schedule,
available capital, and other factors enter into
materials handling decisions.
Mechanization in the greenhouse industry has
developed slowly due to a lack of standard growing
methods, variability of the physical arrangement of
growing facilities, and the large varieties of crops
grown. Several companies produce a wide range
of equipment that can increase the efficiency of
greenhouse operations by applying basic industrial
principles. This chapter will review some of these
principles and indicate how to best use such
equipment.
Operations Analysis
Operations analysis is a technique for studying a
system which utilizes simple diagrams, charts, and
plans to identify components and relationships for
proposing changes for improvement. An operation
process chart shows subject, type, and method.
“Subject” is the operation or system being studied;
Figure 3–1. An operation process chart for the transplanting of a bedding plant production system (adapted from
Ross,
D.S., et al., 1974).
Transport
Operation
Relay
Inspection
Storage
Market flats
from storage
Seed flats from
germination
Move flats convenient
to transplanter
Transplanter sets flat
on transplant table
Level media in flat
Move seed flats to
transplant area
Transplanter takes seedlings
from seed flat
Inspect for size and quality
Transplant seedlings
Flats are set on conveyor
Waterer
Seed flats and waste removed
Flats by conveyor to stacker
Flats stacked on pallets
Pallets moved to greenhouse
Flats unloaded from pallet
Flats moved across greenhouse
Flats placed on ground
to growing
Operation Chart
Symbols
4401
“type” refers to material, person, or machine; and
“method” tells whether the present, proposed, or
revised system is being shown. An example of an
operation process chart for the transplanting phase
of a bedding plant operation is shown in Figure 3–1
on page 39. When using an operation process chart,
consider the following questions: 1) Can events be
combined? 2) Can inspections be eliminated? and 3)
Can delays be eliminated or converted to storages?
A flow process chart is used to study an operation
in detail, so each step is listed regardless of its
importance. Information on direction, distance
traveled, and method of movement may be used for
determining materials handling options. Unit times
may be useful data if individual items, such as pots
and plants for transplanting, are being processed.
Total times, such as greenhouse growing time for
different cultivars or species, may be important.
Data gathered should include labor, machine and
space use, utilities, grade factors, environment,
and any other information that will contribute to
understanding and improving the operation.
Figure 3–2 shows another form of flow diagram
used to indicate equipment needs.
A plan layout is used to show either an existing
system or one rearranged for improved operation.
It should show the site with orientation, wind
direction, service roads and utilities, and a floor
plan with walls, columns, etc. Figure 3–3 on page
41 shows a plan layout for a bedding plant facility.
Plan layouts should be developed based on the
following: 1) Material from one operation should
be placed where it can be picked up easily for the
next operation; 2) The distance an operator must
move to obtain or deliver material should be kept
to a minimum; and 3) Time spent by a machine
performing an operation which does not require the
operator’s immediate attention is idle time for the
operator and should be put to other use.
The greenhouse plant production rate depends
on efficient use of labor, work and storage space,
transportation, and all other facilities that contribute
to the operation. In a well-planned range, all
Figure 3–2. Flow diagram—soil mix preparation.
SOIL
(bulk)
PEAT
(bags)
VERMICULITE
(bags)
Bucket loader
SHREDDING
Shredder w/ screen
PASTURIZATION
Chemical
Bucket loader
Bucket loader
BATCH MIXING
2 yd. Ribbon Mixer
STORAGE
(bulk)
POT FILLING
Belt Conveyor Conveyor & Feeder Bin
Scale
LIME
FERTILIZER
Bucket loader Bucket loader
41
Figure 3–3. Floor plan of a bedding plant facility showing activity areas now in operation.
processes and operations must be integrated to
permit movement with minimum interruptions.
Some simple aids can help in planning or analyzing
a system. An operations chart shows points at
which materials enter the process and the sequence
of operation and inspection—it examines the
entire process. A flow process chart shows all
operations needed to carry out a process—it will
show transportation, storage operations, delays,
and inspections occurring during a process. It can
show information such as time required to perform a
procedure and distance traveled to complete a task.
A process as a part or a complete production system
can be described by a few types of steps in various
combinations. An “operation” is any activity that
alters or adds to the physical characteristics of a
material or object; an example would be mixing
rooting media. “Transportation” is any movement
of material from one place to another, unless such
movement is an integral part of the process; an
example would be moving pot plants from the
greenhouse to an order assembly area. “Inspection”
is an examination by an individual to determine
quality or quantity or to verify conditions; an
example would be checking flowering plants to
determine growth stage. “Storage” is a desirable
interruption of activity; an example would be
mixed media stored for later use. “Delay” is an
undesirable interruption activity; an example would
be transplanters waiting for seedlings. A “combined
B. Support buildings layout showing work and storage areas and equipment.
Flat holding area is removed when marketing begins.
Germination Conditioning
Transplanting Room
Customer
Entrance
Flat Holding
Conveyor
Soil Mixer
Soil Mix
Storage DRY
Flat STORAGE
Filler
Flat Storage
Seeding
A. Plan Layout
GROWING HOUSES
Growing House
Perennials
Soil Pile
Customer
Entrance
Seeding
Transplanting
Germination
Soil Mixing,
Flat Filling,
Storage
423
operation” could consist of stored bulbs continuing
to develop or plants growing in the greenhouse.
Process charts can be built around materials,
people, or machines. They may show movement of
materials and all operations performed on them, the
movements of people in producing a given item, or
the movement and actions of a machine.
Materials Handling Basics

ELIMINATE OR COMBINE TASKS
When reviewing present growing operations,
look first for tasks or jobs that can be eliminated.
Examples include frequent spacing of containers,
double handling of materials, and dudding (the
replanting of vacant cells in cell packs). Evaluating
the cost of doing these jobs can determine whether it
will pay to change the growing method.
Sometimes tasks can be combined to increase labor
efficiency. For example, a screen attachment on a
shredder can eliminate extra handling, and a steam
line on a concrete mixer enables it to pasteurize and
mix soil in one operation. Each handling of materials
that is eliminated will save money.
ELIMINATE LABOR PEAKS
AND VALLEYS
The work load in a bedding plant operation usually
peaks during the spring. Planting, growing, and
shipping all take place at the same time. Extra labor
is hired to handle the extra work. At other times of
the year, usually during the winter, work is slack
and labor is either let go or kept busy with cleanup
or maintenance. Consider shifting some of the
work load by mixing soil, filling pots or flats, and
even dry-seeding during the winter slack period.
Equipment maintenance can also be carried out
during slack periods.
MAKE MOVEMENT CONTINUOUS
Handling efficiency is generally highest when
materials travel in a straight line with minimum
interruptions and backtracking. This works well
for potting and transplanting. Use belt or chain
conveyors to connect the pot/flat fillers, dibble
machine, and potting operation. Roller conveyors or
carousels can be used as accumulating sections.
Timing the equipment to the rate of workers is
important. Machines with variable-speed motors can
be used to pace workers and increase output.
USE AN ASSEMBLY LINE
FOR PLANTING
An assembly conveyor, on which materials or
plants to be worked with are carried, is often used
in potting and transplanting operations. Filled
containers are fed at one end of a slow-moving
conveyor, and workers standing or sitting beside the
belt perform potting or transplanting as containers
move by. Variable-speed motors should be used to
adjust belt speed for different conditions. Assembly
line production is usually greater than other
production methods because workers do not have
to search for materials and the belt keeps a constant
rate of materials flowing.
MAKE MATERIALS EASILY
ACCESSIBLE
Storage is a necessary part of a plant-growing
business. In most operations, a considerable amount
of time and labor is spent moving materials and
supplies from one location to another. Several basic
guidelines should be followed when developing the
layout:
1. Move materials as short a distance as possible.
2. Keep delivery and shipping traffic out of the
work area.
3. Store materials in or on units that are easy to
move—pallets, bins, boxes, bundles, and bags.
4. Place materials stored outside in an area with
good drainage and easy equipment access.
5. Store labels, seeds, hardware, etc., in bins or
racks for inventory control.
6. Move materials as close to their point of use as
possible.
CLEARLY MARK MATERIALS
With the hundreds of varieties of plants and many
types of supplies used, this is an important time
consideration. For plants, use printed labels on pots
or flats. Plants located in beds or blocks in the field
can be marked with water repellant signs. Tags,
seeds, hardware, and spare parts should be located
in one area and clearly labeled. Racks or bins work
43
well for this. In large operations, a computer should
be used to keep track of the quantity and location of
plants. Software programs are available from several
sources.
SELECT EQUIPMENT WHICH
PREVENTS “BOTTLENECKS”
In developing materials handling systems, especially
those using continuous flow, make sure that
equipment use does not create a situation where all
operations must halt to await completion of part of
the process, or a “bottleneck.” The rate that materials
are fed into the system must match the rate of use
and the rate of removal.
When automated equipment is part of an assembly
line, such as a potting or packing operation, the
conveyors, bin feeders, and pot separators must
be timed to produce an even flow. This is usually
performed by variable-speed motors.
In a manual system, such as transplanting bedding
plants, removal of planted flats should be at the
same rate they are being planted to reduce waiting
time for materials to be received or removed.
MECHANIZE REPETITIVE
TASKS FIRST
Lifting and carrying heavy objects is tiring and
reduces productivity. Where possible, materials
heavier than 50 lbs. should be moved mechanically.
Examples include: 1) using a fork lift to load and
unload bagged fertilizer, lime, and peat-lite mixes;
2) using a conveyor to lift plants being shipped
from the ground to truck height; and 3) using carts
or wagons to move containers in the growing area.
Repetitive, tedious, time consuming jobs should
generally be the first to be mechanized.
USE GRAVITY TO MOVE MATERIALS
Equipment that utilizes gravity is usually less
expensive than power equipment, and operating
costs are lower because motors are not needed. Bulk
materials can be fed by gravity from bins or hoppers
to potting and canning machines. Proper design and
construction is needed to keep materials flowing
freely.
Containers of plants can also be moved to and from
the growing area using gravity conveyors, if proper
elevation differences exist. Several greenhouse
operations in the U.S. and Europe have been built
on hillsides, with the potting operation located at
the top and the shipping area at the bottom. Gravity
conveyors carry plants from the headhouse to the
growing area. When sold, plants are carried on
conveyors to the shipping area at the lower level.
Plants in smaller containers are usually placed in
flats or on pallets to make movement easier.
STANDARDIZE CONTAINERS,
MIXES, AND METHODS
Many sizes of flats and pots are used in the bedding
plant industry. Most sizes are made by several
manufacturers using slightly different materials and
molds. Because of the large selection, development
of equipment for the industry has been slow. Several
trade associations and the Nursery-Greenhouse
Mechanization Committee of the American Society
of Agricultural Engineers are attempting to develop
standard container sizes that may be adopted by the
industry. Limit the number of container sizes and
types to reduce inventory and time spent making
changes in equipment to accommodate different
containers.
Where possible, limit the number of growing mixes
used. Bin shapes and construction and conveyor
equipment may have to be changed to get materials
flowing freely. Each mix has its own angle of repose.
Bridging of the mix in bins is more common where
materials such as peat, sawdust, and wood chips are
used. Vibrators or agitators may be needed to get the
mix to flow.
SPECIALIZATION INCREASES
EFFICIENCY
Greater efficiency can be obtained where only one
crop is grown, such as plug-type bedding plants
or 4-in. chrysanthemums. Equipment set up to
handle one size container year-round eliminates the
time and problems related to adjusting machines
for different container sizes and rates and is less
expensive to install. Specialization can also be
effective in organizing labor forces. Training
individuals to do specific jobs or operate particular
pieces of equipment will increase output.
4445
PROVIDE A SAFE, COMFORTABLE
WORKING ENVIRONMENT
Increased productivity can be obtained by providing
a work area where materials and supplies are
conveniently located. Adequate lighting should be
provided (40–50 foot-candles). Minimum standards
should be met—levels can be measured with an
inexpensive light meter.
Work areas should be clean of debris, waste, and
hazards. Electrical equipment should be grounded,
and ground fault interrupters used on portable
equipment. Safety equipment such as eyeglasses,
earplugs, and gloves should be available to
employees.
Covered areas should be provided for operations
such as potting, canning, and maintenance. Heat
should also be provided to maintain a minimum
of 60°F in the work area. Unit heaters or infrared
heaters work well for this application.
Equipment Selection Basics

UPDATE OLD EQUIPMENT
With new methods and technological advances,
some equipment depreciates and becomes obsolete.
Evaluate present machinery to see if it should be
replaced. New equipment may increase output per
man hour, improve product quality, and reduce
maintenance costs and downtime.
ALTERNATIVES TO PURCHASING
EQUIPMENT
Renting/leasing allows limited use of equipment
without a large investment. Sharing equipment such
as a shredder, potting machine, or sterilizer between
neighbors may be a viable alternative. Custom
potting and transplanting services are available in
some areas and may reduce costs or labor during
peak periods.
OBTAIN MANAGEMENT SUPPORT
In larger organizations, it is best to get the input and
support of management before proceeding too far in
updating equipment. This is valuable for obtaining
needed funds and resources.
Planning the Facilities

Planning can help avoid costly errors and is well
worth the time involved. It provides an opportunity
to arrange facilities for efficient space utilization, to
achieve higher production capacity, and to better
use labor. It should also permit designing facilities
for space changes and future expansion. Planning
involves examining the overall operation, from
the time materials are received until the time they
leave, and should include improved methods for
performing individual tasks. It is easiest to plan on
paper, where mistakes can be corrected and options
evaluated. See Worksheet No. 2, Appendix XII, for a
planning example.
SPACE REQUIREMENTS
Determine space requirements for production,
storage, work area, and equipment. This will help in
evaluating existing buildings and the possible sizes
of new structures.
Depending on the types of plants grown and the
containers used, production may take place on
floors, benches, trays, or racks. Floor production is
common with bedding plants, perennials, and larger
stock plants. A bottom heat system will provide a
warm root zone and automatic watering can reduce
labor requirements.
For crops that require more maintenance (pinching,
pruning, repotting) a bench system is more
convenient because plants are at a convenient
working height. Stationary benches are best for
retail sales areas. Either the traditional longitudinal
arrangement or the more efficient peninsular system
can be used. Typical bench widths are 4–5 ft. and
main aisle widths of 3–5 ft. or side aisle widths of
20–30 in. are common. Several arrangements and
types of construction are shown in Figures 3–4 and
3–5 on the following pages.
MOVABLE BENCHES
For production areas, movable benches increase
growing space 10–25% and can reduce labor in
greenhouses used for pot crops and nursery stock.
Narrow folding conveyors are available to move the
plants into and out of the growing area. An alternate
45
Figure 3–4. Greenhouse bench layouts: a) Longitudinal bench layout–59% growing area; b) Peninsula bench layout–
69%
growing area; c) Movable bench layout—81% growing area.
3'
A. Longitudinal bench layout−59 % growing area
50'
Bench
Aisle
Bench
30"
5'
43'
29"
B. Peninsula bench layout−69% growing area
50'
Bench
Aisle
3'
4'
5'
Aisle 18"
2'
C. Movable bench layout−81% growing area
50'
Aisle
Aisle
2'
30'
4'
13'
2' 5'
Fixed bench
Movable bench
4467
Figure 3–5. Greenhouse bench construction: a) Pipe frame with corrugated cement-mineral fiber board; b) Concrete
block,
wood frame with pressure treated plywood; c) Wood frame with wood; d) Wood frame with welded wire or expanded
metal.
C. Wood frame with wood
See 'A'
See 'A'
1/4" space
1" x 4"
1" Lumber sides
2" x 4"
3/8" CC Grade Exterior
Plywood Gusset both sides
A. Pipe frame with corrugated cement-mineral
fiber board
B. Concrete block, wood frame with pressure
treated plywood
3/8" Corrugated cementmineral
fiber board
3/8" Cement-mineral
fiber board
11 Ga. Galv.
Steel Corner
1-1/4" x 1-1/4" Split Tee at each Joint
1-1/4" Galv. Steel Pipe
1-1/4" Pipe Flange
10" Dia. x 12" Deep Conc. Pier
or set up legs on Level Patio Blocks
3/8" x 5" x 5" Galv. Steel
angle 2' O.C.
See 'A'
2" x 4"
Concrete Blocks
Use Redwood or
Pressure Treated Lumber
3/4" Pressure
treated plywood
D. Wood frame with welded wire or expanded
metal
See 'A'
See 'A'
See 'C'
1" x 4"
2" x 4"
1" x 4" x 14 Gauge or
2" x 4" x 12 Gauge Galv. Steel
Welded Wire
or Expanded Metal
1" Lumber sides
Use Redwood or
Pressure Treated Lumber
General Notes
1. Height from floor 30"–32"
2. Width−to suit, 4' max
3. Leg spacing 4' O.C. max.
4. All steel hot dipped
galvanized
See 'A'
2" x 4"
47
Figure 3–6. Movable benches and pallets can improve space use and labor efficiency.
design utilizes pallet trays 4–6 ft. wide by 6–16 ft.
long that are handled on roller conveyors, tracks,
or by a lift truck (Figure 3–6). Trays are moved to a
work area for transplanting, potting, and shipping.
The basic concept of the movable bench system
is to convert all but one aisle to growing space.
The bench tops are supported on pipe rollers and
allowed to move sideways 18–24 in., the width
needed for a work aisle. When there is a need to get
to a particular bench, other benches in the house are
pushed together, leaving an open aisle at the desired
bench. Only one side of the bench can be worked on
at a time. Because the benches move, connections for
water, heat, and electrical systems that are attached
to the bench are flexible. Benches as long as 200 ft.
can be moved easily by turning one of the support
rollers with a crank at the end of the bench.
There are many variations in bench design. Benches
can be fabricated of wood or metal with either a
solid or mesh bottom. Several manufacturers make
an aluminum extrusion that adapts to an expanded
metal bottom. A molded polyethylene grow tray is
also available. The support unit can be made from
pipe, tubing, or concrete blocks. The key to a smooth
working unit is to have metal surfaces for the pipe
rollers to move on.
Plans for 5- and 6-ft. wide benches are shown in
Figure 3–7 on the next page. Dimensions for other
bench sizes and aisle widths are shown in Appendix
VIII. To plan a system for a greenhouse, lay out a
cross section of the floor area on graph paper. Note
the size and location of existing side wall benches,
if any. These can usually remain in place. Place one
aisle next to a side bench. Generally, an 18-in. aisle
can be used with 5-ft. wide benches and a 24-in. aisle
with 6-ft. benches. Adjust the number of bench tops
and their widths to fill the remaining width of the
greenhouse.
RACKS
Where foliage plants or certain types of hanging
baskets are grown, a rack system with effective
coverage of over 100% of the floor area should be
considered. Several types of racks are shown in
Figure 3–8 on page 49.
Pallet System
Movable Benches
4489
Pipe is one of the best materials for a rack system.
Common galvanized or black water pipe can be
used, but a less expensive choice is slightly thinner
fence pipe. As most greenhouse manufacturers
now use it for their hoop houses, this may be a
good source. It can also be purchased through steel
companies or fencing suppliers.
Pressure treated lumber provides a low-cost,
maintenance-free system. Be sure that it has not
been treated with creosote or pentachlorophenol,
the fumes of which are toxic to most plants. Use
galvanized nails for longer service life. Space
between frames along the length of the rack system
can be 10–12 ft. unless large or heavy pots are
supported. The aisle between racks should be wide
enough for convenient access and plant handling;
2 ft. is a minimum, but a wider distance may be
needed if more light is desired.
Generally, racks are oriented to run north-south
within the greenhouse. This provides equal light to
all the plants as the sun crosses the sky during the
day. Most rack systems are supported on the floor,
and a solid footing is needed to keep them level. The
edge of a concrete walk or a buried solid concrete
block works well. Before attempting to support a
system from the greenhouse frame, be sure that it
will take the extra load. Most crops will add
4–5 lbs./ft2. (psf) to the structure. Because most
Figure 3–7. Plans for 5 ft. and 6 ft. wide movable benches.
1" Rough Lumber
(Wire mesh or expanded
metal may be substituted)
1/8" x 1" Steel Strap
1-1/2" Steel Pipe
Length of Bench
1/8" x 1" x 3"
Steel Strap Stop Weld
to Channel Ends
1-1/2" x 3'2-1/4"
Steel Pipe
6" Dia. x 12" Deep
Concrete Pier
3" x 4.1 lb/ft x 3'3"
2'10"
2'8"
2'2-1/4"
5'0"
Note: Place Support Frames
4' O.C. for Bench Crops &
5' O.C. for Pot Plants
6'0"
2'6"
2" x 4" x 5'10-1/4"
3'1-1/2"
1/8" x 1" Steel Strap
Fasten to 2" x 4"
with #8 x 3/4" FH
wood screws, 12" O.C.
Countersink all screws.
Stop, Welded to Channel
3" x 4.1 lb/ft x 3'8" lg.
Steel channel for 24" aisle.
3'6" long for 18" aisle
49
16"
C. Wood A-frame pot rack
72"
16"
16"
16"
16"
1" x 6" 10"
2" x 4" x 26"
2" x 4" x 39"
2" x 4" x 50"
2" x 4" x 62"
2" x 4" x 72"
2" x 6" x 18'
stagger joints
2" x 4" x 8"
Note:
Frame spacing−9' apart.
Use pressure treated lumber.
91"
D. S-type hanger rack support
48"
24"
24"
24"
6"
support
pipe
2" x 4" x 22 lg.
V-notch ends
5/8" dia. x 84" lg.
steel rod each side
1" dia. steel fence
or water pipe
5/8" dia. x 4" lg.
steel rod–welded
B. Pipe frame rack support
72"
30"
20"
20"
20"
Note:
Frame spacing−10'–12' apart. A jig can be
set up on a wooden floor or trailer bed to
bend the pipe. Use a 15" diameter block.
Overbend slightly.
U-bolt
1" dia. x 18' lg. steel
fence or water pipe
1" dia. steel
fence or water pipe
15" dia.
bend
A. Wood A-frame rack support
60"
28"
22"
22"
22"
Wire or rod to keep
frame from spreading
1" dia. steel water or
fence pipe. Drill holes
for a slip fit.
2" x 4" x 8' lg.
pressure treated lumber
Note:
Frame spacing−10' apart
Figure 3–8. Greenhouse rack systems: a) Wood A-frame rack support; b) Pipe frame rack support; c) Wood A-frame
pot
rack; d) S-type hanger rack support.
2"
501
greenhouse frames are designed to support a total
load, including snow and wind, of 10–15 psf, they
can be easily overloaded.
When using a rack system, take advantage of the
different light and temperature levels between the
top and bottom of the rack. Light levels may be
several hundred foot-candles lower on the bottom
than on top. Unless an air circulation system is in
operation, the temperature can also vary from 6–8°F.
Some growers use the floor area under the racks for
newly planted containers or growing ground cover.
HEADHOUSE
A headhouse provides an area to do potting,
transplanting, and shipping and houses the support
facilities needed to run an efficient business. It
can also serve to tie the greenhouses together,
providing access without having to go outside, an
advantage during inclement weather. A headhouse
arrangement is shown in Figure 3–9 on page 51.
The following services and operations might be
included in a headhouse:
Office
Every operation needs a private area for phone
conversations, keeping records, receiving
customers, and giving instructions to employees.
In larger businesses it can also house the secretary,
bookkeeper, and sales staff. The office should be
located near the main entrances to the headhouse.
Allow at least 100 sq. ft. per office occupant. Some
growers install a large window in the office that
overlooks the work area.
Utilities
The headhouse is a good place to locate the main
electric panel and water supply tanks. Its central
location with access to the greenhouses keeps wiring
and piping distances short. A central fertilizer
injector system can also be located here. Tanks and
equipment should be enclosed by a containment
equal to the tank capacity. Provisions should be
made to locate the electrical system in a dry area.
Restrooms
Depending on the size of the operation, one or more
restrooms may be needed. Connection to a sewer
system or septic system generally requires a permit.
Lunchroom
An area separate from the work area should be
provided for lunches and breaks. This should be
partitioned to keep out dust and odors. In large
facilities, space for lockers, refrigerator, microwave,
and sink is desirable.
Pesticide Storage
If properly designed, the pesticide storage can
be placed in the headhouse. The room must have
continuous ventilation with makeup air brought
in from outside. Identification signs and positive
locking are also required. The area for mixing should
be nearby.
Storage
Much of the smaller items (replacement parts,
hardware, labels, etc.) can be stored where there
is easy access and good inventory control. If the
headhouse has a high ceiling (14 ft. minimum), a
raised storage area above some of the other rooms
can be used to hold containers and other light
material. Bags of growing mix, peat, etc. are usually
stored outdoors or in a vacant greenhouse.
Work Area
The remaining area in the building should be open
so that it can be used for a work area. Flexibility
is important as the needs change from season to
season. In early spring, the space is needed for
potting and transplanting. Later, when the plants
are grown, more space is needed to assemble orders
for shipping. Except in large operations, equipment
such as the mixer and pot/flat filler should be
portable so that they can be moved out of the way
when not in use.
TYPE OF STRUCTURE
Style
The most desirable style is a clear span, wood
or metal frame building. Because they are less
expensive to construct, sections of gutter-connected
greenhouses have been used by some growers.
The disadvantage of this type of structure is the
potential for high temperatures during the summer.
An advantage is that it can be used to grow hanging
baskets or other plants when not in use as a work
area.
51
GREENHOUSE
SIZE
APPROXIMATE HEADHOUSE
AREA NEEDED PER 1,000 ft.2
OF GREENHOUSE AREA
10,000–40,000 ft.2 150 ft.2
40,000–80,000 100
over 80,000 75
Size
The building should be long enough to connect all
the greenhouses. This makes access and materials
handling easier. A minimum width of 24 ft. is
necessary to be able to locate equipment and still
have room for moving plants. In larger operations,
widths to 60 ft. are common. Table 3–1 gives "rule of
thumb" sizing for headhouses.
Ceiling height should be a minimum of 10 feet
and higher if a bucket loader or fork lift is used.
For growers who do a lot of shipping during cold
weather, a ceiling high enough for a van or truck
is convenient. Access doors large enough for the
equipment should be provided.
Figure 3–9. Tying greenhouses together with a headhouse allows for better labor efficiency.
Floor
The concrete floor should be at least 4 in. thick and
6 in. thick where heavy equipment will be operated.
Wire reinforcing is necessary to keep cracks from
spreading. A system of drains with sediment traps
will allow the floor to be washed.
Table 3–1. "Rule of thumb" sizing for headhouses.
GREENHOUSE
GREENHOUSE
GREENHOUSE
OFFICE
UTILITIES
FLAT/POT FILLING
TRANSPLANT
AREA
MEN WOMEN
SHIPPING
ORDER
ASSEMBLY
HEAD
HOUSE
SUPPLIES
EXPANSION
AREA
523
Walls
Insulation, 4 to 6 in. thick in the walls, will
reduce winter heating costs and the need for
summer ventilation. At least 6 in. of insulation is
recommended for the ceiling.
Wall and ceiling surfaces should be of a material that
is strong and easy to clean. Plywood covered with
acrylic or epoxy paint is a good choice.
Windows
Large windows in the work areas provide natural
light. Where sheet metal is used for roofing, an
occasional clear fiberglass panel can be substituted
to provide overhead light.
Artificial lighting (fluorescent or metal halide) is best
for work areas. Install it at a level of 20 foot-candles
at the work surface for potting, transplanting, and
office space and at 10 foot-candles in storage areas.
Heat
Oil or gas-fired, hot air unit heaters work well for
space heating. They can be placed overhead out of
the way of equipment operation. They have a quick
recovery when open doors cool off the room. In the
office and lunchroom, electric baseboard units give
more uniform heat without the blower noise.
Equipment
A significant amount of equipment has been
developed specifically for the production of
ornamental plants. Equipment used in other
industries, especially materials handling, can also be
adapted for the production of ornamental plants.
One problem is to determine what is available and
where to purchase it. Product directories published
by trade magazines or the Nursery and Greenhouse
Mechanization Equipment and Manufacturers
Directory, available from the American Society of
Agricultural Engineers, 2950 Niles Road, St. Joseph,
MI 49085, are the most complete sources. Visits to
trade shows, greenhouse equipment suppliers, or
other growers can also help.
The following is a brief review of some major types
of equipment and some factors to consider before
purchasing.
MIXING
Although some growers purchase premixed
growing media, many growers prepare their own.
Two types of equipment are available: batch and
continuous flow (Figure 3–10).
Figure 3–10. Media mixing equipment.
Belt Shredder
Barrel Mixer
Continuous Mixer using Feeder Bins
and In-line Rotary Mixer
Hopper Mixer
53
Figure 3–11. Flat and pot filling systems.
Concrete and drum mixers are available in capacities
of 1–10 yd.3 and use a revolving drum or agitators
for mixing action. Features to look for include
self-unloading, steam pasteurization injector, and
variable-speed. Care must be taken during operation
to ensure a homogeneous mix without excessive
pulverizing or ball formation. Complete mixing can
be accomplished in no more than two minutes.
Shredders are often used for mixing. Alternate loads
of each component (soil, peat, vermiculite, etc.) are
put through the shredder and into a pile one or more
times. A paved floor or pad area is desirable for ease
in handling. A disadvantage is production of fine
particles by the shredder.
Roto-tillers can be used for mixing. Alternate layers
of components are placed on a paved surface and
the tiller is driven slowly over the pile several times.
It is generally difficult to get a uniform mix with this
system.
A system using feeder bins, an open-ended drum,
and belt conveyors will provide a continuous
quantity of mix for a flat or pot filling line. Bins
with 1–5 yd.3 capacities are available. Flow rate is
controlled by the speed of the bottom conveyor and
adjustable end gates. The mixer receives the metered
components from the feeder bins at one end, mixes
them with a tumbling action, and discharges the
mix to a conveyor at the other end. Rates of up to 50
yd.3/hr. are possible.
CONTAINER FILLING
Many flat and pot filling systems are available
(Figure 3–11). Most contain a soil supply hopper,
metering device, leveling device, and container
support conveyor. Optional features include soil
return conveyor, soil level control, compactor,
pot holders, pot and tray dispensers, dibble, and
automatic pot take-off.
All filling machines can be adapted to various
container sizes within certain limits. Filling rates
vary, but generally are in the range of 10–30 flats per
minute and 20–50 pots per minute. Most machines
require two or three operators to perform efficiently.
Container filling systems range in price from about
$4,000 to over $30,000. For the smaller grower
(10,000 flats/yr.), it is hard to justify purchasing this
equipment when it may be used less than 12 hours
per year. For larger growers, significant savings can
be made since the production rate per man-hour
can be three or four times the hand filling rate.
Another advantage is that flats are filled much more
uniformly than by hand filling.
Pot Filler
Flat Filler–Belt Feed
Flat Filler–Conveyor Feed
545
For the small grower it may be more cost effective to
purchase pre-filled containers. These are available
from some suppliers.
SEEDERS
Two types of seeders are used. The inexpensive
hand or electric vibration type is used for bulk
seeding of flats. Seedlings are separated and
transplanted by hand. The second type is used for
precision seeding of plug trays. The plug system
provides the bedding plant grower with enhanced
transplanting ease, either by manual or mechanical
means.
Precision seeders operate using either vacuum or
vibrating mechanisms to pick up and drop 1–3
seeds per cell. They will handle most bedding plant
seed sizes, from the very small petunia to the larger
tomato or pepper. Seeding rate varies with seed type
and number of cells, but ranges from 4–8 flats per
minute (Figure 3–12).
Prices vary from about $2,000 for a unit that uses
a template to over $15,000 for one that is fully
automatic. For the small grower, it may be more cost
effective to allow someone else to seed, germinate,
and grow the plugs.
TRANSPLANTING
The latest advances in mechanization are in the
area of transplanting. Robotic-type devices that
select plug or rooted cuttings and place them into
containers are available. The high cost of these
units, more than $20,000, limit their use to large
operations. Some machines include machine vision
that selects the seedlings for quality and size.
There are a number of things that small growers
can do to increase transplanting efficiency. A dibble,
either hand or power operated, will pre-punch a flat
or pot to accept the seedling. Dibbles can be made to
fit any size flat or pot and any size plug.
The use of plugs, whether you purchase them or
grow your own, will reduce labor because the
seedlings are easier to handle and can be planted
with both hands. If used with an assembly conveyor,
transplanting rate can be doubled over traditional
hand planting methods.
Figure 3–12. A seeder.
Workstation design can also influence production
rate. Maximum dexterity and performance occur
when the flat, seedlings, and other items used are
located within a 16" horizontal and 17" vertical
radius of the normal elbow location. Workstation
height is also important with the most comfortable
position being with the top of the flat about 1" below
elbow height. Tilting the top of the table slightly will
help to give better visibility and match the normal
arm slope.
CONVEYING EQUIPMENT
Growers of all sizes can benefit from using some of
the many types of materials handling equipment
available. Because of its widespread use in other
industries, used equipment is often available.
Belt conveyors are available in widths of 4–24 in.
and lengths of 3–30 ft. (Figure 3–13 on the opposite
page). For loading and unloading boxes, bags,
pots, and flats at a potting or transplanting line, the
flat belt conveyor works best. When formed into a
trough, bulk materials can be handled.
Roller and skate wheel conveyors operate without
power. Available in 5–10 ft. long sections, they
require a 4–10% slope for materials to move freely.
Materials to be moved must have a flat bottom or
plywood slip sheets. Accessories include curved
sections and transfers.
Manual overhead monorail conveyors are common
in bedding plant greenhouses. Racks supported by
55
Figure 3–14. Carts and wagons.
the rail are usually designed to hold from 20–50
flats. Care must be taken during installation to
ensure that the greenhouse frame can support the
extra load.
Carts and wagons can be adapted to many jobs and
can be fitted with platforms, bins, or racks
(Figure 3–14). They usually work best over distances
of less than 200 ft., but will work well for longer
distances if a garden tractor or electric cart pulls
several at a time. Steering is accomplished by using
a combination of fixed and swivel casters. Large
diameter molded rubber or polyurethane wheels
and a firm surface make movement easier.
Pallets save labor by allowing more materials to
be handled at one time, reducing loading and
unloading time. Equipment for moving pallets
varies from the hand lift truck to the larger capacity
electric lift stackers (Figure 3–15, next page).
Shipping
The responsibility for receiving and dispatching
orders is usually given to a person who is familiar
with the geographic area served. As orders
are received, they are separated by area and
consolidated to make up loads for delivery on
succeeding days.
A further consideration in accepting orders is to
require customers to order in standard units. For
Figure 3–13. Conveyors.
Double Wheel Cart
Four Wheel Cart
Tractor-Trailer Train
Roller Conveyor
Chain Conveyor
Belt Conveyor
Overhead Conveyor
567
example, the unit could be one cart, one truck shelf,
or one cabinet. This makes order assembly easier
and can reduce errors in loading and unloading.
Orders are assembled in either of two ways:
1) Individually, by collecting the number of flats
or particular varieties needed to fill each order from
individual greenhouses and then moving that order
to the loading area; or 2) Collectively, by gathering
the total day’s needs of each variety, moving
materials to the shipping area, and assembling and
loading orders into the proper truck or cabinet.
With the many varieties of ornamental plants grown,
assembly time can be reduced and fewer errors
made by identifying each variety with a large sign
placed over it in the greenhouse.
Most growers load flats onto trucks by hand.
Usually, one person stands on the ground and hands
the flats to a second person on the truck. Flats that
are transported in cabinets or racks are usually
loaded by fork lift truck or hydraulic tailgate.
TRUCK BODIES AND VANS
Greenhouse trucks and vans are usually fitted
with shelves spaced 8–12 in. apart. Plywood or
sheet metal should be used to allow flats to slide in
smoothly. A body that holds about 200 flats can be
fitted on a pickup; one that holds 1,000 flats or more
can be built on a large truck.
Carts supported on skids or caster wheels are
becoming more popular as a system for handling
flats and are built to hold 50–100 flats (Figures 3–16
and 3–17 on the facing page). Carts are loaded in the
greenhouse and rolled to the loading area, where
they are loaded by fork lift or hydraulic tailgate onto
the truck.
Most large wholesale growers have adopted the
cabinet shipping method. Cabinets are boxes about
5 ft. wide by 4 ft. deep by 8 ft. high and are built of
steel or plywood. Seven or eight shelves are fitted
inside, spaced 9–11 in. apart. Every other shelf can
be removed to accommodate tall plants. Cabinets are
loaded back-to-back on a flat bed truck and held in
place by chains or rails on the truck bed. A fork lift is
used to load and unload the cabinets. Most growers
have enough cabinets so that one set is being loaded
while another set is being delivered. One advantage
of this method is that any flat bed truck can be used.
Using leased or rented trucks is common during the
shipping season, since few growers own enough
vehicles.
Economics
From the preceding discussion, it is obvious that
there are many methods and systems available for
materials handling. The final decision as to which
equipment to purchase or method to use involves a
cost study. Worksheet No. 3, Appendix XII, outlines
a procedure for placing a dollar value on different
options. Accurate cost figures can be obtained for
most items, but estimates may have to be made of
factors such as hours of use or useful life.
Loading Docks
Receiving and shipping efficiency can be increased
significantly with a well-designed loading dock.
Figure 3–15. Pallet moving equipment. The location must have convenient access to the
57
Figure 3–17. Flat handling.
Figure 3–16. Plant shipping container with two-way entry for a fork lift.
10" T-Hinge
57-1/2"
47"
89"
4" x 5.4 lb/ft
steel channel
Notes
1. Frame of welded 2" x 2" x 3/16"
steel angles.
2. Shelf supports of 2" x 1" x 1/8"
steel angles. Welded to
frame 6" on center.
3. Shelves frame of 1" x 1" x 1/8"
steel angles to set on
shelf supports.
4. Top, sides, back of 18 Ga.
Galv. steel sheet.
5. Overlapping doors of 1/2" AC
grade, exterior plywood.
6. Shelves of 3/8" CC grade,
exterior plywood.
Shipping Cabinet Shipping Cart System
589
greenhouses and highway and adequate space for
storing materials and maneuvering a fork lift.
Provide easy access from the main road and
minimize the slope from the drive to the dock area
to reduce mistakes or accidents. A one-way service
road should be 12 ft. wide at minimum; two-way
roads should be no less than 26 ft. wide. The road
should be able to accommodate weights in excess
of 40,000 lbs. Use a well-compacted sub-base,
topped with 8 in. of gravel and overlaid with 6 in. of
asphaltic concrete. If trailers are to be detached from
the tractor, a concrete strip to support the landing
gear should be provided. Adequate drainage should
be provided in the dock area to allow access in all
weather conditions.
The number of dock positions will depend on
volume at the busiest time of the year. Design the
dock so that it can be easily expanded. Do not forget
to provide access for a fork lift to move from the
dock to the road.
Since 1983, use of 8 ft.-6 in. wide trailers has been
permitted, so allow 12 ft. of width per stall or
truck position. Where flat bed trucks are used with
bedding plant containers, for example, side loading
docks are desirable. A cutout in the dock is needed
with adequate space, usually 12–15 ft., for fork lift
operation. It is best if dock height is lower than truck
bed height for easier access to containers or pallets.
Figure 3–18 shows a loading dock layout.
Figure 3–18. Loading dock layout.
APRON SPACE TRUCK LENGTH
TRAFFIC CIRCULATION
LOADING
DOCK
Stall Width
Dock Width
59
Although most docks are 48 in. high, many truck
beds are higher or lower. Table 3–2 gives typical
truck bed heights and overall body heights. If truck
traffic will be predominantly one type, the dock
should be designed to fit the dimensions of that
vehicle. Dock levelers that adjust the rear height of
a truck or trailer can be installed to increase safety
and speed of operations. Figure 3–19 shows dock
construction details.
Figure 3–19. Loading dock construction details.
Table 3–2. Typical truck dimensions.
TYPE OF TRUCK BED HEIGHT
(in.)
OVERALL HEIGHT
(ft.)
LENGTH
(ft.)
Panel truck 20–24 8–9 15–20
Step van 20–30 8.5–10 15–20
Stake truck 42–48 15–40
City delivery 44–48 11–12.5 17–40
Flat bed 48–60 55–70
Straight semi 48–52 12–13.5 55–70
Double axle semi 46–56 12–13.5 55–70
High cube van 36–42 13–13.5 55–70
2'6"
1'0" 1'6"
7'6"
4'0"
6"
4" Drain Tile
#4 Steel Reinforcing Bar
20" lg. 4' O.C.
Gravel or Stone
3" x 12" Oak Bumper
3/4" x 12" Bolts 6' O.C.
4" Reinforced Concrete
(alternative: 4" Asphalt)
#4 Steel Reinforcing Bar
Dock surface should be at least
16' wide for fork lift operation.
Slope surface 1–2% for water
drainage.
Concrete Retaining Wall−
Place Expansion Joint
every 30'. Use concrete
with 28-day Compressive
Strength of 3,000 psi.
60
LENGTH OF TRACTOR TRAILER
(ft.)
WIDTH OF STALL
(ft.)
APRON SPACE
(ft.)
50 12 86
50 14 70
55 12 97
55 14 84
60 12 116
60 14 99
The amount of apron space required for
maneuvering equipment into the dock depends
on the length of the tractor trailer or truck unit, its
turning radius, and the width of the stall. Table 3–3
lists typical space requirements for several tractor
trailer sizes. Where a truck must back into a stall
within a shipping building, doors large enough for
easy maneuvering are needed. A door 8–9 ft. wide
by 10 ft. high is needed for an open dock. Provisions
must also be made to vent the engine exhaust fumes.
Weather seals around the door will minimize heat
loss from the building. For night operations, good
lighting should be provided.
References
Ross, D. A. et al. 1975. Simulation of Bedding Plant
Production. Transactions of the ASAE. Vol 18:
No 1. St. Joseph, MI 49085.
———. 1983. Greenhouse and Nursery Mechanization:
A Compilation of Published Papers. Publ. 0183.
ASAE. St. Joseph, MI 49085.
———. 1983. Selected Papers in Greenhouse and
Nursery Engineering. Publ. 0583. ASAE.
St. Joseph, MI 49085.
———. 1983. Selected Papers in Greenhouse and
Nursery Mechanization Concepts. Publ. 0683.
ASAE. St. Joseph, MI 49085.
Table 3–3. Apron space required.
61
Chapter 4:
Greenhouse Environment
Introduction
Photosynthesis, respiration, and other essential plant
processes involve many chemical reactions that are
affected by the plant’s environment. A greenhouse is
constructed and operated to provide an acceptable
plant environment that will contribute to a profitable
enterprise.
Photosynthesis is the process by which light energy
in the 390–700 nanometer wavelength interval is
converted into usable chemical energy by green
plants. It is a process by which carbon dioxide
(CO2) and water (H2O), in the presence of light and
chlorophyll, are converted to carbohydrates and
oxygen.
Respiration, the reverse of photosynthesis, is
the process by which carbohydrates and fats
are broken down and CO2, H2O, and energy are
released. Maximum reactions are dependent on
temperature, with lower and upper limits between
50–85°F for most economically important plants.
Net photosynthesis depends on temperature, light
intensity, water, and nutrient availability. Respiration
processes are temperature sensitive.
Effects of Environment on
Plant Growth
LIGHT
Visible light (390–700 nanometers) provides essential
energy for plant development and growth. Intensity,
duration, and spectral distribution of light affect
plant response.
Ultraviolet light (290–390 nanometers) is generally
detrimental to plants. Photosynthesis proceeds
only with visible light, of which the red and blue
wavelengths are used most efficiently. The change
from vegetative to reproductive development in
many plants is controlled by red (660 nanometers)
and far red (730 nanometers) light. Light intensity is
the most critical variable influencing photosynthesis.
Flower crops can be classified as sun or shade plants.
Sun plants can be grown in full sunlight with no
adverse effects, while shade plants are injured if
exposed to light intensities above a specific level.
Plants which respond to relative length of day and
night are termed photoperiodic. Photoperiodism
affects flowering and is generally independent
of light intensity. Plants can be grouped as long
day, short day, or day neutral, with the length of
darkness being more important than the length
of the light period. The number of 24-hour light/
dark cycles required for flower initiation varies with
species and variety.
TEMPERATURE
Plant temperature is affected by radiation energy
transfer, convective heat transfer, and evaporation
from the plant surface. The relationship between
plant growth and temperature is complex because it
is a factor in the reaction rates of various metabolic
processes. Greenhouse crops are grown at specified
night temperatures with a daytime minimum
increase of from 10–15°F. Recommended night
temperatures for several greenhouse crops are given
in Appendix XI.
RELATIVE HUMIDITY
Relative humidity is the ratio of actual vapor
pressure of water vapor in the air to the vapor
pressure that would be present if the air was
saturated with moisture at the same temperature.
Water vapor moves from one location to another
because of vapor pressure differences, so relative
humidity affects transpiration from plants by
affecting the vapor pressure difference between a
plant leaf and surrounding air. Normal plant growth
will generally occur at relative humidities between
62
GAS
AIR POLLUTION INJURY HAS BEEN
DETECTED AT LEVELS AS LOW AS:
Acetylene (C2H2) 1 ppm
Carbon Monoxide (CO) 50
Hydrogen Chloride (HCl) 0.1
Ethylene (C2H4) 0.05
Methane (CH4) 1000
Nitrous Oxide (N2O) 2
Ozone (O3) 4
Peroxyacetyl nitrate (PAN–smog) 0.2
Propane (C3H8) 50
Sulfur Dioxide (SO2) 1
25–80%. A secondary effect of relative humidity is
the response of pathogenic organisms. For example,
most pathogenic spores will not germinate at
relative humidities below 95%.
CARBON DIOXIDE
Carbon dioxide is the raw material which, along
with water, is required for photosynthesis; it is
usually the limiting factor in the greenhouse
environment. In a tight greenhouse, carbon dioxide
concentration may be 400 parts per million (ppm)
before daylight and drop to 150 ppm shortly after
light is available. Outside air is about 330 ppm.
Carbon dioxide is absorbed into the plant leaf
through stomates, the rate of absorption depending
on several factors, including concentration, stage
of growth, temperature, and light intensity. All
plants will respond to increases in carbon dioxide
levels, but not all responses will be economically
profitable. The combination of high carbon dioxide
levels (1,500 ppm), elevated day temperatures,
and optimum light levels will reduce the time
between germination and harvest by as much as
50% for some crops. Increases in carbon dioxide
levels result in improved plant quality, yield, and
development. The optimum combination of carbon
dioxide-temperature-visible light energy has been
determined for very few species or cultivars.
AIR SPEED
Air speed influences many factors that affect plant
growth, such as transpiration, evaporation, leaf
temperature, and carbon dioxide availability. In
general, air speeds of 20–50 ft./min. (fpm) across
leaf surfaces facilitate carbon dioxide uptake. At
an air speed of 100 fpm, carbon dioxide uptake is
reduced, and at 200 fpm, growth is inhibited.
POLLUTANTS
The most common pollutants are photochemicals,
oxidants, ethylene, sulfur dioxide, fluorides,
ammonia, and pesticides. Ethylene is produced
during ignition of gaseous or liquid fuels and, at
concentrations of 1 ppm or less, causes injury to
some plants. Sulfur dioxide is produced by burning
sulfur-producing fuels; exposure to concentrations
of 1 ppm for 1–7 hrs. causes injury to most plants.
Mercury vapor is injurious to plants at very low
concentrations. Phenolics are injurious to plants,
and, as volatiles from wood preservatives, will burn
petals and foliage (see Table 4–1).
ROOT ENVIRONMENT
Rooting media provide plant support, serve as a
source of water and plant nutrients, and permit
diffusion of oxygen to the plant roots. During
respiration, oxygen moves into roots and carbon
dioxide moves out. The media should have
sufficient pore size and distribution to provide
adequate aeration and moisture retention necessary
for acceptable crop production. Media range from
mineral soil and amended soil mixes to soilless
media such as gravel, sand, peat, or liquid films.
Table 4–1. Levels at which air pollution injury can occur.
63
Figure 4–1. Energy exchange between a greenhouse and the surroundings.
Environmental Control
SOLAR RADIATION
A greenhouse is built and operated to produce crops
and return a profit to the owner. In many areas of the
country, sunlight is the limiting factor in production,
especially during the winter; therefore, a greenhouse
should provide for optimum use of available
sunlight. The amount of sunlight available to plants
in a greenhouse is affected by the structural frame,
covering material, surrounding topography and
cultural features, and orientation of the greenhouse.
The amount of sunlight available outside is a
function of latitude, time of year, time of day, and
sky cover.
A greenhouse cover with high transmissivity for
solar energy can produce temperatures that are
higher than desired in the crop zone. Most surfaces
within a greenhouse have high absorptivities for
solar energy and, thus, convert incoming radiation
to thermal energy. Figure 4–1 shows energy
exchange for a greenhouse during daylight. Table
4–2 on the next page lists transmissivities of several
glazing materials for solar radiation and infrared
radiation from surfaces at about 80°F. Table 4–3 on
the next page lists absorptivities of several surfaces
for solar radiation and emissivities at about 80°F.
Transmissivity is the percent (in decimal form) of
solar energy transmitted when the sun’s rays strike
the surface at a right angle to the surface. Emissivity
is the ratio of the total radiation emitted by a body
to the total radiation emitted by a black body of the
same area for the same time period.
Infra-Red Thermal
Radiation from
Atmosphere
Infra-Red Thermal
Radiation from
Walks, Soil, etc.
Transpiration
Evaporation
Infra-Red Thermal
Radiation from Plants
Reflected
Sunlight
Reflected
Sunlight
Sun
Air
Dust
Particles
Direct
64
MATERIAL
ABSORPTIVITY FOR
SOLAR RADIATION
EMISSIVITY AT
ABOUT 80°F
Concrete 0.60 0.88
Red brick 0.55 0.92
Window glass 0.03 0.90
Paint, gloss white 0.35 0.95
Soil, dry 0.78 0.90
Soil, moist 0.90 0.95
Aluminum:
Commercial finish
Painted white
Painted black
0.32
0.20
0.96
0.10
0.91
0.88
Galvanized steel:
Oxidized
Painted white
0.80
0.34
0.28
0.90
Table 4–2. Transmissivity of glazing materials. (a)
Table 4–3. Solar absorptivity and emissivity for several surfaces.
TRANSMISSIVITY
Solar Infrared
Temperature of radiation source (°F) 10,000 80
Wavelength of radiation (nanometers) 380–2,000 4,000–10,000
Material
Window glass 0.85 0.02
Fiberglass 0.88 0.02
Acrylic 0.92 0.02
Polycarbonate 0.85 0.01
Polyethylene 0.92 0.81
Acrylic, double layer extrusion 0.83 <0.02
Polycarbonate, double layer extrusion 0.77 <0.01
(a) Values are for nominal thickness and single layer unless otherwise indicated.
65
HEAT LOSS AND GAIN
Heat exchange between a greenhouse and the
environment is illustrated in Figure 4–2. Heat
exchange between the greenhouse interior and
exterior is the sum of heat available from all sources
such as solar, furnace, lighting, electric motors, etc.,
and the rate of heat loss from the greenhouse:
Furnace Heat + Electric Motor Heat + Lighting
Heat + Solar Heat = Heat Loss by conduction
through the greenhouse shell + Heat Loss by air
exchange between inside and outside air + Heat
Loss by evaporating water.
Furnace heat is estimated for night heating when
there is no sun, and heat from electric motors and
lighting is ignored. Heat used in evaporating water
is also ignored.
hf (Furnace heat) = hc (Conduction heat) +
hsa (Air exchange heat)
The largest exchange is by conduction through the
greenhouse cover, including glazing and frame.
Conduction heat transfer is estimated by the
following equation:
hc = AU (ti – to) (4–1)
where hc = conduction heat , Btu/hr.
A = surface area of the greenhouse, ft.2
U = overall heat transmission coefficient,
Btu/hr.-°F-ft.2
ti = inside temperature, °F
to = outside temperature, °F.
In most greenhouses, the frame accounts for less
than 5% of the surface and may be ignored in
calculations. Many greenhouses have opaque lower
walls of concrete, masonry, or other decay resistant
materials. The U values for several greenhouse
construction materials are given in Table 4–4 on the
next page.
The second major heat transfer mode is air exchange
between inside and outside the greenhouse. Heat
is transferred in both sensible and latent forms.
Figure 4–2. Heat loss from a greenhouse.
The sensible heat is transferred by increasing the
temperature of incoming air. The latent heat is
removed as water vapor from evaporation and
transpiration. Sensible heat transfer can be estimated
by:
hsa = 0.02 M (ti – to) (4–2)
where hsa = air exchange heat, Btu/hr.
M = air exchange, ft.3/hr.
The rate of air exchange between inside and outside
is affected by wind and the type and quality of
greenhouse construction. Reasonable estimates of air
exchange are given in Table 4–5 on the next page.
hf = hc + hsa = AU (ti – to) + 0.02 M (ti – to) (4–3)
where hf = furnace heat (Btu/hr.) needed to
keep the greenhouse air
temperature at the desired level.
The solar gain on sunny days will replace some or
all furnace heat needed to maintain temperature at
the proper level. If solar gain exceeds heat loss, the
greenhouse air temperature will rise and cooling
may be required. The solar gain can be estimated by:
hs = T Is AF (4–4)
Cold Sky Cold Outside Air
Conduction into Ground
Perimeter
Conduction
Infiltration
(Cold Air)
Radiation to
Cool Sky
Exfiltration
(Warm Air)
Convection
Conduction
to Air
Convection
66
GREENHOUSE GLAZING
U
(Btu / hr.–°F-ft.2)
Single layer glass 1.1
Single layer plastic film 1.2
Single layer fiberglass 1.2
Double layer plastic film 0.7
Double layer acrylic or polycarbonate extrusion 0.5
Double layer plastic film over glass 0.5
Single layer glass plus internal thermal blanket 0.5
Double layer plastic film plus internal thermal blanket 0.4
Standard concrete blocks, 8" 0.51
Poured concrete, 6" 0.75
Cement-mineral fiber board, 1/2" 1.10
Softwood, 1" nominal 0.60
Foamed urethane, 2", plus 1/8" cement-mineral fiber board 0.08
Foamed polystyrene, 2", plus 1/3" cement-mineral fiber board 0.11
Concrete block, 8", plus 2" foamed urethane board 0.07
Concrete block, 8", plus 2" foamed polystyrene board 0.10
Poured concrete, 6", plus 2" foamed urethane board 0.07
Softwood, 1", plus 2" foamed urethane board 0.07
Framed polystyrene 1-1/2", plus aluminum surface 0.12
Perimeter, uninsulated 0.80 Btu / hr.-ft.
Perimeter, insulated (a) 0.40 Btu / hr.-ft.
Table 4–4. Overall heat transfer coefficients for greenhouse glazing materials and systems.
(a) Insulation equivalent to 2" of foamed polystyrene extending 24" into the ground.
Table 4–5. Air exchanges for greenhouses.
CONSTRUCTION SYSTEM
AIR EXCHANGE
PER HOUR (a)
New construction, glass or fiberglass 0.75–1.50
New construction, double layer polyethylene film 0.5–1.0
Old construction, glass, good condition 1–2
Old construction, glass, poor condition 2–4
(a) One air exchange is the volume of the greenhouse (ft3). Low wind speeds or protection from wind will reduce the
rate to
a minimum value of 0.5 exchange per hour in some situations.
67
where hs = solar gain, Btu/hr.
T = transmittance of the greenhouse
cover to solar radiation
Is = intensity of solar radiation on a
horizontal surface outside,
Btu/hr.-ft.2
AF = area of greenhouse floor, ft.2
Tables of solar radiation intensity (Is) can be found in
ASHRAE Fundamentals.
Transmittance will vary with angle of incidence (the
angle between the sun’s rays and a perpendicular
to the surface), but an average value of 60%
will give reasonable estimates. In equation 4–4,
multiply rated T by 0.6 if the angle of incidence is
unknown. More accurate estimates can be calculated
using mathematical modeling with computer
programming.
Evapotranspiration rate in a greenhouse is affected
by the solar radiation received by the crop and the
stage of crop growth. The ratio of solar radiation to
evapotranspiration for actively growing plants in a
greenhouse averages about 0.5; that is, about onehalf
the solar radiation received by the plant is used
to evaporate water. In equation form:
hcv = E F hs (4-5)
where hcv = evapotranspiration rate, Btu/hr.
E = ratio of evapotranspiration to solar
radiation
F = floor use factor—ratio of ground
covered by plants to total ground
area.
hs = solar gain, Btu/hr.
Combining equations 4–4 and 4–5:
hcv = E F T Is AF (4-6)
If evaporative cooling is used, to will be the
temperature of the air leaving the cooler. Most
systems will reduce the dry bulb temperature about
0.8 of the difference between dry bulb and wet bulb
temperatures. The temperature of air leaving the
cooler would be:
to = to – 0.8 (to – twb) = 0.2 to – 0.8 twb (4-7)
where to = temperature of air leaving the
cooler, °F
twb = outside air wet bulb
temperature, °F.
hsa = 0.02 M (ti – (0.2 to – 0.8 twb) ) (4-8)
In a cooling situation, hsa is the excess amount of
solar heat that can be removed by air exchange to
keep temperature at the desired level. Figure 4–3 on
the next page shows the relationship between rate
of air exchange and temperature differences for one
solar radiation value. Figure 4–4 on the next page
shows the effect of evaporative cooling at different
outside temperatures and relative humidities.
Energy Conservation
Any system that will reduce heat loss will reduce
heating fuel use. A compromise may be necessary
to satisfy light requirements for plant growth while
reducing heat loss. For example, a second layer of
light-transmitting material will reduce conduction
loss by about one-half and light transmission by
about one-tenth of a single layer. Movable insulation
can be installed that is stored during the day and
encloses the crop volume during the night. Material
stored in the greenhouse causes some light loss and
may interfere with normal greenhouse traffic. A
properly installed double glazing layer or thermal
blanket will also reduce air exchange between the
crop and the outdoors. Estimates of overall heat
transmission values can be made for thermal blanket
installations. Some values are given in Table 4–4 on
page 66.
68
Figure 4–4. Evaporative cooling effect as a function of relative humidity of outside air.
Figure 4–3. Temperature rise in greenhouses as a function of air exchange rate. Solar intensity is 280 Btu/hr.-ft.2 on a
horizontal
surface at solar noon. The greenhouse is full of actively growing crops.
No shading on greenhouse
50% of solar
energy reflected
by shading
Temperature Rise, °F
Air changes per minute
0
0
1234
9
18
104
Temperature of cooled air leaving pad, °F
86
95
77
Outside Average Temperature, °F
59 68 77 86 95
RH of outside air 30% RH 50% RH 70% RH
90% RH
69
Humidity Control
A tight greenhouse will have reduced air exchange
and higher relative humidity. Thermal blankets or
double glazing layers will also result in increased
relative humidity. Reduced air exchange will
reduce the amount of water vapor removed from
the greenhouse. Additional insulation will result
in higher inside surface temperatures, reducing
the condensation potential. The condensation rate
depends on the rate of air movement across the
surface, the rate at which heat of condensation
is removed from the surface, and the rate of
evaporation from other surfaces in the greenhouse.
In general, the relative humidity of the inside air
will be controlled by the temperature of the coldest
inside surface. For example, if the inside surface
temperature is 36°F and the inside temperature is
60°F, the inside relative humidity will be about 40%.
Table 4–6 illustrates the effects of different energy
conservation construction practices on inside surface
temperatures. Refer to references at the end of the
chapter for further explanation of properties of airwater
vapor mixtures (psychrometer charts).
The simplest method for relative humidity control
in cool or cold weather is to bring in outside air,
heat it, and allow it to absorb moisture before
exhausting it to the outside. The evapotranspiration
rate for greenhouse crops will vary depending on
crop and solar radiation. A greenhouse filled with
mature pot plants may lose up to about 0.15 lb. of
water vapor per square foot of greenhouse floor
area per hour during the day; loss at night will be
less. If evaporated moisture is not removed, relative
humidity will increase until the air is saturated or
until condensation begins on a cold surface.
Horizontal air flow in the greenhouse will help
alleviate the problem by moving air across plant
surfaces to keep them dry. Moving air also increases
mixing and prevents temperature stratification in the
greenhouse. If outside air at 20°F and 80% relative
humidity is brought into the greenhouse and heated
to 60°F, it will absorb 0.0005 lb. of water vapor per
cubic feet of air if the final relative humidity is
70%. It would take 300 ft.3 of air/hr. to remove the
0.15 lb. of water vapor produced per square foot of
greenhouse floor area. It would require about 300
Btu/hr. to warm the air to 60°F. A change in any of
these conditions would result in changes in air flow
and heat required.
Table 4–6. Inside surface temperatures of greenhouse enclosures and maximum relative humidities with 60°F inside air
temperature.
CONSTRUCTION SYSTEMS
Outside
Temperature
(°F)
1234
Temp(a)
(°F)
RH(b)
(%)
Temp
(°F)
RH
(%)
Temp
(°F)
RH
(%)
Temp
(°F)
RH
(%)
47 52 72 56 86 57 89 58 92
27 39 45 50 69 52 74 54 81
7 26 26 43 53 47 61 51 72
-8 16 20 38 42 43 53 48 65
CONSTRUCTION SYSTEMS: 1—Single glazing
2—Single glazing with eave-to-eave thermal blanket
3—Double glazing
4—
Double glazing with eave-to-eave thermal blanket
(a) Temperature of the surface facing the plants.
(b) Maximum relative humidity (RH) with no condensation on the surface facing the plants.
70
Estimating Heating and

Cooling Loads
The equations presented earlier can be used to
estimate either heating or cooling loads on a
greenhouse. The following examples will illustrate
their use.
HEATING
The estimated heat loss for temperature control
is based on construction system, a minimum
inside temperature, and an outside temperature
generally taken as 10°F below average minimum
temperature. For most locations above 40° North
latitude, a temperature difference of 60°F will result
in an adequate installed heating capacity. Thus, if
the outside temperature is 0°F, the greenhouse air
temperature can be held at 60°F.
The example greenhouse, as mentioned previously,
has dimensions of 96 ft. wide by 192 ft. long. The
96-ft. width consists of four gable roof spans of
24 ft. each. The roof is glass glazed, single layer, with
a slope of 26.7 degrees (6:12 roof cut). Side walls are
8 ft. above grade and constructed of 1.5 ft. of 6-in.
thick poured concrete and 6.5 ft. of single layer glass.
The frame is galvanized steel with glazing attached
to allow < 1% of the frame to extend to the outside.
The owner wants to maintain a minimum night
temperature of 60°F with a night setback of 10°F
from day temperature. An air exchange rate for the
greenhouse is estimated to average 1 volume/hr.
Outside design temperature is 0°F.
From equation 4–1,
hclgl = AglUgl(ti – to),
hclcon = AconUcon(ti – to) and
hclp = P Up(ti – to)
where hclgl = heat loss through glass, Btu/hr.
hclcon = heat loss through concrete, Btu/hr.
hclp = heat loss through the perimeter,
Btu/hr.
Agl = glass area, ft.2
Ugl = heat transmission through glass,
Btu/hr.-°F-ft.2
Acon = concrete area, ft.2
Ucon = heat transmission through
concrete, Btu/hr.-°F-ft.2
P = perimeter, ft.
Up = heat transmission through the
perimeter, Btu/hr.-°F-ft.
The heat loss from exchanging 1 volume of air/hr. is
calculated using equation 4–2.
hsa = 0.02 M (ti - to)
where hsa = heat loss by air exchange
(infiltration), Btu/hr.
M = air exchange rate, ft.3/hr.
The calculations are shown in Worksheet No. 4,
Appendix XII. The total heat loss is the sum of all
losses and, for the example problem, the answer is:
1,953,360 Btu/hr.
This is the required output from heating equipment
installed in the example greenhouse. The heating
system may include a central boiler that produces
hot water or steam, which is distributed through
convectors, piping, or unit heaters. Piping, either
bare or finned, along sidewalls or under benches,
will result in uniform temperature distribution
within the crop if combined with horizontal air
movement. Under-floor piping or a flooded floor
method can be used for on-floor production systems.
In snow regions, distribution systems should
provide means for getting heat to the gutter area for
snow melting.
COOLING
Estimates of cooling requirements for greenhouses
are based on acceptable temperature differences
between inside and outside air if only outside air is
used to remove solar heat. A reasonable compromise
is to design for a minimum temperature difference
of 7°F. Thus, if the outside temperature is 80°F,
the inside air temperature will be about 87°F. An
air exchange ratio of 8 cfm/ft.2 of floor area will
generally satisfy this requirement. If additional
cooling is desired, evaporation can be used if the
relative humidity of outside air is low enough.
Mechanical refrigeration is too costly to be used for
greenhouse cooling.
71
The example greenhouse can be used again, this
time to illustrate sizing a cooling system. The floor
area of the greenhouse is 96 ft. x 192 ft. = 18,432 ft.2;
the installed fan capacity is 8 cfm/ft.2 x 18,432 ft.2
= 147,456 cfm (Worksheet No. 5). Fans should be
placed in one sidewall and the air pulled across the
96 ft. width of the greenhouse. Air should not be
moved more than 150 ft. from inlet to exhaust. The
temperature at which fans start can be set to satisfy
the grower. The vent opening on the opposite side of
the greenhouse should be adjustable to keep the air
speed through the opening at about 250 fpm.
Ventilation is often required during cool, clear
weather to reduce humidity levels. This is
accomplished by installing powered inlet louvers in
gable ends with attached perforated polyethylene
tubes for air distribution. Outside air is warmed as
it passes through the polyethylene tubes, which are
sized to provide about 2 cfm/ft.2 of floor area. Inlet
louver operation is tied electrically to the first stage
exhaust fans.
If additional cooling capacity is needed, evaporative
cooling can be provided by using either wetted pads
through which outside air is drawn or a fogging
system that produces very fine droplets, less than
10 microns diameter, that evaporate before reaching
plant surfaces. Pads of cellulose materials have
largely replaced aspen shaving pads because of
longer life with less maintenance. They are sized the
same way a vent opening is sized — by dividing the
installed fan capacity by 250 fpm to get square feet
of pad. Water flow should be 0.5 gpm per ft. of pad
length and sump capacity, 0.75 gal./sq. ft. of pad
(Worksheet No. 6, Appendix XII). For walls over 100'
in length, the sump should be placed at midpoint
and water pumped to the ends of the wall. A float
valve on the supply to the sump will maintain a
constant water level. An algicide should be added to
the water to reduce fouling.
Fogging systems are sized according to the heat load
to be cooled and the weather conditions expected
for the greenhouse location. For example, water
evaporated at 80°F will absorb approximately 1,100
Btu/lb. Therefore, if the solar load is 100 Btu/sq. ft./
hr. in a greenhouse, it will require approximately
0.1 lb. of fog/hr./sq. ft. of greenhouse area to
maintain the temperature. The saturated air must be
removed as the fog evaporates so that evaporation
can continue to remove the excess heat. The rate
of fog production in either pounds or gallons per
hour is determined based on heat loads expected.
In general, the greenhouse air temperature can
be held to wet bulb plus three degrees. Wet bulb
temperature is defined as that temperature at which
the air is saturated by a constant enthalpy process
or without a change in the total heat in the air-water
vapor mixture.
Shading can also be used to reduce solar heat load
in the greenhouse. There are shading compounds
that can be applied to the outside roof surfaces in the
spring and removed in the fall. Some compounds
will be gradually degraded by the action of the rain
and the sun so that very little remains on the roof
surfaces by fall. Shading materials are available
that are installed inside the greenhouse to reflect
the solar heat to the outside. They can be installed
to be pulled across the greenhouse horizontally or
parallel to the roof between the trusses. Materials
are available that combine shading for cooling in the
summer with heat retention in the winter.
Insect Screens
Greenhouse structures provide easy access for insect
pests through ventilation openings, vents, louvers,
and poorly fitting doors and windows. Screening
vents, doorways, and other openings can prevent
many unwanted insects from entering. Screens can
prevent entrance of insects, but they will also limit
the airflow unless openings are modified to make up
for the reduction in clear area for cooling air to enter.
There is a relationship between screen opening and
insect size for the screen to be effective. Table 4–7 on
the next page gives insect size and maximum hole
size to restrict entrance.
Many screen materials are made of uniform threads
that are called mesh. The mesh refers to the number
of threads per inch in each direction. A 64 mesh
screen has 64 threads running in each direction
at right angles to each other. The diameter of the
threads must be known to determine the net open
area through which air can flow.
72
For example, assuming a thread size of 0.008"
in diameter, and a 64 mesh screen, the total area
covered with thread is 0.512" (64 x 0.008"). The
amount of open area is 0.488" (1 – 0.522"). With 63
openings across the inch, each opening is 0.007746"
wide (0.488 / 63). Each opening is 0.007746" square
giving an area of 0.00006 sq. in. Since there are 63
x 63 per sq. in., the total open area will be 0.238 sq.
in./sq. in. of screen (63 x 63 x 0.00006"). In other
words, the screen has an open area that is 23.8% of
the total gross area of the vent or other opening it is
covering.
A reduction in free area will mean the same airflow
in cfm for which the original opening was designed
will have to pass through the reduced area at a much
higher speed, resulting in higher energy loss or a
higher pressure for the fan to work against.
Therefore, when insect screens are installed, their
gross area must be large enough so their free area
is equal to or greater than the opening they are
covering. In the case presented, the insect screen
gross area would have to be more than four times
the original opening area.
Because of the small openings, insect screens tend
to trap dust, dirt, and pollen rapidly. They must be
cleaned regularly to maintain the open area and
desired airflow rate. This can be done by washing or
vacuuming.
Christianson and Riskowski recommend designing
screened openings for a 0.033 inch water pressure
drop in addition to the pressure drops through the
fan, housing, and louvers. Thus where a fan may
be selected based on a pressure drop of 0.125" of
water with no screens, it should be selected for a
drop of 0.160 to 0.175" of water if insect screening is
installed.
There are several screen materials available, but
some do not indicate the free opening area or
thread size nor do they indicate the relationship
between airflow and pressure drop through the
screen. Without this information it is difficult to
correctly select fan size for a particular greenhouse
installation.
References
Mastalerz, J.W. 1977. The Greenhouse Environment.
John Wiley & Sons.
ASHRAE. 1993. Handbook of Fundamentals. Am. Soc.
of Heating, Refrigerating and Air Conditioning
Engineers. Tullie Circle, NC, Atlanta, GA 30329.
Christianson L.L. and G.L. Riskowski. 1992.
Structural Screening for Insect Management:
Design and Management Factors. Univ. of Illinois
Research Report.
Table 4–7. Anti-insect screen selection criteria.
INSECT PEST TO
BE EXCLUDED
INSECT SIZE SCREEN HOLE SIZE
microns inches microns inches
Leafminer 640 0.025 266 x 818 0.0105 x 0.0322
Melon Aphid 340 0.013 266 x 818 0.0105 x 0.0322
Whitefly 462 0.018 266 x 818 0.0105 x 0.0322
Western Flower Thrip 192 0.0075 150 x 150 0.0059 x 0.0059
1" = 25,400 microns, 1 mil = 0.001"
73
Chapter 5:
Equipment for Heating and Cooling
Heating Equipment
The selection of heating equipment depends on the
size and type of greenhouse operation, structures,
and availability and cost of fuel system components.
A system is made up of a fuel burner, heat
exchanger, distribution, and controls. Fuel can be
gas, oil, coal, or wood.
A fuel burner can be located within the greenhouse,
with heat delivered to the crops by convection and
radiation. These burners are direct-fired units and
use either air or water as the heat transfer medium.
They are generally used in separate greenhouses and
in seasonal operations (Figure 5–1).
A central boiler is used in large operations with
gutter-connected greenhouses. Either water or
steam is used as the heat transfer medium. Most
steam systems use a low pressure boiler, meaning
that pressure within the boiler does not exceed 15
pounds per square inch (psi) (Figure 5–2).
Figure 5–1. Direct-fired floor-mounted warm air furnaces.
Ducts can be perforated PE tubes or galvanized steel.
Figure 5–2. Example of a central boiler system with ringline and 4-way mixing valves.
Warm Air Discharge Flue
Circulating
Burner Fan
Assembly
Fire
Box
A. Top discharge only
Flue
Flue Gases
Heat Exchange
Burner
Assembly
Barometric
Damper
Warm Air
Discharge
B. Bottom discharge
Greenhouse 2
Ringline Supply
Ringline Return
Check Valve
Ringline
Circulators
Boiler Room
Return
Supply
4-Way
Valve "B"
4-Way
Valve "A"
Greenhouse
Circulators
Greenhouse Return
Greenhouse Supply
Greenhouse 1
Expansion Tank
4-Way Valve A allows
water temperature
in the ringline to be
based on outside
temperature.
4-Way Valve B allows
water temperature in
the greenhouse to be
based on greenhouse
temperature.
74
Heat distribution in the greenhouse depends on
furnace type and location, growing system used,
and crop produced. Direct-fired units in individual
greenhouses generally use air to move heat through
ducts of either galvanized steel or polyethylene
film. Ducts are designed to provide acceptable
distribution and temperature control. Polyethylene
film tubes are available with holes sized and spaced
to provide required distribution. The tubes are
placed overhead for floor crop systems and on the
ground for bench systems. The tubes can also be
used with unit heaters supplied with hot water or
steam from a central boiler.
Bare pipe or finned tube can be used for perimeter,
under bench, beside raised bed, or under floor
heating. A combination of perimeter and under
bench piping in either bare pipe or finned tube can
provide even distribution of heat.
It is best to provide at least two stages of heat
supply to permit closer control of temperatures.
Motorized proportioning valves on water or steam
lines also will help in temperature control. Table 5–1
opposite lists approximate values for heat output of
bare pipe and finned tube. Consult manufacturer’s
information for unit heater capacities and
installation.
Under floor systems can be either buried pipe or
flooded floor. If a buried pipe system is installed,
the pipe can be placed under a 4-in. layer of porous
concrete or 12 in. deep in soil. Considerable soil
depth is required to avoid damage from tillage
equipment. Floor heating systems will not provide
enough heat to maintain acceptable greenhouse
temperatures, so additional heat distribution
equipment must be installed above ground. General
guidelines for under floor heating systems are
given in Table 5–2 and Figures 5–3 through 5–5 on
pages 74–77. Figures 5–6 and 5–7 on page 78 show
estimated heat flow from under floor systems.
The flooded floor system consists of a waterproof
membrane about 16 in. below finished floor level,
extending up all sides to the surface, and 12 in. of
Figure 5–3. Piping schematic for bottom heat system.
Fuel
Supply
Heating
Element
Pressure
Relief Valve
WATER
HEATER
or
BOILER
From Supply
Pressure
Reducing
Valve
Check
Valve
Thermometer
Thermometer
Mixing Valve
Pressure Gauge
Air Eliminator
Air Purger
Expansion
Tank
Gate Valve
Pump From Floor
or Bench
To Floor
or Bench
75
BARE PIPE
Size
(nominal dia.)
No. of lines Location Output in Btu / hr.-ft. (a)
180°F Water 215°F Steam
1-1/4" 1 overhead 117 180
1-1/4 1 sidewall 87 162
1-1/4 2 (b) sidewall 166 312
1-1/4 3 (b) sidewall 237 430
1-1/2 1 overhead 134 210
1-1/2 1 sidewall 100 185
1-1/2 2 sidewall 190 348
1-1/2 3 sidewall 273 485
2 1 overhead 195 291
2 1 sidewall 145 263
FINNED TUBE (c)
Size
(nominal dia.)
Fin Size Fins / ft No. of lines Output in Btu / hr.-ft.
180°F Water 215°F Steam
1" 2" x 4-1/4" 32 1 458 670
1 2" x 4-1/4" 40 1 580 780
1 3" x 3-3/4" 38 1 745 1,080
1 3" x 3-3/4" 38 2 (7-1/2" O.C.) (b) 1,267 1,836
1 3" x 3-3/4" 38 3 (15" O.C.) 1,764 2,484
1 2-3/4" x 3-3/4" 24 1 620 920
1-1/4 2-3/4" x 3-3/4" 24 1 690 1,030
1-1/4 3-1/4" x 3-1/4" 49 1 1,138 1,440
1-1/4 4-1/4" x 4-1/4" 38 1 1,200 1,740
1-1/4 4-1/4" x 4-1/4" 38 2 (7-1/2" O.C.) 2,040 2,957
1-1/4 3-1/4" dia. 32 1 931 1,350
1-1/2 3-5/8" dia. 32 1 979 1,420
2 3-1/4" x 3-1/4" 24 1 —
1,330
2 4-1/4" x 4-1/4" 24 1 995 1,260
2 3-7/8" dia. 24 1 859 1,245
Table 5–1. Approximate heat output for bare pipe and finned tube.
(a) Adapted from ASHRAE handbook 1983 Equipment.
(b) Lines are stacked vertically.
(c) Adapted from manufacturer's literature. Consult manufacturer's information for more specific data.
76
Figure 5–4. Typical pipe layout for floor or bench heating (reverse return).
POLYETHYLENE
Nominal size
(in.)
I.D.
(in.)
Area
(in2)
Volume
(gal. / ft.)
1/2 0.622 0.30 0.016
3/4 0.824 0.54 0.028
1 1.049 0.87 0.045
1-1/4 1.380 1.49 0.077
1-1/2 1.610 2.05 0.106
2 2.067 3.40 0.180
2-1/2 2.469 4.80 0.250
POLYVINYL CHLORIDE
1/2 0.720 0.41 0.021
3/4 0.930 0.69 0.036
1 1.195 1.11 0.058
1-1/4 1.532 1.83 0.095
1-1/2 1.754 2.41 0.125
2 2.193 3.75 0.195
2-1/2 2.655 5.50 0.290
Table 5–2. Nominal sizes and inside diameters for polyethylene (PE) and polyvinyl chloride (PVC) pipe.
Warm water
supply
Cold water
return
Pipe loops
Maximum length
3/4" pipe = 400'
1/2" pipe = 200'
77
crushed stone with 4 in. of porous concrete as the
working surface. Voids between the crushed stones
are filled with water to provide the heat transfer
medium. Warm water is circulated through the
system to maintain the sump at the desired level.
Figure 5–5 shows such a system. Pipe loops can be
installed in the rock fill as a heat exchanger.
Bench heating systems are similar to floor systems,
except pipe loops require closer spacing. Three
systems are available in small diameter tubes
(approximately 0.2 in. I.D.) of EPDM elastomer that
are used for both under floor and bench heating
systems. One is a single tube, another is a two- or
four-tube design with tubes 3/4 in. on center. A
third system is a multi-tube design with tubes 3/8
in. on center. Water temperature for bottom heat is
generally in the 90–110°F range, depending on plant
requirements. Flow rate is set to produce an average
water velocity of 2–3 ft./sec. in the pipes to obtain
acceptable heat transfer without excessive friction
loss.
Electric resistance heaters are also available as
mats or grids. They can be used for bottom heat
with pots or flats set directly on them. Follow the
manufacturer’s directions for installation and use.
The example greenhouse will be used now to
illustrate selection of heating equipment. The
estimated heat loss for the greenhouse was
1,953,360 Btu/hr. (See page 70, Chapter 4). This can
be supplied by one or more distribution systems
depending on the situation.
SYSTEM NO. 1
This system consists of perimeter finned tube plus
a snow line of bare pipe under each gutter. A snow
line is a separate heat pipe under each gutter that is
valve-controlled; it is turned on during snowfall to
induce melting. Water at 180°F will supply heat. The
outer sections have more wall area than the inner
sections and will need more finned tube. Since the
bare pipe under the gutter is for snow removal, its
output will not be considered in sizing the finned
tube.
ht = 540,650 Btu/hr. for each outer section
ht = 436,100 Btu/hr. for each inner section
(Air exchange was the same for all sections.)
From Table 5–1 on page 75, two vertically stacked
lines 7-1/2 in. on center of 1-1/4 in. diameter pipe
with 38 4-1/4 in. x 4-1/4 in. fins/ft. will deliver
Figure 5–5. Flooded floor heating system.
Perforated PVC
supply pipe
Supply
Water flow
through rock fill
Perforated
return pipe
Return
4" porous concrete
12" crushed stone
3/4" average size
20 mil vinyl liner
1" foamed plastic board
6 mil polyethylene film
3"
Polyethylene pipe loop for
supplemental heat 12" O.C.
78
Figure 5–6. Pump capacity and supply header size for PE pipe bottom heat.
Figure 5–7. Heat flow from bottom heat in floors or benches.
For supply pipe length over 75' use next size larger than
indicated. Maximum loop length for 3/4" pipe = 400'.
Maximum loop length for 1/2" pipe = 200'.
No. of loops of maximum length indicated
Pump Capacity (GPM)
Supply Pipe Size (in.)
80
72
64
56
48
40
32
24
16
8
0
3
2-1/2
2
1-1/2
1-1/4
1
3/4" pipe
1/2" pipe
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
20 Btu/sq.ft.-hr.
Plants in soil or pots
15 Btu/sq.ft.-hr.
Surface covered with flats
Heat output (1000 Btu/hr)
Bed or bench area (sq.ft.)
1000 2000 3000 4000 5000 6000
40
30
20
10
60
50
80
70
100
90
0
79
2,040 Btu/hr.-ft. One line will deliver
1,200 Btu/hr.-ft. If two stacked lines are placed
along the outside wall, approximately 180 ft. of line
will be available. A single line will be placed across
the ends and along the interior column line to hold
approximately 140 ft. of finned tube and 90 ft. of
bare pipe. The stacked line will deliver
367,000 Btu/hr. and the single line 176,000 Btu/hr.,
for a total of 543,000 Btu/hr. The interior sections
require one line around the perimeter to hold
approximately 360 ft. of finned tube and 50 ft. of
bare pipe to provide about 436,000 Btu/hr. The
layout will have a main across the 96 ft. width at the
center, with heating lines branching from the main
to each section. If steam is the heating medium,
smaller tube, smaller fins, or less tube length will be
needed.
If a bench system is used, heating lines can be
mounted under each bench to provide bottom
heat. Benches must be in place prior to heating line
installation.
SYSTEM NO. 2
This system consists of bottom heat from buried
polyethylene pipe. The snow line below gutters is
also needed. Because bottom heat cannot supply the
maximum required, perimeter finned pipe will be
installed to provide additional heat.
ht = 540,650 Btu/hr. for each outer section
ht = 436,100 Btu/hr. for each inner section
From Figure 5–7 on page 78, the heat flow from the
floor will be 20 Btu/hr.-ft.2 for plants in pots. The
total heat available per section will be:
192 ft. (24 ft.) (20 Btu/hr.-ft.2) = 92,160 Btu/hr.
The outer section will need an additional
448,490 Btu/hr.; the inner sections will need
343,940 Btu/hr. One line of 1-1/4 in. diameter
tube with 38 4-1/2 x 4-1/2 in. fins/ft. around
the perimeter of each section will provide about
380 ft. at 1,200 Btu/hr.-ft. Each inner section will
have about 280 ft. of the same finned tube, plus 100
ft. of bare pipe. Approximately 19,000 ft. of 3/4 in.
diameter polyethylene pipe will be placed 12 in. on
center under the floor. This system requires a dual
heating system to provide dual temperature water:
180°F in the finned tube and 110°F in the floor loops.
A system providing 180°F water with a mixing valve
to get the 110°F water could also be used.
Natural convection air movement will develop in
a closed greenhouse with warm air rising to cool
against roof surfaces, then falling to the floor to be
warmed. The result is a warm air mass in the ridge
volume with large temperature variations possible
in both vertical and horizontal directions. Uniform
temperatures in the crop zone can be obtained by
using small fans to create slow horizontal movement
of the air mass (Figure 5–8 on next page).
Total fan capacity should be equivalent to moving
one-quarter of the greenhouse volume per minute
to assure relatively uniform distribution. Fans
should be mounted high enough to be clear of
personnel. Wire enclosures (guards) are necessary
unless the fans are 7 ft. or higher above the floor. If
greenhouse plants have tall, dense foliage such as
roses, tomatoes, or cucumbers, air movement can
be provided by using perforated polyethylene film
ducts that discharge within the crop.
Overhead perforated PE ducts used to distribute
warm air can also help maintain uniform
temperatures. However, if they are too high, warm
air may not reach the plants. Air leaving the
perforations has to overcome buoyancy forces and
does not have high enough velocity to reach the
floor if the tube centerline is more than eight feet
above the floor.
Cooling Equipment
Cooling equipment includes such items as vents,
fans, shading, evaporative pad systems, fogging
systems, and control elements. Propeller blade
fans used for greenhouse cooling are low pressure,
medium volume fans, either direct-connected or
belt-driven. Two-speed units are available to help
match supply with demand. There are some fan and
motor units available for which output varies from
maximum to about 10% of maximum. Fans are rated
according to output in cubic feet per minute (cfm)
against pressure in inches of water. Most greenhouse
fan assemblies, including housing, louvers, etc., are
80
Figure 5–8. Fan layout for horizontal air flow systems to provide uniform temperature distribution.
70'–120'
6-row
9-row
Notes:
1. Add a row of fans for each
additional 50 ft. of greenhouse
length.
2. For greenhouses with three
bays, air in the two outside bays
should move in the same
direction. For greenhouses with
odd numbers of bays, air in the
center three bays should flow in
the same direction.
3. Total fan capacity in cubic feet
per minute (cfm) should equal
one-fourth the house volume.
16" dia. circulating fans with
1/15 hp motors will generally
be sufficient.
Fan
Direction of air flow
8-row
7-row
Individual
2-row
3-row
4-row
5-row
81
rated at either 0.125 or 0.100 inches of water static
pressure. Motor size will vary with fan output.
Table 5–3 lists some fan specifications of output in
cfm with power required in watts. The power input
can be estimated by assuming one horsepower of
electrical output is equal to 1,000 watts of input.
Gravity and motorized louvers are available for both
inlet and exhaust use. Figure 5–9 on page 82 shows
some manually operated wall vents. Motorized
louvers should be used to prevent wind from
opening the louvers when heat is being supplied to
the greenhouse. Wall vents should be continuous to
avoid producing hot areas in the crop zone. Vents
should be motorized and their action controlled by
fan operation.
It is possible to cool greenhouses by using the
natural forces of wind and temperature, but
reasonably close temperature control requires a
mechanical system. In the example greenhouse,
147,456 cfm was required for maximum cooling. If a
48-in. diameter fan is selected with a rating of
18,900 cfm at 0.125 inches of water static pressure,
eight fans will be required.
147,456 cfm/18,900 cfm/fan = 7.8 fans—use 8 fans.
SIZE, DIA.
(in.)
SPEED
(rpm)
CAPACITY
(cfm)
MOTOR
(Free air) (0.125" W.G.) (hp)
Single speed, direct driven:
10 1,100 560 380 1/20
10 1,725 910 840 1/6
12 1,150 1,240 780 1/8
12 1,725 1,640 1,525 1/6
14 1,050 1,250 1,020 1/20
14 1,725 2,100 2,005 1/6
16 1,150 2,630 2,190 1/6
16 1,725 2,800 2,680 1/4
18 1,150 3,110 2,620 1/6
18 1,750 4,130 3,720 1/2
24 1,140 4,400 4,100 1/4
30 860 11,000 10,150 1
Single belt, belt driven:
30 650 8,570 7,520 1/8
30 650 8,570 7,520 1/2
30 670 12,100 10,700 1
36 476 10,900 9,550 1/2
36 505 14,200 11,900 3/4
42 420 15,300 13,330 3/4
42 462 16,800 15,200 1
42 385 14,700 11,800 1/2
48 308 17,500 13,400 1/2
48 382 21,400 18,900 1
Two speed, direct drive:
16 1,725 2,543 2,353 1/3
1,140 1,675 1,374
18 1,725 4,065 3,880 5/8
1,140 2,686 2,395
24 1,110 5,520 4,800 1/3
800 4,010 2,800
Table 5–3. Typical fan performance data.
82
Figure 5–9. Manually operated ventilation walls: a) Winch rolled film, opens from bottom; b) Winch raised film, opens
from top; and c) Hand-crank rolled plastic film, opens from bottom.
A. Winch rolled, opens from bottom.
B. Winch raised film, opens from top.
C. Hand crank system to roll plastic
film, opens from bottom.
Brackets to keep
plastic in place
Attach plastic film to
PVC or aluminum pipe.
Hand
Crank
Film battens
Greenhouse
frame
Greenhouse frame
7/32" dia. PVC wrapped
steel cable
Pulley
1/2" dia. steel cable
steel
conduit
Bracket
3" dia. PVC
or aluminum
pipe
Batten for film
Manually operated
worm gear winch
Manually operated
worm gear winch
Greenhouse frame
Film battens
steel cable
3/4" dia. steel conduit
or 3/4" PVC pipe
83
The eight fans could be staged to operate as follows,
with the thermostat setting (°F) activating fans:
First stage 75°F 2 fans running
Second stage 78°F 4 fans running
Third stage 81°F 6 fans running
Fourth stage 84°F 8 fans running
Maximum vent opening should be 147,456 ft.3/min.
÷ 250 ft./min. = 590 ft.2 and should extend the length
of the wall. The maximum opening width should be
590 ft.2 ÷ 192 ft. = 3.1 ft. (use 3 ft.).
If a cellulose pad system is used for evaporative
cooling, pad area should be equal to vent area.
Water flow should be 96 gpm and sump capacity 432
gal. The calculations are shown in the worksheets
in Appendix XII. Figure 5–10 shows a complete
environmental control system. Figure 5–11 shows a
fogging system as an alternative for evaporative pad
cooling.
Control Systems
A control system consists of a sensor (to detect a
change and produce a signal related to the change),
a signal receiver, a comparator and an operator (to
respond to the change to bring about an increase
Figure 5–11. Fog system for evaporative cooling.
Figure 5–10. A complete system for temperature control in a greenhouse.
Perspective
Intake louver for
mild weather cooling
Exhaust fans
PE tube
Unit heater
Powered side wall vent
for intermediate cooling
Aspirated Sensor
Box Wetted pad for
maximum cooling
Finned tube
Perimeter heat
Circulation and mild
weather cooling fan
Fog
nozzles
Intake louver
Pump control thermostat
Exhaust fan and inlet louver
High pressure pipe control thermostat
Pressure gauge
Pressure relief valve
Pump (2–300 psi)
Filter
Water supply Exhaust fans
Notes
1. Nozzles−4.5 gal/hr @ 200 psi
2. Filter−100 mesh
3. Pipe−copper or steel, 3/8" ID for up to
20 nozzles
4. Pump−1–2 gal/min at 2–300 psi
5. Pressure gauge−0–500 psi
84
or decrease in supply). All control systems attempt
to satisfy the conditions represented by the sensor;
therefore, the sensor location is critical. Sensors
placed in an aspirated box will result in better
control than if exposed directly to the greenhouse
environment. Figure 5–12 shows an aspirated box
for all air environment sensors.
Automatic control systems sense and measure the
variable, compare the measurement to a standard
and, if needed, activate proper components to bring
the measured variable into agreement with the
standard. Environmental control systems deal with
supply and demand.
CONTROL SYSTEM TERMS
Range—The value of the variable between upper
and lower limits of operation. The range of a
thermostat might be 35–95°F.
Sensitivity—The ratio of output response to a
specified change in the variable—that is, how much
the temperature has to change before the control
responds.
Differential—In a two-position controller, the
smallest range of values through which the variable
must pass to move the final control element from
one fixed position to another. Many thermostats
used in greenhouse temperature control have a
3–5°F differential.
Capacity—Usually the size of electrical contacts
of the controller. Ratings are generally given in
amperes, volts, watts, or horsepower.
Precision—The ability to reproduce a given
measurement at different times and obtain the same
value. Precision is affected by static and dynamic
errors.
Lag Coefficient—The time required for a sensor to
respond to 63.2% of the total change in a variable.
If air temperature changes, it will take a certain
amount of time for the thermostat sensor to sense
the entire change. This is also referred to as the
speed of response.
There are two basic control system classifications:
those providing on-off control action and those
providing proportional control action. The typical
control systems in greenhouses provide on-off
action. For example, a watering system is either
supplying water or not supplying water; a fan is
either operating at a constant speed or not operating
at all. A two-position valve on a steam line is either
fully open or fully closed.
Figure 5–12. Aspirated box for control sensors.
Box or muffin fan
40−60 cfm
Mounted to exhaust air
from box continuously
Mount box at plant height.
Make box large enough
for all sensors
Sensors
Air intake
Hasp
Hinged door
85
The demands of plants in the greenhouse vary with
species, cultivar, stage of growth, light intensity,
temperature, carbon dioxide content, and nutrient
supply, none of which are constant with respect
to time. Thus, an on-off control system generally
results in supply oscillating above and below
demand. The range defined by the upper and lower
limits is referred to as the band width; the objective
is to keep band width to a minimum.
TEMPERATURE
The original temperature control system consisted of
the grower observing plant conditions and sensing
temperature changes, then adding fuel, etc., if the
temperature dropped lower than desired, or opening
doors if it rose too high. Improvements included
hanging a thermometer in the greenhouse and
adding hand-powered valves and vents to help the
grower. Early electrical/mechanical control systems
included motorized valves and vents activated by
thermostats. The greenhouse need for heating or
cooling will vary with outside temperature, and,
because of lower thermal mass, a change in outside
temperature will result in an almost immediate
change in demand. If a uniform temperature is
desired, the control system must be able to respond
quickly to changes in demand.
Temperature sensors can be any one or more of the
following: bimetallic strips, mercury-filled tubes,
gas-filled capillaries or wafers, thermocouples, or
thermistors. All except the last two sensors respond
relatively slowly to temperature change. The sensed
change produces a switching action to activate
valves, start motors, ignite burners, etc., to satisfy
demand. All of the above sensors are being used in
greenhouse environment control systems, the gasfilled
capillary being most common.
A thermostat consists of a sensor and a switch to
control equipment operation. The differential of a
thermostat is the number of degrees (°F) between
switching actions. Most greenhouse thermostats
have a 3.5–5°F differential, so if a heater control is set
to supply heat when the temperature falls to 55°F,
the heater will remain operating until the sensor
temperature reaches 58.5–60°F.
The range of a thermostat is the temperature span
between maximum and minimum temperatures
within which switching action will occur. Most
greenhouse thermostats operate in a range of
35–105°F. Thermostats normally provide on/off
control—that is, equipment is operating at rated
output or is not operating at all. This is also referred
to as two-position control and generally produces
temperatures either above or below the desired
value, called overshooting.
Control can be improved by staging the supply—by
using more than one thermostat, each set to operate
at a different temperature and control a part of the
supply. The grower must be satisfied with a range
of temperatures if this system is used. Heating
systems seldom use more than two stages; cooling
systems may use as many as five. A simple five-stage
electrical/mechanical control system is shown in
Figure 5–13 on page 86.
Temperature control can be improved by using
a system in which supply varies with demand.
An example is a proportioning valve for steam or
hot water or a fan motor speed that varies with
demand. Computer-operated control systems are
now available that have the ability, with proper
programming and supply equipment, to maintain
not only temperature but any other environmental
parameter that the grower desires.
RELATIVE HUMIDITY
Several materials can be used to sense changes in
relative humidity. Human hair is used in commercial
humidistats. Hair length changes in response to
moisture content of the air, producing a switching
action to activate equipment. Other sensors include
certain wood species, hygroscopic salts on noble
metal, and optical/fogging devices.
A simple sensor uses two thermocouples or
thermistors, one of which is enclosed in a wetted
wick, both suspended in a moving air stream. The
wetted sensor will cool to the wet bulb temperature
of the air; the dry sensor will remain at dry bulb
temperature. At any given dry bulb temperature,
there is a corresponding wet bulb temperature for
each relative humidity value. Humidistats require
frequent checking (at least weekly) to ensure
their accuracy. They can be calibrated using a
psychrometer, an instrument for measuring wet and
dry bulb temperatures.
86
Controlled equipment may be fans, heaters, valves,
or vents, depending on the system used to add or
remove moisture. Moisture can be added by water
spray or steam, and can be removed in cool or cold
weather by exchanging greenhouse air with outside
air.
PRESSURE
Boiler operation, irrigation and misting systems,
and bin filling level control are all examples of
operations using pressure sensing. Several devices
can be used to sense pressure. Bellows are used in
water systems and air compressors in which fluid
pressure causes the bellows to expand or contract
to control an electrical switch. A bourdon tube is
formed on an arc with one end closed, the other
end open to the fluid pressure. The tube is mounted
at the open end so an increase in pressure tends to
straighten the tube, causing the free end to move
and control equipment action. Helical and spiral
wound tubes are also used to transfer pressure
differences to mechanical action. Diaphragms can be
Figure 5–13. An example of greenhouse temperature control with five cooling stages.
THERMOSTAT #1 Hot THERMOSTAT #2 THERMOSTAT #3
Neutral
115 v.
12345
Relay Relay Relay Relay Relay
SPST SPST SPDT SPDT SPST
11
1
22
Neutral
Hot
115 v.
Circ. Fans Louver Ex. F. Ex. F. Ex. F. Vent Ex. F. Pump
1-L2-L1-H2-H
Stage
Normal
1
2
3
4
5
Circ. fan
on
on
on
off
off
off
Louver
closed
open
open
closed
closed
closed
Vent
closed
closed
closed
open
open
open
Exh. Fan 1
off
low
low
high
high
high
Exh. Fan 2
off
off
low
low
high
high
Pump
off
off
off
off
off
on
87
used to sense and respond to pressure changes, with
diaphragm movement used to control equipment
operation.
TIMERS
Many greenhouse operations are time dependent.
Examples are misting systems for propagation units
and watering systems for pot plants.
Twenty-four hours and seven days are common
cycle or interval lengths for time clocks, which
open and close contacts at preset times by inserting
appropriate trippers, riders, or pins in a dial.
Percentage timers have switches that close electrical
contacts a percentage of the cycle. Variable interval
timers or recycling timers continuously repeat a
cycle, the length of the cycle being adjustable from
a few seconds to several hours. Timers can be either
spring or electrically driven.
LIGHT
Light intensity or quantity can be used to control
operations such as thermal blanket position or
carbon dioxide supply. In a photo-conductive cell,
the current flow is a function of light intensity,
voltage drop, and cell design. A photovoltaic cell
converts light energy directly to electrical energy,
causing a current to flow without external voltage.
An example of a light sensitive device is a dusk-todawn
safety light controller.
Controllers and
Computers
As more environmental factors in the greenhouse
are controlled, there comes a point when individual
controls (thermostats, humidistats, etc.) cannot be
coordinated to prevent system overlap. An example
is the greenhouse thermostat calling for heat while
the exhaust fans are still running. To overcome this
overlap, several manufacturers have developed
controllers which handle specific segments of the
control job.
Most controllers use a microprocessor, a solid state
integrated circuit, to receive environmental data and
create output signals that activate equipment based
on a set of internal programmed instructions. The
microprocessor is a simple, low-cost device that is
reliable, accurate, and works well in a greenhouse
environment.
Greenhouse controllers are most commonly used for
temperature and irrigation. Temperature controllers
are available in sizes from 5–11 stages. They will
sequence the operation of fans, louvers, wet pad
pumps, and heaters. Day-night changeover, override
switches and adjustable band widths are included
on most models. The use of solid state electronics
reduces maintenance. Irrigation controllers can be
programmed for day of the week, cycle time, and
number of cycles per day. Available in 5–23 stations,
they are designed to activate 24-volt solenoid valves
for each zone. The program can be changed easily to
fit changing plant needs.
The microprocessor is the basic processing unit
of the microcomputer system. Also included are
additional input/output devices, peripherals,
interfaces, and other hardware. The computer has
an advantage in that information can be displayed,
stored for future use, or printed. Instructions to the
controller should be easy to change.
Computers have been used for some time in
the greenhouse industry for inventory control,
order processing, scheduling, billing, and general
bookkeeping. They were not used for environmental
control until recently, and very few systems are
in place or available. The primary reasons for the
slow adoption for environmental control are lack
of software, cost, and inadequate sensors for the
environmental parameters. Their use will gradually
increase as more control programs become available,
along with facilities and technicians for installation
and service. Computers probably will be used first
in new facilities rather than to replace controls
already in operation. With proper programming
and equipment, it should be possible to control all
parameters affecting plant development as precisely
as management requires.
Before computers become common in greenhouses,
better data on plant environment requirements must
be available. For example, how is plant growth or
flowering affected by light level or total daily light
energy received? Developing plant models that
88
predict response to changes in environment is time
consuming and expensive, but, once the information
is available, it will change greenhouse production by
allowing the grower to more accurately match input
to plant requirements. The results should be shorter
production time and better quality control.
Some advantages of computer use are:
1. The computer always knows what all systems
are doing and, if programmed properly, can
coordinate these systems to provide the
optimum environment.
2. The computer can record environmental data.
This can be displayed to show current
conditions or stored and processed to provide a
history of the cropping period. Data may be
displayed in table or graph form.
3. A high-speed computer can control several
remotely located greenhouses. By placing the
computer in a central area, the results can be
monitored frequently by management.
4. With proper sensing systems and programming,
the computer can anticipate weather changes
and make adjustments in heating and
ventilation systems, thus saving energy.
5. The computer can be programmed to sound an
alarm if conditions become unacceptable and to
detect sensor and equipment failure.
To be effective, the greenhouse should have systems
with variable or proportional control or, at least,
equipment that can be staged. There is no need
to use a computer to turn a single fan or heater
on or off when a thermostat can perform this just
as effectively. However, simple controls cannot
integrate temperature, light, humidity, carbon
dioxide, plant moisture, and nutrient needs along
with weather conditions. A computer with proper
programming can provide the integration desired.
Select a computer based on the following features:
1. The ability to sense and control environmental
parameters considered essential for optimum
crop production.
2. User friendly software with meaningful and
versatile output.
3. Technical assistance available for startup and
troubleshooting.
4. Maintenance, service, and spare parts readily
available.
5. Versatility, so that new equipment, plant
models, and cultural practices can be added to
the system.
In the future, computers may be used in seeding,
transplanting, and materials handling equipment,
as well as in environmental and financial control
systems.
Alarm Systems
An alarm system is an inexpensive form of
insurance that can protect the large investment
in greenhouse plants. Alarms can indicate that an
environment control system has failed, a power
failure has occurred, a fire has started, or an intruder
has entered a building.
The basic alarm system consists of sensors, a
power supply, wiring, and a warning device. A
simple alarm is a battery-operated door bell using
a thermostat as a sensing device (Figure 5–14,
opposite page). When the greenhouse temperature
falls below the thermostat setting, the bell is
activated. Additional sensing devices can be added
in parallel. A review of the basic system components
follows.
Many types of sensors can detect an emergency
condition. The sensor must be designed so that
a switch is closed when an emergency condition
exists, completing the electrical circuit and activating
the warning device. Table 5–4 on the opposite page
lists some common emergency conditions which
can be sensed in a greenhouse, the type of sensing
device commonly used, and where it should be
located.
Most alarm systems are powered by low voltage DC
batteries (6–24 VDC) and are not dependent on 115-
volt electric utility supply that could be interrupted.
89
Figure 5–14. Basic alarm system.
Some systems contain a 115-volt battery charger to
keep the DC battery charged.
The warning device must get the operator’s
attention and result in corrective action. The
following devices are commonly used:
Bell
Located in the home or office, it can be installed to
ring continuously until manually disconnected.
Siren or Horn
Used in large ranges or nurseries, it is mounted
outdoors for maximum area coverage.
Table 5–4. Typical alarm system sensors.
EMERGENCY CONDITION SENSING DEVICE LOCATION OF SENSOR
Air temperature—too high or low Thermostat–thermistor Plant height
Humidity too high Humidistat Plant height
Power failure Relay Electric supply line to furnace,
fans, etc.
Boiler failure Low pressure switch
Low water switch
Steam or water line
Water tank
Pump failure Pressure switch Supply line from
pressure tank
Soil temperature Soil thermostat Bed or bench
Soil moisture Pot scale
Evaporator simulator
Electrical conductivity device
Bench
Bench or bed
Soil bed
Burglar intrusion Proximity switch
Switch mat
Ultrasonic detector
Doors, windows
In front of door
Headhouse/garden center
Tank water level Float switch In water or nutrient tank
Smoke Smoke detector
(photoelectric or ionization)
Near ceiling in headhouse,
greenhouse, or garden center
Fire
Thermal switch
U.V. fire detector
Near furnace
Near ceiling
Snow Snow detector Outside in unobstructed area
Other sensors
Power failure relay
Thermostat
Bell, buzzer or
light
Switch
Battery
90
Light
Located on panel boards in the office or home;
sometimes a light is placed on the top of each
greenhouse to indicate which one has the
emergency.
Telephone
Used when the operator’s home is relatively far
from the greenhouse or so that a second or third
person can be called if the first does not respond.
This type of unit requires the use of an existing
or separate telephone line. A short time delay can
be installed in some units so that a short power
interruption is disregarded. Most units have a sensor
that activates the circuit, and a continuous tape with
several telephone numbers inscribed starts dialing.
If the first number is not answered after a short
time, the unit dials the second number, etc. When a
telephone is answered, a second tape is activated to
play a recorded message indicating an emergency.
Except for the telephone systems, plastic-covered
bell wire (16–20 gauge) is commonly used for hookup
wires. Maximum distances should be checked
before purchasing wire. Locating the wires below
ground is best to prevent damage from snow and ice
storms.
Standby Generators
Power interruption can create serious problems
for plant growers any time throughout the year.
If power outages occur in winter, greenhouse
temperatures can drop to freezing levels in a short
time. If they occur in summer, ventilation systems as
well as watering systems will be inoperative.
A list of all electrical equipment in each greenhouse
and accessory building should be made, and should
include the size, type, HP, amperage, voltage, and
phase of all motors, and the number and wattage
of all lamps. Identify those which must be operated
during an emergency and, before purchasing a
generator, go over the details of the installation with
an electrician and a representative of the power
company. The local building code and National
Electrical Code must be followed. The following
example illustrates how to size a standby generator.
A grower has two 20 ft. x 100 ft. glass greenhouses
and a small retail sales stand. Table 5–5 lists
equipment that must continue to operate (not all at
the same time) during a power outage.
The maximum load would be during the summer
when all equipment except the furnaces and lighting
may be operating at the same time. The total starting
load of this equipment is 11,100 watts. Because all
the motors will not be started at the same time,
reduce this figure by one-third, for a total of 7,400
watts. A 7,500-watt generator will handle this
load during a power outage. If future expansion is
planned, a 10,000-watt generator should be installed.
Several requirements must be met when installing
a standby unit. The unit should be placed in a dry
location, and, if it is to be powered by a tractor, a
readily accessible location is needed. Power unit
exhaust should be vented to the outside of the
building.
The standby power unit must be connected to the
wiring system through a double pole-double throw
switch (Figure 5–15, opposite page). This keeps
EQUIPMENT SIZE VOLTAGE
STARTING
AMPS
STARTING
WATTS
FULL LOAD
WATTS
2 Furnace motors 1/2 hp 110 20 ea. 4,600 1,150
4 Fan motors 1/4 hp 110 10 ea. 4,800 1,200
1 Water pump 1/2 hp 110 20 ea. 2,300 575
1 Refrigerator 1 hp 220 18 ea. 4,000 1,000
Plus ten 100-watt lights 1,000 1,000
Table 5–5. Equipment which must continue to operate during power outages.
91
Figure 5–15. System transfer switch.
power from the generator from being fed back
through the power company lines and injuring
linemen working on the wires.
After the standby generator has been installed, a
strict maintenance schedule should be followed so
that equipment will always be ready to operate. Run
the equipment at least once a month under load and
keep a record of the testing dates. Store extra fuel in
a safe place. Train personnel to operate the unit in
the event of a power interruption.
An emergency operating procedure should be
developed. Before starting the generator, shut off
all electrical equipment. Place the double throw
switch in position to operate the generator. After the
unit starts, check the voltmeter, then place essential
equipment into operation, starting with the largest
motor first.
References
ASHRAE. 1992. Handbook of Equipment, Tullie
Circle, Atlanta, GA 30329.
Edwell, D.L. et al. 1985. Soil Heating Using Subsurface
Pipes. Res. Bul. 1175. Ohio Ag. Res. & Dev.
Center, Wooster, OH.
Koths, J.S. and J.W. Bartok. 1985. Horizontal Airflow.
Bul. 85-14. Coop. Ext. Service, University of
Connecticut, Storrs, CT 06268.
Roberts, W.J. and D.L. Mears. 1984. Floor Heating and
Bench Heating for Greenhouses. Publ. E-047. Coop.
Ext. Service, Rutgers University, New
Brunswick, NJ 08903.
To power company service
Meter box
Transfer switch
Polarized 220 volt
Plug and outlet
To generator
Main
disconnect
switch and
fuse box
923
Chapter 6:
Environmental Modification
Lighting
Light is generally considered the most limiting
factor in plant growth and development. Recent
improvements in lamp design and lighting methods
have increased the use of electric lighting for
commercial production of ornamental and vegetable
plants in greenhouses and growth rooms.
In selecting and designing a lighting system, many
factors have to be evaluated. These include:
1. Plant response to light,
2. Influence of other environmental factors,
3. Light level, duration, and spectral requirements
of the plants,
4. Light sources that will give the best results,
5. System layout that will give the most even light,
and
6. Initial and operating costs of the system.
LIGHTING BASICS
Photosynthesis is the conversion of carbon dioxide
and water to carbohydrates using light energy.
Plants respond to the visible light part of the radiant
energy spectrum (Figure 6–1). Traditionally, this
response has been considered to be maximum in
the blue and red regions (called Photosynthesis
Action Spectrum I) as compared to maximum visual
eye response in the green-yellow region. Recent
research indicates that, at higher light levels, plant
growth is independent of spectral differences and is
proportional to the total radiation received between
400 to 850 nanometers (Figure 6–2, opposite page).
Light can be expressed in photometric or
radiometric quantities. Photometric refers to human
eye response and radiometric to plant response to
light.
Figure 6–1. Radiant energy spectrum.
Frequency (cycles per second)
Wavelength (meters)
Hertzian waves
Wavelength in nanometers Power
Transmission
Broadcast
Short wave
Television
Directional
Radio (Radar)
FM
Infrared
Near Far
Ultraviolet
Vacuum U.V.
X-rays
Hard Soft
Gamma rays
Cosmic rays
Light
Violet Blue Green Yellow Red
380 400 500 600 700 760
10 -14 10 -12 10 -10 10 -8 10 -6 10 -4 10 -2 1 10 2 10 4 10 6 10 8
10 24 10 22 10 20 10 18 10 16 10 14 10 12 10 10 10 8 10 6 10 4 10 2
1 X-unit
1 angstrom
1 nanometer
1 micron
1 cm
1 meter
1 kilometer
93
Figure 6–2. Plant growth vs. spectral differences.
PHOTOMETRIC QUANTITY
Luminous Flux—The rate of emission of light from
a source with respect to the sensitivity of the human
eye, measured in lumens (lm).
Illuminance—The luminous flux density incident
on a surface, in lumens per square meter expressed
in lux (lx) or lumens per square foot (lm/ft2)
expressed as foot-candles (fc). One lux equals 10.76
foot-candles.
RADIOMETRIC QUANTITY
Irradiance—The radiant flux density incident on
a surface; that is, the radiant energy received by a
surface. The units are Watts per square meter (W/
m2) or milliwatts per square meter (mW/m2) or in
watts or milliwatts per square foot (W/ft2, mW/ft2).
Luminous Efficacy—The ratio of total luminous
flux emitted by a lamp to the energy consumed
expressed in lumens per watt (lm/W).
The best unit for expressing the energy requirement
of a specific plant species is the irradiance expressed
in milliwatts per square meter or milliwatts per
square foot (mW/m2, mW/ft2). It is a measure of
the quantity of energy in wavelength band 400 - 700
nanometers (nm) received by the plants. Since footcandle
meters are readily available, it is easier to
evaluate lighting levels in foot-candles and convert
the reading to mW/ft2 using the conversions given
in Table 6–1 on the next page.
There is a fixed relationship between the lumen
output of a given lamp and the mW experienced
by the plants; however, this relationship is different
for the different types of lamps. For example, an
incandescent lamp of 150W produces 2,850 lumens
of visible light and 11,970 mW of radiation usable
by the plants. The ratio of 11,970 divided by 2,850
equals 4.2 mW/lm, the conversion factor for that
lamp. Table 6–1 on the next page gives energy
values and conversion factors for several lamp
types.
The light intensity at any point distant from the
source varies inversely as the square of the distance;
that is, if the distance between plant and light
source is doubled, the light intensity is reduced
to one-quarter of its original value. Therefore, the
distance from light source to the plant is important
in positioning lamps for both irradiance (intensity)
and distribution of light over the plant area.
Incandescent and HID lamps can be considered
point sources of light while fluorescent tubes are
line sources of light. Reflectors can help equalize
the distribution and increase intensity at the plant
from both point and line sources. It is important to
remember that the irradiance being considered is the
light at the surface in question — for example, the
bench top or plant container top. The relationship
400 500 600 700 800
NANOMETERS
RELATIVE RESPONSE
Standard Luminous
Efficiency Curve
(CIE)
Photosynthesis Action
Spectrum I
Photosynthesis Action
Spectrum II
9945
between light source and distance from the source is
illustrated in Table 6–2. Note that the inverse square
relationship does not hold for the units shown
because of the effect of the reflectors.
Most manufacturers and suppliers of HID lamps
have methods for calculating the number, spacing,
and height above the crop to produce a given light
level at the crop. The spacing and height mounting
for a particular application will depend on the
fixture being used. A uniformity ratio, the ratio of
minimum irradiance, Emin, to maximum irradiance,
Emax, (Emin/Emax) of 0.7 or greater is recommended
since the more uniform the irradiance, the more
uniform the growth.
Table 2 of Appendix IX gives recommendations for
plant irradiation.
The following is an example of locating lighting
fixtures for plant growth:
A grower has a 9' x 128' hydroponics table over
which 400-watt high intensity discharge (HID)
lamps are to be suspended. A light intensity of 8600
lux (800 fc) is desired. From Table 6–1, the effective
LIGHT SOURCE INCANDESCENT
150W
FLUORESCENT
F40CW
40W
HP SODIUM
400W
METAL HALIDE
400 W
Total Input (W) 150 48 440 425
Lamp Flux (lm) 2,850 3,150 48,000 31,500
Effective Flux (lm)** — — 38,400 25,200
Lamp Flux (mW) 11,970 9,135 110,400 88,200
Conversion Factors (mW/lm) 4.2 2.9 2.3 2.8
Effective Flux (mW)** — — 88,300 70,600
Table 6–1. Energy values and conversion factors for four types of lighting units.*
* Poot, J. 1984. Application of Growlight in Greenhouses. Poot Lichtenegie B.V. Westlander 42, 2636 CZ Schipluiden, The
Netherlands.
———Horticultural Lighting. Philips Lighting Company, 200 Franklin Square Drive, P.O. Box 6800, Somerset, N.J.
08875–
6800.
** The effective flux is assumed to be approximately 80% of the lamp flux for the two HID lamps. It can vary from a
low of
less than 50% to a high of 70% for incandescent and fluorescent lamps, depending on reflectors.
Table 6–2. Illumination at various distances from cool white or warm white fluorescent lamps (fc).* Measurements
made
directly under the center of the fixtures.
DISTANCE FROM LAMP
(ft.)
STANDARD 40W T12 FIXTURES
2-F40 2-F40
0.5 500 700
1.0 260 400
2.0 110 180
3.0 60 100
4.0 40 60
* Cathey, H.M. and L.E. Campbell. 1978. Indoor Gardening—Artificial Lighting, Terrariums, Hanging Baskets, and Plant
Selection. U.S. Department of Agriculture, Washington, D.C.
95
flux from a 400W, HID sodium lamp is 38,400
lumens. The number of fixtures is equal to the light
level times the surface area to be lighted divided by
the effective flux, or,
N = light level x surface area = 800 x 9 x 128 = 24 fixtures
effective flux 38,400
The fixture pattern is defined as the horizontal
spacing and the height above the crop surface. If H
is the height, L the distance between fixtures along
the line, and B the distance between lines, then for
a PL-1078/400 high pressure sodium luminaire, L
should not exceed 1.55H, and B should not exceed
2.7H for a uniformity of at least 80% (Poot, 1984).
These relationships will be different for each
luminaire depending on manufacturer and type.
The light level is equal to the effective flux divided
by the area, or
The area A = L x B = 1.55H x 2.7H = 4.2H2
Therefore, H (the height above the table) =
L = 1.55 x H = 1.55 x 3.38 = 5.24 feet
B = 2.7 x H = 2.7 x 3.38 = 9.13 feet
The fixtures should be placed with the long axis of
the fixture across the table and spaced 5' 3" apart
down the length of the table.
Vegetative response in plants is directly related
to the amount of light energy received by the leaf
surfaces. Leaves near the top of the plant receive
more light and tend to grow more. Plants also have
a saturation level, a level at which additional light
does not increase growth. This varies from
100–300 fc for foliage plants to over 3,000 fc for
certain vegetable and ornamental crops. The
saturation level also varies with the age of the plant
and other environmental factors. Generally, it is
more efficient and cost effective to supply a lower
light level over a long period of time than a very
high light level for a short period.
Light and dark periods (photoperiod) and their
relative lengths have an effect on plant maturity,
blossoming, tuber and bulb formation, and seed
germination. This relationship, first reported in
1920 by two USDA scientists, has greatly influenced
greenhouse crop production.
Although many plants can grow under continuous
light, most require a dark period each day for
normal growth. Since ideal photoperiods of plants
vary, plants have been classified into three main
groups: short day, long day, and indeterminate
(those influenced by temperature and latitude).
Classification of some common plants is shown in
Table 6–
3.
Table 6–3. Light period length for some common plants.
SHORT DAY
(10–13 hr.)
LONG HOUR
(14–18 hr.)
INDETERMINANT
(12–18 hr.)
China Aster Annuals African Violet
Christmas Begonia Calceolaria Begonia
Chrysanthemum Carnation Coleus
Cineraria Coreopsis Cucumber
Gardenia Dahlia Geranium
Kalanchoe Nasturtium Gloxinia
Pointsettia Spinach Lettuce
Rose
Tomato
AF
4.2 x E
38,400
4.2 x 800
3.8 feet
42.

E
F
A
and, therefore, A =
F
E

9967
Research has shown that the growth controlling
mechanisms of some plants respond to extremely
short periods of supplemental light (flashlighting).
For example, experiments conducted at the
University of Connecticut have shown that paper
birch seedlings luminated with only one second
of light each minute will grow equally as rapidly
as those illuminated with continuous light. This
lighting pattern can result in significant energy
savings, but much additional research is needed to
determine which plants will respond in a positive
manner and at an economically profitable rate. In
the commercial practice of delaying flower bud
initiation in chrysanthemums and other similar
crops, it is necessary to provide as much as five
hours of additional light each night. The application
of flashlighting with only four seconds of light per
minute has proved to be as effective as continuous
light, with energy savings of over 80%.
Regulation of specific growth responses
(photomorphogenesis) is a complex process and is
not fully understood. Together with photoperiodism,
this is the method by which light regulates
germination, rooting, growth, elongation, flowering,
and many other morphogenic plant functions. Light
in certain parts of the spectrum is needed for these
reactions. In a greenhouse, sunlight usually meets
this need, whereas, in growth rooms, lamp selection
is important to obtain desired results.
The specific reaction of a plant to unequal light
energy on opposite sides is known as phototropism
(a bending of the plant toward the light). This
can often be observed in growth rooms with nonuniform
or point source lighting, or in greenhouses
with north wall or roof insulation. Careful
placement of the lights and the use of white or
aluminized surfaces to reflect light will reduce this
effect.
LIGHT MEASUREMENT
Lighting measurements concern three basic
quantities:
Luminous Intensity
Luminous intensity is the total output of a
light source measured in candle power. This
measurement is usually made by the lamp
manufacturer.
Illumination
Illumination of a surface is defined as the amount
of light falling on a unit area and is measured in
foot-candles (fc). For example, the illumination of
an operating room in a hospital should be at least
1,000 fc, whereas in a storage room it can be as low
as 5 fc. Illumination is the value you commonly
see for artificial lighting on plants. For instance,
African violets need about 600 fc for 12–
18 hr./day
to produce good growth.
Luminance
Luminance (brightness), measured in foot-lamberts,
refers to light that a surface gives off in the direction
of an observer. It can be either self-luminous or
reflective. Some surfaces reflect more light than
others, depending on whether they are lighter or
darker in appearance. Also, as you go further from a
surface, the apparent brightness decreases.
Instruments
Photometers measure illumination and are
commonly used in lighting work. They are lowcost
and readily available from greenhouse
suppliers. The photovoltaic type uses a selenium
cell containing a receiver that, upon absorption
of radiant energy, generates sufficient voltage to
operate a small electrical ammeter. It is usually
calibrated to give readings in fc. To get accurate
readings, the photometer should be color corrected
and cosine corrected. Color correction is done by
covering the cell with a filter that adjusts output to
the sensitivity of the human eye. Cosine correction
reduces the tendency of the cell to respond more
strongly to radiation perpendicular to it than
radiation at a wide angle.
The photometer, because of its sensitivity, can also be
used to obtain comparative values of radiant energy
(light + ultraviolet and infrared). A comparison of
the output of two lamps of the same type can be
made, such as the light output of two fluorescent
bulbs. It cannot, however, be used to compare
fluorescent lamps with incandescent lamps without
using a conversion factor that takes into account
97
variation in output at different wavelengths. This
conversion is easy to make, multiplying the reading
on the light meter in fc times the conversion factor
from Appendix IX. For example, a reading of
44 fc obtained under a cool white fluorescent bulb is
equivalent to 44 x 0.032 = 1.4 watts/m2.
Photometers, often referred to as light meters, are
available in several models. Things to consider when
purchasing one include:
1. Range—If the readings are to be made only on
artificial light in a growth room or indoor light
chamber, then a maximum reading of 2,000 fc is
adequate. For measurements in a greenhouse or
outdoors, a capacity of up to 10,000 fc is needed.
Most instruments have several ranges to provide
more accurate readings. A filter or multiplier is
frequently used to allow reading higher levels.
2. Accuracy—Meters having an accuracy within
5% or less are adequate for measurements for
hobbyists. Greater accuracy significantly adds to
the cost of the instrument.
3. Digital Readout—Although convenient, a
digital readout is not necessary to get accurate
readings, and it doubles or triples the cost of the
instrument.
4. Carrying Case—A case provides protection
when the light meter is not in use. Meters can be
easily damaged by banging or dropping.
5. Cost—Good light meters are available in the
$50–$100 range (based on 1994 prices).
To more accurately compare different light sources,
a meter that measures photosynthetically active
radiation (PAR) is desirable. While the photometer
measures the brightness sensation of the human
gene, the PAR meter measures the energy in the
400–700 nanometer waveband which stimulates
photosynthesis. Although no single measure could
represent all of the different ways that plants can
respond to radiation of different wavelengths, two
measurements are common:
1. The number of electromagnetic energy units
(photons) available on the leaf surface in units of
microeinsteins per square meter per second (μE/
m2s). This is called a quantum meter.
2. The amount of radiant energy available on the
leaf surface in units of watts per square meter
(watt/m2). This is called a radiometer.
Some instruments will give all three measurements,
including foot-candles.
LIGHT SOURCES
A knowledge of the construction, efficiency, and
electrical characteristics of light sources is useful in
making the best choice for plant lighting. In the past
decade, a number of new or improved light sources
with increased efficiency have become commercially
available (Figure 6–3 on the next page). Some have
been developed specifically for plant production.
Incandescent
The standard incandescent is used today mainly for
daylength control. Lamps vary in size from 40–500
watts at 115 and 230 volts. This range allows the
grower to vary the foot-candle levels by adjusting
the spacing and mounting height above plants. The
average service life is 750–1,000 hours. The standard
bulb is usually used with a dome reflector, which
directs light downward. Reflector and parabolic
reflector bulbs have built-in reflectors. Porcelain
sockets should be used for safety reasons and
installation should meet the requirements of the
National Electric Code.
Tungsten-Halogen
This is basically an incandescent lamp, but, because
of the design and the iodine vapor, the light output
remains the same throughout its life. The most
common bulb shape used in greenhouse lighting is
the parabolic reflector bulb. Lamp life is about 2,000
hours for most sizes, which are available up to 1,500
watts. However, the efficiency of light output is
relatively low compared to other types of lighting.
9989
Fluorescent
Until recently, fluorescent lamps were the standard
light source for growth chambers and rooms. The
availability of several lengths, outputs, and spectral
variations makes them adaptable to the needs of
most plants. Lamp life is 12,000 hours or greater, and
energy efficiency is 40–60 lumens/watt (Table 6–4 on
the opposite page).
Because the fluorescent lamp provides a linear
light source rather than a point source, as does the
incandescent, more uniform lighting is obtained.
Banks of lights can be used to obtain light levels
over 2,000 fc. A fluorescent lamp must at all times
be connected to an electrical supply through a
ballast specifically designed for it. The ballast, which
provides adequate voltage for starting the electric
discharge and limits the current, adds 5–15% to
the required operating energy. Both 4-ft. and 8-ft.
lamps are commonly used. Where high light levels
are needed, high output (HO) or very high output
(VHO) bulbs can be used. For most horticultural
applications, cool white bulbs will encourage good
growth. Bulbs developed specifically for plants
(Gro-Lux, Plant Light, Agro-Lite) will enhance plant
appearance.
High Intensity Discharge (HID)
These compact, high-output light sources are
becoming very popular for greenhouse and growth
room lighting. They are efficient producers of
photosynthetically active radiation (PAR) light, are
little affected by temperature changes, and require
little maintenance over a long life. Some have
provisions for remote ballasting, which allows the
partial removal of heat from the growing area.
Mercury—This HID lamp produces light by passing
an electric current through a gas or vapor under
pressure instead of through a tungsten wire, as in
the incandescent lamp. The typical mercury lamp
produces a bluish-white light with little output in
the red part of the spectrum. The most widely used
lamps for plant production are the 400 watt and
1,000 watt sizes. Lamp fixtures include the required
ballast and a reflector. Because of the high pressure
needed, several minutes are required for the lamps
to reach full brilliancy. If the current is interrupted,
even momentarily, the arc will extinguish and 5–10
min. will be needed before the lamp cools and can
be relit.
Figure 6–3. Comparison of lamp efficiencies.
* Includes
Ballast
Incandescent
Tungsten-Halogen
Mercury
Fluorescent
Metal Halide
High Pressure Sodium
Low Pressure Sodium
LAMP EFFICIENCY–Lumens/Watt*
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
99
Table 6–4. Comparison of light sources.
Metal Halide—This lamp uses iodides in addition to
mercury, resulting in a lamp design which generates
50% more light than mercury and has better color
quality. Metal halide lamp life ranges from 8,000–
15,000 hours. The lamps are designed for vertical or
horizontal operation, and some interchanging with
lamps in a mercury system is possible. For plant
growth, combinations of metal halide and high
pressure sodium on a one-to-one ratio are common.
Metal halides contribute more light in the blue-violet
part of the spectrum.
High Pressure Sodium (HPS)—This very high
output lamp provides light mostly in the yelloworange
part of the spectrum. Because of its high
efficiency, fewer fixtures are needed. Light is
produced by passing an electric current through
vaporized sodium under pressure at high
temperature. Development of a new ceramic arc
tube has increased the lamp life to over 20,000 hours.
Both 400 watt and 1,000 watt lamps are used in
greenhouse applications, the 1,000 watt lamps being
more cost effective if adequate mounting height
is available. As with other HID lamps, the high
pressure sodium lamp requires time to reach full
light output (3-4 min.) and about 1 minute after a
power interruption before it can be relit.
Low Pressure Sodium (LPS)—Light produced by
the low sodium lamp is yellow. Because they are
more efficient than high pressure sodium lamps,
research has been conducted by the USDA to
evaluate their potential for plant lighting. Cathey
and Campbell (1982) concluded that LPS plus the
addition of light from incandescent lamps applied
simultaneously generally produced plants of better
LIGHT
SOURCE
TYPICAL
WATTAGE
BALLAST
WATTS
TOTAL
WATTS
AVERAGE
LIFE
(hr.)
INITIAL
LUMENS
MEAN
LUMENS
LUMENS/WATT
inc. BALLAST
Incandescent 40 — — 750 460 430 12
100 — — to 1,740 1,630 17
200 — — 1000 3,940 3,500 20
Tungsten-
Halogen
75 — — 2,000 1,400 — 19
250 — — 2,000 5,000 — 20
Fluorescent 40 8 48 20,000 3,150 2,770 66
CW 75 16 91 12,000 6,300 — 69
CW-HO 110 16 126 12,000 9,000 7,700 74
CW-VHO 215 10 225 10,000 15,000 11,500 67
Gro-Lux 40 6 46 12,000 925 — 20
Wide Spectrum 40 6 46 12,000 1,700 — 37
Agro-lite 40 6 46 — 1,900 — 41
Vita-lite 40 6 46 — 2,180 — 47
Mercury 100 10 110 16,000 4,000 3,200 36
400 40 440 24,000+ 23,000 20,100 52
1,000 100 1,100 24,000+ 61,000 47,000 55
Metal Halide 400 25 425 15,000 40,000 31,000 94
1,000 60 1,060 10,000 125,000 100,000 118
High Pressure
Sodium
400 25 425 24,000 50,000 45,000 117
1,000 60 1,060 24,000 140,000 126,000 132
Low Pressure
Sodium
180 50 230 18,000 33,000 — 143
1001
quality and fresh weight than those grown under
LPS alone. To date, however, LPS lamps are not
often used in commercial production.
The bulbs are similar in design to fluorescent bulbs
but emit much more radiant energy. For example,
three 180 watt LPS lamps can produce as much
radiant energy as eight 150 watt fluorescent lamps.
Average life is about 18,000 hours. The lamp will
restart immediately after a power interruption.
Because less heat is generated, LPS lamps can be
placed closer to plants than HPS lamps.
Reflectors—Uniform distribution of light is
impossible without reflectors. Reflectors should be
designed to direct light in a uniform pattern over
the plant area. To reduce the amount of shading
from lamps used for supplemental lighting in
greenhouses, incandescent and fluorescent lamps
are available with internal reflectors. Considerable
research has gone into developing reflectors for high
output HID lamps (Figure 6–4). Original designs
limited the distance between fixtures to about
1.5 times the mounting height. New designs are
available that allow this distance to be increased
to as much as 4.5 times the mounting distance and
still attain uniform lighting. This is particularly
important in greenhouses with benches or low
ceilings and in multi-layer growth rooms. Figure
6–5 on the facing page and Figure 6–6 on page 102
show germination units using fluorescent tubes. The
walls and ceilings of greenhouses and growth rooms
should be painted white to serve as a reflecting
surface. Shields are available for some reflectors
to reduce the amount of light that spills into nonproduction
areas.
Figure 6–4. Greenhouse supplemental lighting: a) individual bench lighting; b) area lighting.
A. Individual Bench Lighting B. Area Lighting
101
SYSTEMS
The following is a discussion of typical lighting
systems used:
Photoperiod Lighting
This is usually accomplished by continuous lighting
for a period of four to eight hours before sunrise
or after sunset, or two to five hours during the
middle of the night. It can also be provided by cyclic
lighting of one to four seconds during each minute
or one to four minutes each hour. Light levels of 0.5–
5 watts/ft.2 of growing area are used. Incandescent
bulbs with internal or external reflectors suspended
over the benches work best.
Supplemental Greenhouse Lighting
HID lamps, either sodium vapor or in combination
with multi-vapor, are commonly used for
supplemental lighting. Bulb wattage depends on
crop requirements and height of the greenhouse (see
Appendix IX). For example, plants will utilize more
of the light energy supplied at 300 fc for 24 hours
than at 600 fc for 12 hours.
There are many factors in the design of an efficient
system. Placement of the luminares will depend
on the crop grown, light level desired, height of
the greenhouse, size of bulb used, etc. Most lamp
manufacturers use computer programs to design
systems; contact the manufacturer or supplier to
make use of this service. Another available option
is to install a movable lighting system. Luminares
can be mounted on overhead tracks or gantries
and moved continuously or intermittently over the
plants.
Growth Rooms
A closed, well-insulated room with optimum
environmental conditions provides for better
germination and seedling production. Often, multilevels
are installed, one above the other, to maximize
Figure 6–5. Germination/starting unit.
PLANT TRAY
1/2" x 4' x 8' Ext. CC Plywood
1" x 2" Furring Strip
CROSS BRACE
LIGHT FIXTURE SPACING
4'
4" 10"
3' 0"
8' 9"
2' 10-1/2"
4' 3"
Cross Brace
2" x 4"
2" x 4"
18"
6' 6"
Corner Post
4" x 4"
Notes:
1. Attach 2-tube 8' long fluorescent
strip fixture to bottom of cross
braces.
2. For 25 watts/sq.ft. use 10 bulbs
per shelf.
3. Each shelf requires a 10 amp
circuit.
4. Shelf spacing can be varied
depending on type and size of
plants to be grown.
5. Top and sides should be covered
with white polyethylene or
aluminum foil.
6. Joints fastened with #12 x 3"
flat head brass wood screws.
1023
space utilization. Levels as close as 18 in. can be
obtained using fluorescent lamps, and 30 in. with
some of the new HID lamps.
Light levels of 1,000–2,000 fc are common, creating
excess heat that could be utilized in adjacent work
areas or greenhouses. A heat pump and water
storage could be adapted to store the heat for later
use.
CONTROLS
Lighting systems require adequate electrical service
with proper wire size. When installing a system,
total the amperes of electricity needed for the lamps
and ballasts. Add this value to the amperes required
for heating, ventilation, pump, and materials
handling equipment that may be operating
simultaneously to size the service entrance
capacity.
Figure 6–6. Germination cart.
Lamps should be installed in zones that cover one
or more greenhouse benches or growth room levels.
Electrical conductors should be sized so that voltage
drop within the building is no more than 3%.
Time control is commonly accomplished using a
24 hr. on /off time clock. Standard industrial
time clock switches are available with a 40 amp
capacity. Larger loads require the use of a power
relay. Cyclic lighting for photoperiod control utilizes
cam-operated microswitches, which are available
from electrical equipment suppliers. Daytime control
of a supplemental greenhouse lighting system
utilizes a photoelectric cell that can be adjusted
to the desired light level. A rule of thumb is that
the lighting system should be activated when the
sunlight level falls to twice the level provided by the
lights. For example, if the lighting system provides
500 fc at plant level, it would be turned on when
GERMINATION CART
10"
10"
10"
4' - 8"
2' - 0"
Seedling
Flats
4' - 2" tube
Fluorescent Strip Fixtures
with cool white tubes
Use Heating Tape or Agritape on Bottom
Shelf. Make provisions for Temperature
Control. Enclose sides with white polyethylene
film to retain heat and reflect light.
103
the sunlight level falls to 1,000 fc. Often a one- or
two-minute time delay is installed in the system to
prevent the activation of the lights when the sun is
covered by a cloud. Computer control of lighting
is also possible. As plant models are refined, better
integration of the environmental factors affecting
plant growth, including lighting, will allow more
optimal conditions to be maintained.
ECONOMICS
Because of the large investment, costs and benefits
must be carefully considered before plant lighting is
installed. Research should be carefully reviewed to
determine the level of light needed and the expected
growth benefits. A comparison of systems using
the format in Table 3 of Appendix IX developed
by Bickford and Dunn (1972) should be done.
Information for completing the chart is available
from county extension agents, lamp manufacturers
and suppliers, and electrical system installers.
One of the indirect benefits of lighting is the
additional heat developed. It is more expensive than
heat supplied by conventional means and should
be conserved and used to heat greenhouses or
accessory buildings or to preheat irrigation water.
The amount of heat available can be calculated from
the following formula:
Heat (Btu/hr.) = 3,412 x Kilowatts of lighting
(including ballasts) x Efficiency factor
An efficiency factor of 75–80% is commonly used
and takes into account the energy that goes into
plant growth and the heat that cannot be recovered.
Watering
Water in the greenhouse is used for two purposes:
to wet the soil in pots or beds so the plants can
take water up through the root system and to coat
the surface of the plant material, often cuttings,
with a film of moisture that reduces transpiration
and slows metabolism to preserve energy for root
growth while at the same time adding moisture to
the air. The first is considered watering or irrigation;
the second is called misting.
The rates of evaporation and misting should be
equal for successful cutting propagation. Wilted
cuttings will not root properly; and excess moisture
can reduce the amount of oxygen available to the
newly formed roots, reduce soil temperature, and
create drainage problems.
Plants require adequate moisture for optimum
growth. Water is the medium by which nutrients are
absorbed. Water absorbed by root moves through
the roots and xylem into branches and leaves. Water
vapor is then transpired through stomates in the
leaves into the atmosphere surrounding the plant.
For each ounce of dry matter produced by the plant,
as much as two gallons of water moves through the
plant.
Moisture is needed by the plant for many functions:
Cell division—Turgid cells reproduce faster.
Photosynthesis—Where moisture is deficient,
stomates close and CO2 movement is limited.
Rooting of cuttings—Moisture is needed to keep
stems from drying.
Germination of seeds—Uniform moisture results in
a high germination rate.
Soil air supply—Amount of moisture regulates the
air supply.
An adequate and properly regulated supply
of moisture will help control plant growth and
flowering.
WHEN TO WATER
Most of the variables in growing plants have been
measured and controlled to varying degrees, and
optimum levels of temperature, humidity, nutrients,
and light are known for most commercial crops.
These can be measured and then adjusted with
acceptable accuracy. Rooting medium moisture
measurement and control information, in general, is
not available. Various methods of indicating soil mix
moisture are used, but, to date, no one method is in
general use throughout the country. The following
1045
are methods used to indicate the moisture content of
the soil mix:
Appearance or Feel
Growers usually water when the soil mix will
crumble easily when compressed in the hand.
Examination should be made at several soil depths.
Tensiometers
This device consists of a porous cup attached to a
vacuum gauge. The cup is inserted in the soil and
the apparatus filled with water. As soil dries, water
leaves the cup and the resulting tension (vacuum)
is recorded on the gauge. Limitations are lack of
soil uniformity and variations in the clay cup.
Tensiometers must be calibrated for different soils.
Weight of Soil Moisture
One pot plant on a bench is used as a control. It
rests on a scale that is adjusted to trip a switch when
the moisture level drops below a certain level. The
setting has to be adjusted as the plant grows to
compensate for the added plant weight.
Light Accumulators
This device utilizes a photoelectric cell and counter
to activate a solenoid valve when a predetermined
quantity of light has been received. It is based
on the idea that increased light causes increased
evaporation. It does not take into account air
movement or variations in soil mix.
Evaporation Simulators
A stainless steel screen is used to simulate a leaf.
It is placed among the plants and receives the
same amount of water as the plants. The screen
is attached to a switch which activates a solenoid
valve when the water that has collected on the
screen evaporates. This device is limited to use with
misting or overhead irrigation systems.
Soil Moisture Conductivity
Several devices relate soil moisture to electrical
conductivity. When the soil dries to a preset level,
the electronic circuit activates the solenoid valve.
Most of the above devices use a timer to shut off the
water supply after a predetermined length of time.
HOW MUCH WATER TO SUPPLY
The amount of water required is affected by the type
of soil or soil mix and the size and type of container
or bed. Proper watering should provide 10% more
water than is necessary so that leaching will reduce
salts and good fertilizer distribution will occur.
Frequent light sprinklings induce shallow rooting
and may increase soluble salt concentrations.
Table 6–5 lists estimated maximum daily water
requirements for different cropping systems.
WATER SUPPLY
A correctly designed water system will supply
the amount of water needed each day of the year.
CROP GALLONS OF WATER
Bench crops 0.4 gal/ft2
Bedding plants 0.5 gal/ft2
Pot plants 0.5 gal/ft2
Mums, Hydrangea 1.5 gal/ft2
Roses 0.7 gal/ft2 of bed
Tomatoes 0.25 gal/ft2 of bed
Nursery—
Beds 0.25 gal/ft2 of bed
Containers 0.3 gal/ft2
Field grown 0.2 gal/ft2
Table 6–5. Estimated maximum daily water requirements.
105
The amount will depend on area to be watered,
crop grown, weather conditions, time of year, and
whether a heating or ventilation system is operating.
The maximum varies from 250–1,500 gal./1,000
ft.2 per watering. During a hot summer dry spell,
application may be needed on a daily basis. The
greenhouse water system should be able to supply
the total daily needs in a 6-hr. period, so that plants
can be watered during the morning and early
afternoon and the foliage has time to dry before
sunset. Peak use rate is the maximum flow rate
during this 6-hr. period. Peak use rates are needed
to determine pump capacity, pipe size, type of
distribution system, and storage tank size.
Example: Determine the maximum daily water
requirement and peak use rate for a 25' x 100'
greenhouse full of bedding plants. From Table 6-5
on the previous page, bedding plants require 0.5
gal./sq. ft. per day.
0.5 x 25 x 100 = 1,250 gallons per day
add 10% for leaching, 0.10 x 1,250 = 125 gallons
additional water.
Total water required = 1,250 + 125 = 1,375 gallons
per day.
If this were applied through a distribution system
over a 2 hour period:
1,375 gal./day = 687.5 gal./hr.
2 hrs./day
This is the peak use rate.
687.5 gal./hr. = 11.46 gal./min.
60 min./hr.
This is the water system flow rate.
The distribution system must be designed to
provide the flow rate needed. If the water supply
is insufficient to meet the design rate, then either
the flow rate must be reduced by increasing the
irrigation time or intermediate storage must be
added to insure an adequate water supply.
Ponds
Most larger growers in rural areas use ponds. If they
are fed from spring or watershed runoff, a pond
should be large enough to store about one year’s
water requirements. Evaporation losses can be
reduced by digging the pond 10–15 ft. deep rather
than a shallow pond covering a larger area.
Concrete or Steel Storage Tank
This type of intermediate storage is used when flow
rates from wells or springs are not high enough to
supply peak use rates. This type of storage should be
large enough to hold at least one day’s water needs.
Tanks can be elevated or placed on a hill to supply
water by gravity or can be connected to a pressure
tank and second pump to supply water under
correct pressure to the point of use.
WATER QUALITY
All water from natural sources contains some
impurities. Some of these adversely affect plant
growth, while others may improve growth.
Hard Water
Contains dissolved calcium and magnesium; causes
a rise in pH. Hard water has no known detrimental
effect on plant growth.
Chlorine
Added to water to reduce the number of
microorganisms. Escapes rapidly when aerated.
Concentrations used in water for human
consumption are not toxic to plants.
Fluorine
Added to water for its beneficial effect on teeth. It is
not toxic to plants at levels used in water for human
consumption.
Total Salts
Fertilizers are referred to as salts. Where natural
water is high in dissolved mineral elements, the
addition of fertilizer can raise total salt concentration
to toxic levels. Soil tests can provide an accurate
indication of both water and soil salt levels.
Research at the University of Connecticut indicates
that some systems used to treat water for various
pollutants can have an adverse effect on plant
growth. Further research is necessary to determine
whether the treatment systems remove some of the
1067
trace elements usually found in water or whether
the filtering materials are adding something to the
water.
Water System Components

The complete water system used in supplying water
to the greenhouse consists of a pump, pressure tank,
piping, and controls. The following section discusses
equipment and its selection for different systems.
PUMPS
Many types and sizes of pumps are available for
supplying water. The type of pump most commonly
used in greenhouse watering systems contains an
impeller connected to the motor shaft. The following
are some commonly used pump and pumping
terms. Table 6–6 lists pump characteristics.
Commonly Used Pump Terms
Suction head—Vertical distance from water surface
to pump [ft. or lb./in.2 (psi)].
Pressure head—Pressure required at point of
delivery [ft. or psi].
Friction head—Pressure lost in overcoming friction
between water and pipes or fittings [ft. or psi].
Elevation head—Vertical distance between pump
and point of delivery [ft. or psi].
Table 6-6. Pump characteristics.
TYPE
TYPICAL
SUCTION
HEAD
(ft.)
TYPICAL
TOTAL
HEAD
(ft.)
TYPICAL
TOTAL
HEAD
(psi)
REMARKS
Centrifugal 15 230 100 Advantages:
Reliable, good service life; will pump water
containing sand and/or silt
Disadvantages:
Loses prime easily; capacity decreases as
suction head increases
Jet 85 162 70 Advantages:
Few moving parts; high capacity at low head
Disadvantages:
Damaged by sand or silt in water; capacity
decreases with service time
Submersible >1,000 >430 Advantages:
Easy to frost-proof; high capacities and
efficiencies
Disadvantages:
Damaged by sand or silt; repair requires
pulling from well
Deep well turbine >1,000 >430 Advantages:
Easy to frost-proof; high capacities and
efficiencies
Disadvantages:
Needs straight well casing; repair requires
pulling from well
107
Total head—Sum of all heads against which a pump
must deliver water.
Pump horsepower—Power required by pump to
move the required flow rate.
pump hp = flow (gpm) x total head required (ft.)
3,960 x pump efficiency
Motor horsepower—Pump and motor efficiencies
vary. Check manufacturer’s specifications.
motor hp = pump horse power
motor efficiency
PUMP SELECTION
When selecting a pump to supply water to a
greenhouse system, consider the following factors:
Capacity of water source—If the source is a pond,
capacity is usually adequate for maximum use rate.
If the source is a well or brook, the yield rate in
gal./min. or gal./hr. must be determined.
Suction Head—The vertical distance from pump
to water surface is measured in feet. If a well has a
low yield rate, water surface in the well may drop
rapidly if demand is consistently great, which can
affect centrifugal pump capacity by increasing
suction head. Pump capacity should be matched to
well yield.
Well diameter—If the water source is a well, the
diameter of the casing will determine the equipment
size that can be installed and the well’s reserve
capacity. Always specify a 6-in. or larger casing for
new wells.
Power available—Adequate wiring is essential for
continuous operation and safety of a water pump.
Fuses or circuit breakers are required to protect
wiring in case of accidental ground or short circuit.
Thermal overload protection is available on most
pump motors. Table 1, Appendix VII, shows wire
size and fuse rating for various size 60 cycle AC
single-phase motors.
Pumps should supply water under sufficient
pressure to provide required flow rate and coverage.
The total pressure against which a well pump
must work is made up of four parts: (1) suction
lift, or vertical distance water is lifted to the pump
by suction, (2) vertical distance from the center
line of the pump to the point where water is to be
delivered, (3) required pressure at the outlet, and
(4) friction in the piping system between the pump
and the outlet.
These values can be given in feet of water or psi.
Multiply psi by 2.31 ft./psi to convert the value to
feet of water. For example: 40 psi is equal to 92 ft. of
water—the water pressure at the bottom of a 92 ft.
depth of water is 40 psi.
Example:
A shallow well, which has a yield in excess of the
pump capacity, is used to supply a pump located
15 ft. above water level when the pump is running.
The suction line is a 1-1/4 in. diameter galvanized
steel pipe. The greenhouse is located approximately
250 ft. from the well and is 35 ft. above pump level.
The pipe from the well to the greenhouse is 1-in.
diameter plastic line. Required pressure at the
greenhouse is 40 psi and desired flow is 12 gpm.
What pressure is needed at the pump to meet these
conditions? The solution is to add the four parts of
the total pressure. (Neglect elbows and fittings for
the example.)
1. Suction lift 15 ft.
2. Elevation lift 35 ft.
3. Pressure 40 psi x 2.31 ft./psi = 92 ft.
4. Friction 1) 15 ft. of 1-1/4 in. steel
(from pipe, 1.9 psi/100 ft.—
Tables 3 & 4, 0.019 psi/ft. x 15 ft. x
Appendix X) 2.31 ft./psi ≈ 0.7 ft.
2) 250 ft. of 1" plastic—
3.8 psi/100 ft. x 250 ft. x
2.31 ft./psi = 21.8 ft.
Total
Pressure = 15 ft. + 35 ft. + 92 ft. + 0.7 ft. + 21.8 ft.
= 164.5 ft. or 71.2 psi
A question often asked is what size pipe to buy.
From Table 4, Appendix X, 1-1/4 in. plastic would
have a friction loss of 2.31 psi (1.0 x 2.31 ft.) instead
of 8.8 psi (3.8 x 2.31 ft.) for the 1 in. pipe. Since the
outlet pressure difference between the two pipe sizes
1089
is only 6.5 psi, the additional cost for the large pipe
may not be justified. If future expansion may occur,
the 1-1/4 in. pipe may be justified.
Pump horsepower requirement can be approximated
by the following formula:
hp = Total pressure (ft.) x gpm
3,960 x pump efficiency
For the example:
hp = 164.5 ft. x 12 gpm ≈ 1.00 hp
3,960 (0.50)
Pipe size and distance between the pump and outlet
determine friction loss. The right pipe size will do
the job for the least cost. Small pipe size can cause
high friction loss and require additional pumping
energy; large pipe size can cause low friction,
but high pipe costs. When selecting pipe sizes,
determine the effects of different friction losses on
pump selection.
PRESSURE TANKS
Most greenhouse watering systems not on a central
water system contain a pressure tank to store small
amounts of water under pressure. This tank is
located between the pump and point of water use,
and pressure is developed by forcing water into
the tank until air in the tank is compressed to
a preset pressure. The pressure switch for a
greenhouse system is usually set at 30–50 psi or
40–60 psi. The pump will start when tank pressure
reaches the lower setting and will stop when it
reaches the higher setting. The proper setting
depends on outlet pressure needed for nozzles and
pressure loss due to pipe friction between tank and
nozzles.
Pressure tank size depends on pump size. The
storage volume that can be utilized in most tanks
is only 20–40% of total tank capacity. For example,
in a 120 gal. pressure tank with air volume control,
only 24 gal. will be discharged between 39 and 50
psi. If the tank was precharged, 48 gal. would be
discharged. For most installations, a pressure tank
with a total capacity of ten times the pumping rate
in gpm will be adequate (12 gpm pump; 120 gal.
capacity tank). Standard tank sizes are 42, 82, 120,
240, 315, and 525 gal. capacity.
PIPING
Several types of pipe are available for use in
greenhouse installations, with selection usually
made on the basis of cost, pipe location, ease of
installation, and expected life of the installation.
A description of the types of pipe used and their
advantages and disadvantages follows.
Polyethylene (PE):
Advantages—Low initial cost, easy to install,
resistant to inside pipe corrosion, lightweight.
Disadvantages—Can be damaged by sharp objects,
cannot be used for hot water, must be supported
in overhead installations.
Uses—Good for underground supply lines, bench
watering systems.
Remarks—Fittings of nylon or brass and clamps
of stainless steel should be used. Available in
pressure ratings from 80–160 psi. For greenhouse
installations, use 100 psi or greater.
Polyvinyl Chloride (PVC):
Advantages—Low initial cost, ease of application,
resistant to inside pipe corrosion, much lighter
than metal pipe.
Disadvantages—Cannot be disassembled without
cutting.
Uses—For all underground and above-ground
piping where nozzles are to be inserted in the
line.
Remarks—This is the most recently developed pipe
and adapts very well to greenhouse watering
systems. CPVC (a special class of PVC pipe) can
be used for hot water, but PVC cannot.
Galvanized Steel:
Advantages—Resists mechanical damage, needs less
support than other types of pipe, many types of
fittings available.
Disadvantages—Corrodes, heavyweight, requires
more time to install.
109
Uses—Hot and cold water applications, all
underground and overhead sprinkler
installation systems.
Remarks—Galvanized steel pipe is gradually being
replaced by PVC & PE pipe.
Rigid Copper:
Type: K—heavy duty
L—standard weight
M—lightweight (not used in greenhouses)
Advantages—Requires minimal support, resists
mechanical damage, many types of fittings
available.
Disadvantages—High cost, requires sweat or
soldered joints.
Remarks—Not generally used in greenhouse
installations.
Flexible Copper:
Type: K—heavy duty
L—standard weight
Advantages—Resists mechanical damage, many
types of fittings available.
Disadvantages—High cost, needs support.
Remarks—Not generally used in greenhouse
installations.
Friction loss in pipe is determined by flow rate,
pipe diameter, age, and the pipe material. Appendix
X provides values for several pipe materials. An
example in reading the tables shows that a standard
1-in. steel pipe which has a flow rate of 10.1 gpm
will cause a pressure drop of 5.1 psi for every 100 ft.
of length. A plastic pipe under the same conditions
will have a pressure drop of 2.7 psi, and a rubber
hose will have a drop of 3.38 psi. Other conditions,
such as price, placement, and application, also
determine the proper choice for a given situation.
Additional energy losses occur at fittings such as
valves, elbows, tees, unions, etc.
PREVENTING BACKFLOW
All potable water must be protected against
backflow to ensure that contaminated water is not
mixed with that used for human consumption.
Backflow or backsiphoning occurs when a negative
pressure develops in the water supply line, causing
water that has been contaminated to be drawn back
into the supply lines. The National Plumbing Code,
which has been adopted in most states, requires
that backflow preventers be installed on any
supply fixture when the outlet may be submerged.
Examples of this are a hose that fills a spray tank or
barrel, a fertilizer injector, or an equipment wash
tub.
The most commonly used backflow preventer is the
vacuum breaker shown in Figure 6–7 on the next
page. It is a combination check valve and air relief
valve in one integral unit. If the pressure in the
water supply lines drops below a predetermined
level, the check valve will close, shutting off the
water supply. With the check valve in the closed
position, the air relief part of the unit is open,
allowing air to enter the system. Thus, the vacuum
created by the negative pressure in the supply lines
is broken and water is prevented from backflowing
into the potable water supply. This type of valve
should be installed between the last control valve of
the supply system and the fixture being served. For
example, the vacuum breaker should be installed
just before the intake to a fertilizer injector.
In low pressure watering systems (less than 5 psi),
an elevated mixing tank is sometimes used to supply
water to the drip tubes or trickle hose. Fertilizer is
often mixed in the water to supply nutrients to the
plants. A space equal to at least twice the diameter of
the supply pipe is required between the outlet of this
pipe and the highest possible water level in the tank
(Figure 6–7 on the next page). This air gap prevents
backflow.
If supplied by a municipal water system, check local
regulations prior to installation, as some companies
require a complete break in the water system. If this
is the case, a separate pump and supply tanks will
be required.
FERTILIZER INJECTOR
A fertilizer injector is a mechanical device that
introduces concentrated fertilizer solution into the
supply pipe used for crop watering. Two basic types
of injectors are available. One type uses the venturi
111110
Figure 6–7. Backflow preventers.
principle to create a pressure difference between
the fertilizer container and the water supply line,
causing a flow of solution into the irrigation water.
The other system uses a positive displacement
pump, either water-powered or electrical, that
injects fertilizer solution into the irrigation water.
Each system can be adjusted to vary the ratio of
solution to irrigation water. There are a number of
manufacturers of each type of equipment. Figure
6–8 on the opposite page shows a typical pump type
installation.
When selecting an injector consider the following:
System capacity—Usually rated in gallons of water
that can be treated per minute. Systems are
available from five to several hundred gpm. Select a
size that will handle the capacity of the distribution
system.
Dilution ratios—Injectors are commonly
manufactured with dilution ratios of from 1:15 to
1:2,000. The lower the ratio, the more dilute the
fertilizer solution must be. Too high a dilution ratio
may create problems in dissolving enough fertilizer
in the solution tank. A common ratio for greenhouse
crops is 1:2,000.
Mobility—A portable unit usually works best
for an operation having individual greenhouses.
The injector is moved between greenhouses when
feeding is necessary. Fixed installations with piping
used to carry injected water to the growing area are
used in ridge and furrow ranges. Where automatic
watering is provided, a fixed installation for
fertilizer irrigation is best.
Alternate uses—Although used primarily for
fertilization, injectors can be used to apply other
water soluble materials, such as fungicides and
insecticides.
DISTRIBUTION SYSTEMS
In the greenhouse, two types of watering systems
are in common use today: a low pressure system
operating on a water pressure of less than 10 psi,
and a high pressure system operating above 10 psi.
Schematics of the pressure systems are included in
the forthcoming discussion.
Low Pressure System
This type of system is commonly known as
trickle irrigation (Figure 6–9, opposite). Moisture
is supplied to the root zone of a plant through
drip tubes or soaker hoses. Water is dripped
continuously or intermittently into the root zone
around the plant. Soil between row crops or out of
the plant area does not receive water. Although the
water is applied to a small area around the plant,
lateral transmission of water takes place through the
root system. Major advantages of trickle irrigation
are that plant foliage remains dry and water
application efficiency is high.
Two methods of supplying water to this system
are commonly used. One method uses an elevated
mixing tank which is filled from a high pressure
A. Backflow preventer valve B. Air gap preventing backflow
Normal Flow Condition Backflow Condition
Water
Supply
Gate Valve
Mixing
Tank
Air Gap
Gate Valve
To
Distribution
6–8'
111
Figure 6–8. Typical pump-type fertilizer injector installation.
Figure 6–9. Low pressure greenhouse watering system for groundbeds, benches, or troughs.
1
2
3
2
4
5
6
7
8
9
10
1. Fertilizer Injector
2. Isolation Gate Valves
3. Bypass Gate Valves
4. Concentrate Tank
5. Blending Tank
6. Universal Injector
7. System On-Off Valve
8. Check Valve
9. Wye Stratiner
10. Waste Line to Drain
Line Strainer
Gate Valve
Air Gap
1" Pipe or Larger
Supply Line
Gate Valve &
Backflow Preventor
Strainer
Alternate Supply
Pressure Reducer
or Flow Meter
Gate Valve
300 Gal. Mixing Tank
1" Pipe
X
Distribution
X PRESSURE
2' 0.9 PSI
4' 1.7 PSI
6' 2.6 PSI
8' 3.5 PSI
10' 4.3 PSI
1123
water source. Water should go through a 100–200
mesh strainer before entering the tank. The tank can
be any size, but a 300-500 gal. capacity is adequate
for most installations. The tank should have an
opening in the top large enough to add and mix
fertilizer into the water and should be elevated so
that the correct pressure for the distribution system
is obtained. To determine the elevation of the tank
above the bed or bench level, divide the desired
pressure by 0.43 psi/ft.
Example: A pressure of 3 psi is desired to operate a
soaker hose watering system for a crop of tomatoes.
At what height should the tank be located above the
ground?
H = 3 psi ≈ 7 ft.
0.43 psi/ft.
For the second method, the distribution system is
connected to the pressure tank. A pressure reducer
is placed in the line to lower the pressure to the level
needed for the trickle tubes. A backflow preventer
should also be used for systems that supply drinking
water.
Supply lines can be either 3/4 in. or 1 in. diameter.
Most manufacturers state the number of drippers or
lengths of soaker hose to use with each size supply
pipe. Polyethylene pipe is most commonly used
because it is inexpensive and easy to install. Gate
valves should be placed at the tank and in supply
lines to control water flow to various sections of
greenhouse benches. Drip tubes, also known as
leader or spaghetti tubes, are widely used for pot
watering. This system consists of small diameter
plastic capillary tubes connected to a plastic line.
“Drop in” weights are attached at the other end.
Some weights are available with a shut-off so that
water flow to individual pots can be stopped when
the pot is removed. The diameter and length of
the tube determine its water flow rate. Tubes are
available from 0.036–0.076 in. diameter and from
12–72 in. long.
Low flow porous or perforated hoses are designed
for watering greenhouse benches, beds, capillary
mats, outside planters, and beds. Water oozes from
seams or tiny holes in the hoses under low
pressure.
Ebb and Flow
Ebb and flow irrigation has been used for many
years. It can be used with benches or floor
operations. Watertight benches, generally either
aluminum or plastic, are flooded with up to an inch
of nutrient solution as needed to keep the root zone
of the plants moist. This may be done once or twice
a week or several times a day depending on weather
and the size of the plants. Once the bench or floor is
flooded, the solution is allowed to drain back to the
storage tank by gravity.
The tank must be large enough to store all the
solution, about one-half gallon per square foot of
bench or floor area. Grooved benches allow the
surface to drain and dry rapidly, preventing pools
from forming and reducing algae growth. Adjustable
height support frames will allow benches to be
leveled.
The ebb and flow floor system can be used for
overhead troughs for single rows of potted plants. If
the troughs are hung from the greenhouse framing,
they must be strong enough to carry the extra load
of trough, plants, and nutrient solution.
The ebb and flow floor system has the added benefit
of costing less than a bench system. A floor system
may cost $2 to $3 per square foot compared with $5
to $6 per square foot for a bench system. There are
no aisles in a floor system so all the area can be used
for production. A good system requires a level floor,
so set screed boards for laying the concrete with a
laser level. After the 3-inch concrete floor has set,
1/4" wide by 1/2" deep grooves are cut on 2" centers
to allow the nutrient solution to drain back to the
storage tank.
Some of the benefits of the ebb and flow system are:
1. Less labor than with other systems because
setup and operation time are reduced or
eliminated.
2. Every plant gets the same amount of nutrient
solution, which should produce uniform
growth.
113
3. Reduced potential for ground water pollution
since all nutrient solution is recirculated in a
closed system.
4. The system is flexible in that any size pot can be
used with spacing varied as needed.
5. The system can be used in any greenhouse.
6. There may be lower incidence of disease because
the leaves remain dry.
High Pressure Systems
Fixed spray heads—Originally developed for lawn
irrigation, fixed spray heads may be used to irrigate
small containers such as packs and 2-1/2 in. pots;
they generally have a high application rate
(Figure 6–10).
Heads that spray water in various patterns—square,
full circle, partial circle, and rectangular—are
available, as are stationary and pop-up heads.
Sprinkler head spacing is usually 50–75% of the
spray’s diameter. Since most sprinklers have a spray
diameter of less than 30 ft., many nozzles are needed
for large areas.
Rotating impact sprinklers—Impact sprinklers
rotate slowly, about 1–2 revolutions/min. Rotation
is caused by the impact of an arm that oscillates
in and out of the nozzle jet. For large areas and
containers up to the 2-gal. size, impact sprinklers
are the most efficient form of irrigation. Full
or partial circle sprinklers are available from a
number of manufacturers to fit various pipe sizes.
Interchangeable nozzles are available for all models.
Some nozzles have devices (baffle or screw) to break
up the spray.
Whirling rotating sprinklers spin rapidly. Rotation is
caused by reaction to a jet of water discharged from
the nozzles, which are attached at an offset angle on
the rotating arm. Sprinklers with single or double
arms for either low or high volume discharge are
usable on small, closely spaced containers. These
sprinklers are used mostly in greenhouses or shade
structures because of the small area covered by each
sprinkler. Some of them discharge fine droplets of
water that reduce soil splashing from the pot.
Nozzle lines may be either overhead or along the
ground. Both systems are similar in that each uses a
pipe with fixed nozzles placed at regular intervals.
Overhead lines require rigid pipe. Either jet or fan
nozzles may be used and generally are placed at
Figure 6–10. High pressure greenhouse watering system for groundbeds or benches (pressure greater than 10 psi).
Distribution
1" Pipe−Plastic or Galvanized
Pressure Reducer
or Flow Meter
Faucet
Faucet
Solenoid Valve
Time Clock
or Controller
Pressure
Tank
Gate Valve
Fertilizer
Injector
Check Valve
or Backflow
Preventor
Strainer Gate Valve
1" Pipe or
Larger
111145
3-ft. intervals. Lines may be rotated manually or
automatically to apply water to different areas.
Overhead nozzle lines are generally used only in
greenhouses or shade structures where the pipe
supports will not interfere with movement of
machinery, labor, or materials.
WATER DISTRIBUTION
Water is not uniformly distributed from a sprinkler
nozzle over the entire wetted area. Well-designed
irrigation systems overlap the spray from adjacent
nozzles to create as uniform a pattern as possible.
The type of sprinkler and the wind, if any, determine
the application rate in inches of water per unit of
ground area.
Lateral sprinkler lines should run across the
direction of prevailing wind wherever possible,
because sprinklers are usually placed closer together
along the lateral lines than the distance between
lines, compensating somewhat for wind. Whenever
closer spacing of the sprinklers is used, the discharge
rate per sprinkler should be reduced to maintain the
same application rate in inches of water per unit of
ground area.
Average Wind Speed Spacing of dia. of water
(mph) spray from sprinkler
0 65%
< 4 60%
4–8 50%
> 8 30%
Fixed sprinklers usually have a spacing of no less
than 50–65% of the spray diameter.
Tests for sprinkler distribution uniformity are based
on catching and measuring water on a regular grid
pattern over the area being watered. Containers are
placed at any convenient interval on an area that
represents the entire area covered by the sprinkler
system. Coffee cans and other containers with sharp
edges are commonly used.
MIST CONTROL
There are several devices available to control misting
systems. They range from simple program repeating
timers to computer-operated timers (Figure 6–15,
page 118). All are built to activate solenoid valves
in the water supply line. One device consists of a
stainless steel screen that receives the same moisture
as the plants. As the screen becomes wet, its weight
increases to the point that it trips a microswitch,
activating the solenoid valve. Another uses a
phototube that stores light energy falling on it. It
can be adjusted to produce switching action with
the frequency and duration desired. Multizone
controllers are available in which each zone can be
programmed separately.
WATERING EQUIPMENT
INNOVATIONS
With the shift to plugs, cell packs, and smaller trays,
there is a need for systems that provide uniform
watering. Figure 6–11, opposite, shows systems
developed by innovative growers. Commercial
systems are also available.
Portable Watering Boom
The boom is supported on a track system similar to
those used for energy blankets. One unit can be used
between several greenhouses if the booms can fold
and pivot. The use of aluminum pipe will keep the
weight to about 50 lbs. In selecting nozzles, check
to see that total nozzle capacity does not exceed
available water supply in gpm. If water is supplied
to the greenhouse through a 1-in. diameter pipe,
the maximum output will be about 20 gpm for most
systems. The boom rate of travel will depend on
water supply.
Watering Cart
The cart, originally developed and used for growing
tobacco seedlings in cell flats, could be readily
adapted for other production systems. This cart
is also designed to fold and be moved between
houses. The cart is operated by hooking up the hose,
extending the winch cable, and connecting it to the
deadman. The water supply is activated and the
battery-operated winch is started, slowly pulling the
cart through the greenhouse. When the cart reaches
the opposite end of the greenhouse, a limit switch
turns off the winch. Two sets of booms are used:
the first applying about 1/3 of the water to wet the
surface with a fine spray; the second supplying the
remainder as a coarse spray.
115
Figure 6–11. Examples of movable watering systems.
PORTABLE WATERING ROOM
GREENHOUSE WATERING CART
Hose Reel on Cart
1" dia. Hose w/ Strainer
Harness
Ball Valves
Swivel
1" dia. Aluminum
Pipe Boom
Boom Height
Adjustment
Energy Blanket Track
Full Cone Spray Nozzle
12" spacing−12" above plants
0.6–0.8 gpm = 30 psi
80 deg. spray angle
Manifold with connections for supply
line and four hose connections to
booms
Swivel for pipe
Wide angle spray nozzles
40" spacing−13" height
0.6–0.8 gpm = 30 psi
120 deg. spray angle
3/4" Garden
Hose w/ Strainer
1/2" Galvanized
Water Pipe
Flat Spray Nozzle
20" spacing
18" height−0.15 = 0.20 gpm = 30 psi
80 deg. spray angle
12-volt switch
10 ft/min
1/4 ton capacity
Limit Switch
Steel Guide Pipe
Deadman
111167
One further adaptation of both of the above units is
to change to smaller nozzles and connect to a high
pressure sprayer (>200 psi) for applying fungicides,
insecticides, and growth retardants. This system is
being used by some growers in Florida and Canada.
Although neither of these units will reduce total
watering time significantly, they do reduce the
need for skilled labor and will give a more uniform
watering pattern.
STEPS TO SUCCESSFUL
WATERING SYSTEM DESIGN
1. Calculate the amount of water needed per day.
2. Check the water source or pressure and flow
data to see if adequate quantity is available.
3. Select the type of application devices required
(nozzles, drippers, soaker hose, etc.).
4. Determine a system layout.
5. Divide into zones if necessary.
6. Determine pipe size.
7. Select and locate valves and a controller.
8. Select and locate a pump if needed.
9. Estimate the quantities of materials needed.
10. Install the system.
Example: Calculations for a watering system for a
25 ft. x 96 ft. greenhouse or one bay of a larger ridge
and furrow greenhouse. Bedding plants are grown
on the floor. The desired application rate is
0.2 gal./ft./day. The amount of water needed for
each application equals 0.2 gal./ft./day/ x 2,400 ft.
= 480 gal.
1) Design a system using 2 gpm nozzles—The
whole greenhouse will be watered at one time.
Nozzle spacing 5 ft. on center, 2 laterals
Coverage 12 ft. diameter—double overlap
No. of nozzles 36 (18 per row)
Water supply 36 nozzles x 2 gpm = 72 gpm
Supply pipe size 2-1/2 in. diameter
Lateral pipe size 1-1/4 in. diameter
(each lateral supplies 18 gpm)
Application time 480 gal. = 6-2/3 min.
72 gpm
Controllers should be used to sequence watering
between greenhouses or bays.
2) Design a system using 0.5 gpm nozzles—Each
lateral is controlled by solenoid and sequenced so
that one lateral operates at a time.
Spacing 40 in. O.C., 4 laterals
Coverage 8 ft. diameter—double overlap
No. of nozzles 124 (31 per lateral)
Water supply 31 nozzles x 0.5 gpm = 15.5 gpm
Supply pipe size 1 in. dia.
Lateral pipe size 1-1/4 in. dia.
Application time 120 gal. = 7-3/4 min. per lateral
15.5 gpm
Application time
for greenhouse 31 minutes
Figures 6–12 to 6–16 on pages 116–119 illustrate
watering system layout and equipment.
Figure 6–12. Example layout of a watering system using 2 gpm nozzles.
AISLE
96'
Supply Pipe−2-1/2"
Nozzle Spacing Lateral−1-1/4"
5' O.C.
10'
117
Figure 6–13. Example layout of a watering system using 0.5 gpm nozzles.
Figure 6–14. Samples of typical watering systems.
96'
AISLE 25'
Nozzle Spacing−40" O.C. Lateral Spacing−5' O.C.
Lateral Pipe−1-1/4"
Supply
Pipe
DRIP TUBES SPRAY STAKES
CAPILLARY MAT WATERING
Drip Hose
Capillary Mat
111189
MIST SYSTEM LAYOUT
MIST SYSTEM PLUMBING & CONTROLS
24-hr. timer Program Repeating
Timer
Automatic Brass
Drain Valve
Female Adapter
Male Adapter Saddles
Brass Coupler
Solenoid
Valve
PVC Pipe
Nozzles
Strainer
Bell Wire
Appliance Wire
Transformer
Gravel and drain necessary
on outdoor beds
Rooting medium
(approx. 6' deep)
Wind screen or deflector
for outdoor beds only
Nozzle orifice
12–18 inches
above surface of
rooting medium
Electrical Power
Line Strainer
Water Line
Solenoid Valve
Timer
n
1 load c nc no 2
Figure 6–15. Mist system layout.
Carbon Dioxide Enrichment

Carbon dioxide (CO2) is essential for the growth of
all green plants. The normal atmosphere contains
about 0.03% CO2 or about 300 ppm. Research over
the years on many crops has confirmed that higher
levels of CO2 are beneficial to the growth of most
plants. Crops that show significant response include
chrysanthemums, carnations, roses, snapdragons,
lettuce, cucumbers, and tomatoes. Levels of
1,000–1,500 ppm are commonly provided, but the
optimum level varies for each crop and is dependent
on light intensity, temperature, and stage of crop
maturity.
SOURCES OF CO2
Manufactured CO2—Available in cylinders or bulk.
Cylinder capacities: 5, 10, 15, 20, and 50 lbs. of CO2
Bulk: Special storage tank required
Minimum purity: 99.5%
More expensive than CO2 obtained from
combustion
Combustion—Natural gas, propane, or kerosene
Advantages:
Less expensive than manufactured CO2 Heat generated can supplement normal
heating system
Equipment available for most sizes of
greenhouses
Disadvantages:
Potential for incomplete combustion
resulting in toxic quantities of ethylene
gas and sulfur dioxide.
Use a fuel with less than 0.02% sulfur by weight.
4' apart
(approx.)
119
Figure 6–16. Bench watering system layout.
Provide for combustion make-up air—1 in.2 of air
inlet/2,000 Btu/hr. output.
SIZING CO2 EQUIPMENT
During the night, CO2 is given off by the plants
and may reach levels of 400–450 ppm. When
photosynthesis begins after sunrise, CO2 levels
decrease rapidly (Figure 6–17). Carbon dioxide
should be added so that the desired level is reached
at sunrise and maintained during the day.
Equipment should be sized to provide for
the amount of CO2 used by the plants and for
the amount lost to infiltration air through the
greenhouse surface.
Make-up CO2 = Plant Use + Infiltration Loss
Figure 6–17. CO2 levels in a greenhouse during a sunny
day in winter compared to outside air.
Insert Elbow
Space 180° nozzles 30" apart
on narrow benches (up to 42"
wide−48" wide for roses).
Polyethylene Pipe
Coupling
Second solenoid valve
required for benches
100–200' long.
Space alternating 180°
and 45° nozzles 20" apart
on wide benches (42" or
wider).
Use 2 solenoid valves
for benches wider than
42" and up to 150' long.
Use 4 solenoid valves for
benches 150−200' long.
Insert
Tee
Water Supply
Line
180°
Nozzle
45°
Nozzle
Polyethylene
Pipe
Solenoid Valve
GREENHOUSE
OUTSIDE
PERCENT CARBON DIOXIDE
A.M. P.M.
TIME OF DAY
A.M.
0.05
0.04
0.02
0.03
0.01
6 9 12 3 6 9 12 3 6
112201
Plant usage rate varies with light intensity,
temperature, crop, and nutrient level. An average
rate is between 0.002-0.004 ft.3 CO2/hr.-ft.2 of
greenhouse floor area. Greater amounts may be used
on bright, sunny days (Figure 6–18) or with crops
with large leaf areas, such as roses or tomatoes.
Plant Use =
Greenhouse Floor Area x Plant Usage Rate
Loss of CO2 due to infiltration air depends on the
tightness of the greenhouse cover and wind speed.
Average air changes per hour are given in Table 4–5
(page 66).
Infiltration Loss =
Greenhouse Volume x Air Changes per Hour x
0.000001 x (Desired CO2 level – 300)
Example: This example is based on a new double
layer polyethylene-covered greenhouse. Dimensions
are 96 ft. wide, 192 ft. long, and 9 ft. high (average).
The grower wants to provide 1,300 ppm of CO2.
Plant usage rate is assumed to be 0.003 ft.3/hr.-ft.2.
Calculate the size of the CO2 generator, how much
kerosene or LP gas will be used per hour, and the
heat output per hour.
1) Size of the CO2 generator:
Make-up CO2 = Plant Use + Infiltration Loss:
Plant Use
= Greenhouse Floor Area x Plant Usage Rate
= (96 ft. x 192 ft.) x 0.003 ft.3/hr.-ft.2
= 55.3 ft.3 CO2/hr.
Infiltration Loss
= Greenhouse Volume x Air Changes per Hour
x 0.000001 x (Desired CO2 level – 300)
= (96 ft. x 192 ft. x 9ft.) x 0.5 changes/hr.
x 0.000001 (1300 – 300)
= 165,888 ft.3 x 0.5 changes/hr. x 0.001
= 82.9 ft.3 CO2/hr.
Make-up CO2
= 55.3 ft.3/hr. + 82.9 ft.3/hr. = 138.2 ft.3/hr.
2) Amount of fuel needed per hour:
From Table 6–7 on the opposite page, kerosene
yields 187 ft.3 CO2/gal. and LP gas yields 108
ft.3/gal.
Fuel Needed = CO2 required
fuel yield
Kerosene:
Fuel Needed = 138.2 ft.3/hr. = 0.74 gal./hr.
187 ft.3/gal.
LP gas:
Fuel Needed = 138.2 ft.3/hr. = 1.28 gal./hr.
108 ft.3/hr.
3) Heat output per hour:
From Table 1, Appendix IV, heat output from
kerosene is 134,000 Btu/gal. and output from LP gas
is 91,600 Btu/gal.
Heat
output/hr. = Gal. fuel/hr.
Heat output of fuel
Kerosene:
Heat output = 0.74 gal./hr. x 134,000 Btu/gal.
= 99,160 Btu/hr.
LP gas:
Heat output = 1.28 gal./hr. x 91,600 Btu/gal.
= 119,040 Btu/hr.
Figure 6–18. Rate of photosynthesis in relation to light
intensity with increase in CO2 levels.
RELATIVE LIGHT INTENSITY
RELATIVE PHOTOSYNTHETIC RATE
18
14
10
6
2
2468
0.08% CO2
0.03% CO2
0.01% CO2
121
EQUIPMENT
A typical control system for a compressed gas
installation is shown in Figure 6–19 on the next page.
The CO2 stored as a liquid in the tank at 800–2,000
psi is released through pressure regulators and a
flow meter. Control is through a 24-hr. timer set to
open a solenoid valve before sunrise and to close
it before sunset. The rate of injection is adjusted by
trial and error to yield the desired concentration of
CO2, which is then injected continuously at that rate.
Frequent sampling should be made and the flow
rate adjusted when necessary.
Combustion units are also available for CO2
production. These units contain a burner and a
control system (Figure 6–20 on the next page). Some
use an automatic ignition system, others a pilot
light. On some models, the burn rate can be varied.
Low sulfur fuel must be used to prevent sulfur
dioxide injury to plants. Sampling and burner rate
adjustment should be done to obtain the desired CO2
level.
Two types of burners have been used in small
greenhouses. One simple gas hot plate will burn
about 1/18 gal. propane/hr., yielding 6 ft.3 of CO2 and 5,000 Btu/hr. of heat. Non-vented kerosene
heaters have also been used, which are available
with outputs of 10–30 ft.3 of CO2 and 7,000–
20,000 Btu/hr. of heat. The l-k grade kerosene or
cleaner should be used. Care should be taken to
keep combustibles away from the open flame and to
provide adequate make-up air.
More precise control (and therefore a savings on
the CO2 used) can be obtained with a controller.
The most common type operates on the principle
of selective absorption of infrared radiation
by CO2. Greenhouse air is sampled and the
measured concentration of CO2 is converted to an
electrical signal. When CO2 falls below the desired
concentration, the solenoid valve is activated or the
burner turned on. An accuracy of ±100 ppm can
be obtained. Other systems use phototchemical or
electrochemical sensors, some now being adapted to
computer control.
DISTRIBUTION
A forced air system using either horizontal air
flow (HAF) or fan-jet is the best method to provide
sufficient distribution of carbon dioxide and
continuous wiping of the leaf surface. Without a fan,
delivery of carbon dioxide is through small diameter
plastic tubing that may result in nonuniform
distribution within the plant canopy. Because water
is produced as a by-product of combustion, a slight
increase in humidity may result when fuel is burned
for carbon dioxide production. High humidity levels
can increase disease problems in tight greenhouses;
therefore, good air movement is essential.
Media Treatment
Greenhouse operators using treated rooting media
during production use heat or chemicals for pest
and disease control. Chemicals used include
Table 6-7. Carbon dioxide (CO2) yields from fuels. (a)
FUEL
(lb./gal.)
YIELD
(lb./lb. fuel) (ft.3/gal.)
Kerosene 22.00 — 187
Propane Gas 12.75 3 108
Natural Gas 8.50 0.115 72
Ethanol 11.40 — 97
Methanol 8.75 — 75
(a) At standard greenhouse temperatures.
1223
chloropicrin (tear gas) and methyl bromide.
Personnel safety is the major problem when using
chemicals. Media cannot be used for at least 48
hours after a chemical application. Steam is also
used to treat media, but in doing so all the material
is heated to about 210°F, depending on the system.
Heat is very effective in killing disease organisms,
pest, and weed seeds; however, if heated to above
200°F, the media becomes sterile and contains no
competitive organisms against possible reinfection.
In some soils, steam heating results in manganese
becoming more readily available at levels toxic to
certain plants.
Figure 6–19. Equipment for using compressed CO2 gas.
Figure 6–20. LP or natural gas burner for CO2 production.
DISTRIBUTION SYSTEM IN
GREENHOUSES
Limit switch located on ventilator
turns off CO2 when vents are opened.
24-Hour
Time Clock
Perforated
poly tubing
Solenoid Valve
Flow Meter
Cylinder
Regulator
Line
Regulator
From storage
tank
CO2 burner
Thermostat
Pressure Gauge
24-Hour
Time Clock
123
MIXTURE TEMPERATURE
(°F)
STEAM-AIR RATIO
(lb./ft.3 of air (a) )
HEAT AVAILABLE
(Btu/ft.3 of air (a) )
140 0.0112 12.9
150 0.0157 18.1
160 0.0225 25.7
170 0.0318 37.3
180 0.0487 56.8
The use of high temperature saturated air (aerated
steam) was introduced in England several years
ago as a way to pasteurize rooting media. In such
a system, steam is mixed with exhaust air from a
blower and then moved through the media. As the
aerated steam moves, steam condenses, releasing
heat that warms the media particles, although the
temperature of the media cannot rise higher than
that of the aerated steam. Plant pathologists and
horticulturists recommend a system capable of
heating the media to treatment temperature in no
more than 30 minutes, holding that temperature for
30 minutes, and cooling the media to under 90°F
in less than 30 minutes. Recommended treatment
temperatures vary from 140–180°F, depending on
media and crop.
Basic data is available for use in the design of media
heating systems (Aldrich et al., 1975). Table 6–8
gives physical and thermal properties of selected
media. Properties of most materials used in media
preparation will fall within the extremes listed. Table
6–9 lists properties of saturated air that are useful in
calculating the size of equipment.
Systems can be either batch or continuous flow, a
batch system being generally easier to operate. Each
system should be designed to fit the demands of the
operation. If several media are used, equipment size
should satisfy the most severe requirements.
Treating systems can become portable by having
their components mounted on wheels. One entirely
portable commercial unit consists of a treating cart,
blower, and steam generator mounted separately
on wheels. The treating cart sides drop to provide a
horizontal surface for pot or flat filling. Plans for
18-, 60-, or 192-ft.3 treating systems are available
Table 6-8. Physical and thermal properties of media.
MEDIA
DRY BULB
DENSITY
(lb./cu.ft.)
AVERAGE
PARTICLE
DIAMETER
(in.)
MOISTURE (a)
CONTENT
(%)
BULK
SPECIFIC
HEAD
(Btu/lb.-°F)
PARTICLE
SURFACE HEAT
TRANSFER COEF.
(Btu/sq.ft.-hr.°F)
Silty clay loam 79 0.042 27 0.22 4.0
High organic soil 63 0.043 40 0.31 4.3
Coarse sphagnum
moss peat
11 0.035 320 0.55 —
(a) Moisture content on a dry weight basis is defined as the moisture remaining in a soil subjected to a tension of 1/3
atmosphere for 24 hours after originally saturated.
Table 6-9. Properties of saturated air mixture.
(a) Dry air at 70°F, dry saturated steam at 230°F.
112245
from the Agricultural Engineering Extension at The
Pennsylvania State University.
Saturated air must pass through the media for
water vapor to condense on the particles. A
system in which air is pushed down through the
media (downflow) will generally be more troublefree
than one in which air is pushed up through
the media (upflow). Non-uniform density and
media particle size make upflow difficult and
may prevent acceptable heat distribution. More
pressure is required in downflow systems because
of consolidation, but heating is uniform and there
are no blowout problems as with upflow systems.
It is best to limit media depth to 24 in. or less to
avoid excessive consolidation and resulting pressure
requirements. Pressure required varies with media
type but is generally about 0.75 in. of water per
inch of media depth. Ducting and fittings will add
pressure equal to 2–6 in. of water.
The example illustrates a procedure for selecting
equipment: a pot plant producer schedules 12,000
round containers (6-in. dia.) to be filled and
transplanted in an 8-hr. day. The media is a 1:1:1
mix by volume of soil, peat, and perlite, and is to be
treated at 160°F and cooled to 85°F or lower before
delivery to transplanting stations. From Appendix
V, ≈ 430 pots (6-in. dia.) can be filled per cubic yard
of mix; therefore, to fill 1,500 pots/hr. requires a
media supply of 81 ft.3/hr. Detailed calculations are
provided in Worksheet No. 7, Appendix XII.
Figure 6–21 (opposite) shows a schematic of a batch
system.
Pesticide Application
Equipment
Successful use of insecticides, fungicides, and
herbicides to control pests depends largely upon
three factors:
1. proper selection and dosage of chemicals,
2. proper timing of applications, and
3. proper adjustment, calibration, and operation of
equipment.
This section will review the equipment that can be
used and methods of calibration.
The list of chemicals used in controlling insects,
diseases, and weeds changes each year. Each
chemical has a Materials Safety Data Sheet (MSDS)
that contains information on where and how it
can be applied, the type of equipment to use, the
personal protective equipment needed, and the
proper method of storage and disposal.
Applying too little or too much of any chemical at
the wrong time or place can result in losses in labor,
chemicals, and machine use. Improper amounts of
chemicals and improper timing may also result in
unsatisfactory control or even damage to the crop.
There are three types of pesticide application
machines used in greenhouses: hydraulic sprayers,
low-volume sprayers, and granular applicators.
Hydraulic and low-volume sprayers are
fundamentally different in the way they operate,
each having characteristics preferable for certain
spray jobs. In a hydraulic sprayer, the spray material
is usually distributed through a hand-held gun or
a multi-nozzle boom. The force or energy required
to carry spray droplets from the sprayer to the
foliage comes from the pressure developed by the
direct action of the pump on the spray liquid. Spray
material is usually applied to the point of drip or
runoff.
With low-volume sprayers, the pesticide is carried to
the foliage by a high velocity air stream created by
a fan, blower, jet, or compressor. The spray material
is directed to the plants by a hand-held gun or by a
mist or fog that is circulated within the greenhouse
by an air circulation system.
The granular applicators used in the greenhouse
industry are generally hand operated, broadcast, or
individual pot feed devices. They are primarily used
to apply herbicides and fertilizers.
HYDRAULIC SPRAYERS
Hydraulic sprayers contain the following
components: tank with agitator (either mechanical
or hydraulic), strainer, pump, pressure gauge,
regulating valve, relief valve, control valves, piping
and nozzles, power source, and frame. Figure 6–22
on page 126 shows the components, and Figure
125
Figure 6–21 A batch system for treating media.
6-23 (also on page 126) shows types of hydraulic
sprayers.
Tanks
To resist corrosion and rusting, tanks are made of
fiberglass, reinforced plastic, plastic, stainless steel,
aluminum, or steel protected with a plastic liner.
Plastic and fiberglass tanks have the advantage of
being lightweight and corrosion-proof. If broken
or punctured, however, they are usually difficult
to repair. Although stainless steel tanks cost more
initially, they will probably give the best service over
the long run. Tanks should have a large opening to
allow for easy filling, inspection, and cleaning. The
opening should contain a wire mesh strainer to trap
foreign matter.
Tank Agitators
Most materials applied by a sprayer are a mixture
or suspension in water. The amount of agitation
needed will depend on the kind of material being
used; wettable powders require the most vigorous
agitation.
Jet agitation uses a portion of the pump flow to
create a mixing action in the tank. Either nozzles or a
sparger (tube with discharge holes) can be used.
Mechanical agitation is produced by paddles
attached to a powered shaft in the bottom of the
tank. Agitation should be started when the tank is
partially filled and before the pesticide is added. Do
not allow wettable powders to settle, as it is difficult
to get them into suspension again.
Soil
Peat
Perlite
Supplements
Mixer
MIXING
TREATING
COOLING
RAW MATERIALS
Belt
Conveyor
Media
Chamber
Belt
Conveyor
Belt Conveyor
Media
Chamber
Exhaust
Piernum
Steam
Heating Supply
Fan
Aerated Steam
Supply Piernum
To End Use
Belt Conveyor
Cooling Fan
112267
Figure 6–22. Components of hydraulic sprayer systems.
Figure 6–23. Types of hydraulic sprayers.
TYPICAL CENTRIFUGAL PUMP HOOK-UP TYPICAL PISTON PUMP HOOK-UP
Positive Vent
Line
Jet Agitator
Agitation
Line
Line
Strainer
Control Valve
Control Valve
Boom Shut-off
or Selector
to boom nozzles
Pressure
Gauge
Centrifugal
Pump
Tank Shut-off
Jet Agitator
Agitation
Line
Control
Valve
Pressure gauge
w/ damper Boom Shut-off
or Selector
to boom nozzles
Pressure Relief
Valve
Piston Pump
Surge Tank
Line
Strainer
Tank Shut-off
By-pass Line
COMPRESSED AIR SPRAYER PORTABLE SPRAYER
KNAPSACK SPRAYER TRAILER-MOUNTED BOOM SPRAYER
Valve
Carrying Strap
Hose
Pump Handle
Filler Cap
Pump Flunger
Extension Tube
Nozzle
127
Pumps
Many types of pumps are used on sprayers, each
with its advantages and disadvantages depending
on spray material, volume, pressure, and power
source. A summary of some common pumps is
provided in Table 6–10.
The pump selected should have enough capacity
to supply the gun or boom, provide for agitation,
and offset pump wear. Pump capacity is affected
by design, operating speed, and (for most pumps)
operating pressure.
Nozzles
Nozzles are the most important part of the sprayer
and should be carefully selected for the type of
spraying done. A wide selection of nozzles is
available as shown in Figure 6–24 on the next page.
Nozzle materials include brass, stainless steel,
ceramic, corrosion-resistant plastic, and sintered
materials. The following are typical uses of some
common nozzle types.
Flat fan—Boom sprayer, herbicides, some
insecticides, and fertilizers.
Even flat fan— Same as flat fan.
Flooding flat fan—Same as flat fan but the coarse
droplets work well to reduce herbicide drift.
Hollow cone—Most insecticides, fungicides, and
growth regulators.
Solid cone—Herbicides, insecticides, fungicides, or
growth regulators.
Droplet size is important in spray applications.
Ideally, droplet size should be small enough to
provide good coverage of the foliage but not so
small as to cause excessive drift. In the greenhouse,
drift is not generally a problem, but outdoor drift
of chemicals to neighboring property may result in
legal action against the grower.
Factors that affect droplet size include nozzle type,
pressure, viscosity of spray material, nozzle capacity,
and nozzle spray angle.
Hydraulic sprayers produce droplets with a 200 to
400 micron diameter (thickness of the human hair
= 0.004 in. = 100 microns). Low volume sprayers
develop mist (50 to 100 microns) or fog (0.05 to 50
microns).
Table 6–10. Sprayer pump types and principle features of each.
PUMP TYPE OPERATING PRESSURE
(psi)
ADVANTAGES DISADVANTAGES
Centrifugal Single stage: 0–65
Multi-stage: 0–600
Adaptable to all sprays
Low wear with wettable
powders; high speed; high
volume; low cost
Relatively low pressure
Not self-priming
Piston 0–600 Positive displacement;
adaptable to most sprays;
parts easily replaced;
high pressure
More expensive than
other types of pumps
Roller 0–600 Moderate flow; moderate
pressure; low cost;
low maintenance
Not suited to wettable
powders
Gear 0–200 Positive action; constant
displacement
Low volume; not suited
to wettable powders
112289
One gallon of material will yield about 318 million
droplets 300 microns in diameter or 68 billion
droplets that are 50 microns in size. Coverage can be
more uniform with smaller droplets, but in outdoor
applications, drift should be considered.
In a 3 mile per hour wind, a 200 micron particle will
drift 18 ft., a 50 micron particle 178 ft., and a
1 micron particle 84 miles.
Plumbing and Controls
Pressure regulator — Controls operating pressure
at the nozzle and relieves excess pressure when the
shut-off valve is closed. When operating properly,
the plunger in the valve floats on the liquid.
Pressure gauge — Place near pressure regulator and
where easy to see when the unit is being operated.
Gauge should cover the range of pressure available
from the pump.
Relief valves — Designed to release liquid from the
line when pressure exceeds a safe value. On high
pressure systems, an unloader valve may be used.
Control valves — Placed between the pressure
regulator and boom or gun to control flow of the
spray material.
CALIBRATING AND USING A
HYDRAULIC SPRAYER
Calibrating a sprayer means making trial runs to
determine the application rate. Calibration requires
only a few minutes and is essential to insure that the
right amount of chemical will be applied.
A. Procedure for calibrating a hand sprayer
1. Select a plot to work on – paved parking
area or sidewalk.
2. Partially fill the sprayer with water and
operate the sprayer to determine the spray
band width.
3. Using the following table, determine the
calibration distance.
Select the calibration distance to use, on
the basis of nozzle spacing if broadcast
applying, or of band width if band applying.
Nozzle spacing or Calibration distance
band width (inches) (feet)
10 408
12 340
14 292
16 255
18 227
20 204
24 170
28 146
32 127
36 113
40 102
Figure 6–24. Types of nozzles.
EVEN
FLAT-FAN
REGULAR
FLAT-FAN
SOLID CONE
HOLLOW CONE
SPRAY PATTERN
SPRAY PATTERN
SPRAY PATTERN
SPRAY PATTERN
129
4. Mark off the calibration distance on the plot
selected.
5. Spray the calibrated plot at the desired pressure
and walking speed. Measure the number of
seconds required while walking and pumping at
a comfortable, steady speed.
6. With the sprayer in place and while pumping
to maintain the selected application pressure,
collect the spray output in a container for the
same number of seconds measured in Step 5.
7. Measure the number of fluid ounces collected.
Note: pints x 16 = fluid ounces.
8. The number of fluid ounces collected equals the
application rate in gallons/acre.
9. Determine the sprayer tank capacity.
10. To determine the coverage from one tankful,
divide the application rate by the tank capacity.
11. The main reason for calibrating a sprayer is to
determine the amount of formulated chemical to
add to a tankful of water. Select the application
rate for the pesticide from the label or from
previous experience.
12. To get the quantity of material to add to a
tankful, multiply the application rate (gal./acre)
by the coverage (acre). The result will be the
pounds of material to add.
B. Calibration procedures for a boom sprayer
The basic formula is as follows:
gal./A = 43, 560 ft.2/A x gal. to refill
Distance traveled (ft.) x boom width (ft.)
Lay out a distance of 660 ft., determine amount
of water discharged in this distance with tractor
set at a constant speed and spray system set at a
constant pressure.
gal./A = 43,560 ft.2/A x gal. to refill
660 ft. x boom width (ft.)
= 66 ft./A x gal. to refill
boom width
To adjust the spray rate:
Increase speed to decrease delivery rate;
Decrease speed to increase delivery rate;
Increase pressure to increase delivery rate;
Decrease pressure to decrease delivery rate;
Increase nozzle size to increase delivery rate;
Decrease nozzle size to decrease delivery rate.
For a single nozzle:
gal./A = nozzle output (oz. per minute) x 46.4
boom width (ft.) x speed (mph)
C. Using a sprayer
1. Use clean water—fill the tank through a
strainer.
2. Join each pass carefully—avoid missed
strips or overlaps.
3. Watch the pressure gauge—variations may
mean trouble.
4. Clogged nozzles should be cleaned
immediately. Do not clean with wire, since
slight abrasion of tip can seriously alter
delivery rate.
5. Spray on calm days to avoid drift.
6. Clean out thoroughly when changing to a
different spray material.
7. Operate the boom at the correct height.
Running too low produces poor coverage;
too high produces drift and overlap.
LOW-VOLUME SPRAYERS
Low-volume sprayers provide better coverage
with less spray material by developing smaller-size
droplets. Some sprayers also reduce application time
significantly and, therefore, labor costs are reduced.
Figure 6–25 on the next page shows several lowvolume
sprayers and foggers.
Mist Blower
In the mist blower, a small engine and fan create
an air stream with a velocity of 100 to 200 miles per
hour. Concentrated spray injected into the air stream
by a nozzle is carried to the target by the air.
This spraying technique is more complicated
than with a hydraulic sprayer. The nozzle should
be directed into the plant canopy to get good
penetration and coverage, but it should be kept
at least 6 feet away from the plants to avoid blast
damage. The operator should visualize that all the
air within the canopy must be replaced by air from
the mist blower.
Electrostatic Sprayer
Compressed air forms spray droplets and carries
them to the plants. In addition, the spray material,
113301
as it travels through the nozzle, is given a static
electric charge. This helps to create particles of more
uniform size that disperse well because they repel
each other.
Charged particles are attracted to leaves, metal, and
some plastics. Uniform coverage occurs because a
charged particle, when it strikes a surface, creates a
momentary overcharge that repels other particles.
These land elsewhere on the leaf, so there is more
uniform coverage.
Several types of electrostatic sprayers are available.
The simplest are backpack-mounted and contain a
tank and spray gun. They require an independent
air supply to charge the tank. Other units are cartmounted
with an integral compressor powered by
a gas engine or electric motor. Electrostatic sprayers
work best if the spray distance is less than 15 feet.
Thermal Foggers
In a thermal fogger, the pesticide is injected into an
extremely hot, fast-moving air stream created by
a miniature jet engine. The high temperature and
the rapid air flow vaporize the spray material into
fog-sized particles. These units require a specially
formulated carrier that improves uniformity of
droplet size and distribution. The carrier also
Figure 6–25. Misting and fogging applicators.
BACKPACK MIST SPRAYERS
FOR GREENHOUSE OR NURSERY
PULSE-JET FOGGER
AIR BLAST SPRAYERS FOR USE ON FIELD-GROWN NURSERY STOCK OR TREES
131
decreases molecular weight, allowing the particles
to float in the air for long periods of time, a
disadvantage if you have to get into the greenhouse
to care for the plants.
This equipment allows rapid spraying of a crop.
With the equipment moving from one end to the
other in a greenhouse, an acre can be covered in as
little as 15 minutes. Using air circulation, such as a
horizontal air flow system, will give more uniform
coverage and better foliage penetration.
Temperature and humidity in the greenhouse also
affect the spray droplets. Under high temperature
and low humidity, the spray droplets will tend to fall
out of the air quicker and increase the deposit on the
upper leaf surface.
Because of the noise associated with the jet engine,
hearing protection is recommended.
Mechanical Fogger
Also called cold foggers, these devices use highpressure
pumps or compressors and atomizing
nozzles to produce fog-sized particles. Distribution
of the spray material is through a hand-held gun or
integral fan.
With the fan unit, the distance and amount of area
that can be covered depends on the capacity of
the fan. Multiple units or multiple settings may be
needed to cover large areas.
As with other foggers, penetration and coverage
may not be as good as with mist or hydraulic
sprayers. Small particles don't have enough mass
or velocity to move into heavy foliage. Still, in most
studies, good insect control has been achieved.
Calibration of Low-Volume Sprayers
When making up a tank mix, both the dosage and
water requirement need to be considered. The
dosage, the amount of chemical that should be
applied to a given area, is listed on the label. With
most pesticides, a range is given; for example,
4 - 12 oz./100 gal. Selection of the rate should be
made based on the level of infestation, type and
maturity of the crop, past experience, and other
variables. If this is the first time that the pesticide is
being used, a dosage in the middle of the range is a
good starting point.
The amount of water that is needed to cover the
greenhouse area depends on the type of equipment
that will be used. With hydraulic sprayers a rate of
25 - 50 gal./10,000 sq. ft. is common. Low-volume
sprayers use only 1/4 - 2 gal./10,000 sq. ft.
Most chemical labels state the amount of pesticide
to be diluted into 100 gallons of water and not the
amount of spray concentrate that is to be applied
to a given area. The instruction manual that comes
with each sprayer contains charts or tables that
help to guide you in determining how much spray
material to mix with the water. This is usually based
on 10,000 sq. ft., so it must be adjusted to fit the
growing area that needs to be sprayed. Also, with
low-volume sprayers the rate can frequently be
reduced at least 5% because the spray is not applied
to runoff as with a hydraulic sprayer.
GRANULAR APPLICATORS
For application of some chemicals, a granular form
works best. Handling and control are often easier
than applying materials as liquids, and equipment
is usually lighter and less expensive. For containergrown
nursery and ornamental crops, applying
chemicals in granular form (i.e., fertilizers) to the
container reduces the amount needed and the
amount that leaches out. Several types of equipment
are shown in Figure 6–26 on the next page.
Precision broadcasters are used for field application
of fertilizers, pesticides, and seed. They usually
contain a powered spinner located beneath or at
the end of a hopper, which can be mounted on a
tractor, trailer, or truck. Both gravity and power feed
systems are available with an agitator in the hopper
bottom to prevent bridging.
Application rate is controlled by speed of the
spinner, metering hole opening, and ground speed
of the equipment. Variations in application rates
can be caused by the size of granules, humidity,
temperature, and ground roughness. Equipment is
available with coverage 50 ft. wide and up to
2,500 lb./acre. Some spreaders can be adjusted for
rear or side delivery.
1323
Like other applicators, granular equipment must
be correctly calibrated. The steps below should be
followed based on the operator’s manual that comes
with the equipment.
1. Determine the area to be treated.
2. Determine the quantity of chemical to be applied.
3. Calculate the application rate.
4. Make adjustments to obtain the desired rate.
Hand and push-type spreaders work well on
nursery beds and in greenhouses. Hoppers are made
from plastic, steel, or stainless steel, and capacity
varies from 20–100 pounds. The spinner is operated
by a hand crank or by ground-driven wheels.
Application rate is controlled by a gate in the hopper
bottom and by walking speed.
There are several dispensers available for individual
pot feeding. These are shoulder supported and
contain a 4–5 qt. hopper, a control valve that
dispenses a measured amount of granules, and a
drop tube. They work well for the application of
slow-release fertilizers and herbicides. Application
rate is over 2,000 feedings per hour.
Pesticide Storage
A properly designed pesticide storage area is
important for the safety of the user and non-user
and is required to meet federal and state regulations.
Each storage should be evaluated to see that it meets
minimum standards in relation to the environment
and safety.
Light—Exposure of pesticides to sunlight may
cause chemical breakdown or overheating, possibly
resulting in an explosion. Pesticide containers
(especially glass and aerosols) should never be
placed in front of windows.
Figure 6–26. Equipment for distributing granular pesticides.
TRACTOR-MOUNTED AND TRAILER-MOUNTED BROADCASTERS
HAND PUSH SPREADER FOR LAWN & BED APPLICATION CHEMICAL DISPENSER FOR INDIVIDUAL POTS
133
Temperature—Store pesticides at temperatures
above 40°F and below 90°F. Freezing temperatures
cause some pesticides to break down chemically and
containers to crack. High temperatures can cause
liquid pesticides to expand so that the contents are
under pressure. Extreme temperatures may reduce
the effectiveness of pesticides. Follow the label
instructions regarding temperature requirements for
liquid formulation pesticides.
Humidity—High moisture may cause caking or
degradation of powder chemicals. Metal containers
may rust, with a potential for developing leaks.
Contamination—Within the storage shed, the
different groups of pesticides (herbicide, insecticide,
fungicide, rodenticide, etc.) must be kept separate
to prevent accidental misuse and contamination
of each other. Herbicides, such as 2,4-D esters, are
volatile and their fumes can injure plants and seeds.
In addition, fumes can temporarily contaminate
soils, fertilizers, flats, pots, etc. Special precautions
must be taken when storing weed killers, especially
those in containers that have been opened and
resealed. Volatile fumes can build up in an enclosed
area and follow air currents to escape.
Metal shelves are advisable for storing pesticides
because they are much easier to decontaminate than
wooden shelves. Place shelves, pallets, and drums
along shed walls; the center must be kept clear to
allow access and escape. Use plastic trays under
containers on shelves to contain spillage.
Security—Storages should be kept locked.
Weatherproof signs stating “Danger: Pesticides—
Keep Out!” or a similar warning should be posted
on each door of the facility and over all windows.
In some cases, it may be advisable to post warning
signs in more than one language.
Fire Safety—Whenever large quantities of pesticides
are stored, fire detection sensors and fire fighting
equipment must be provided. A floor plan showing
all locations and natures of pesticides should be filed
with the local fire department.
STORAGE FACILITY CONSTRUCTION
Storing Small Quantities
A steel cabinet works well for storing the amount
of pesticides used in small operations. Place the
cabinet in an area away from heat and freezing
temperatures. Pesticides should be separated by
type and stored in plastic trays. Cabinets should be
kept secure at all times and identified as pesticide
storage cabinets. Additional ventilation should be
provided for tightly sealed cabinets.
Storage Inside an Existing Building
An area adjacent to an outside wall, away from
office, utility, and lunch rooms, is preferable for
pesticide storage. Windows should be covered to
eliminate sunlight. If possible, an area separate from
the storage is desirable for preparation of chemicals.
Walls can be constructed of 2" x 4" lumber, with a
polyethylene vapor barrier on the room side. Walls
and floor should be finished with chemical-resistant
paint, such as polyester or epoxy. A sink and counter
in the preparation area make cleanup easy.
An electric heater or other heat source may be
needed to keep the temperature above 40°F in
winter. A continuously operating exhaust fan in
an outside wall should be sized to provide one
volume air change every 6 min. When the room
is occupied, fan-speed should be increased to
provide approximately one air change every 3 min.
Volume in cubic feet is calculated by multiplying
length x width x height. For example, a room with
dimensions of 10 ft. x 12 ft. x 8 ft. high has a volume
of 960 ft.3. As this volume needs to be exchanged
every 6 min., a fan capacity of 960 ft.3/6 min =
160 cfm is needed. The high speed should have a
capacity of 960 ft.3/3 min. = 320 cfm.
The fan should be rated at 0.125 in. of water static
pressure (wsp) to overcome louver losses. The high
speed on the fan motor should be connected to the
room light switch. The make-up air louver should be
installed in the door or wall.
113345
Figure 6–27. Pesticide storage room within a building. Adapted from Connecticut Plan No. 254.
Place a 10-lb. type ABC fire extinguisher near the
door. A lock and proper identification should be
provided. Figure 6–27 shows a pesticide storage
room within a building.
Separate Storage Building
A free standing building should be considered
where larger quantities of pesticides need to be
stored. Site the building at a distance downwind
and downhill from sensitive areas such as houses,
play areas, wells, gardens, and ponds to minimize
pesticide exposure, especially in the event of a fire.
To reduce the possibility of contaminating surface
and ground water, select an area where flooding is
unlikely. Figure 6–28 on the opposite page shows a
separate building for pesticide storage.
The storage building must be constructed on a
4-in. thick, smooth-finished concrete slab to resist
chemical action and facilitate decontamination in
the event of a pesticide spill. The foundation and
walls should be constructed to contain any spills
or water from a fire. The door sill should be raised
approximately 6 in. above the floor. An alternative
method is to construct a berm around the outside of
the building to contain any contaminated water.
Both cost reduction and improvement in security are
achieved by constructing a windowless structure,
which could also prevent pesticides from being
broken down when exposed to sunlight. Doors on
opposite ends of a shed will provide easy access and
escape routes in case of an emergency. Standard exit
10" Dia. 2-speed kitchen exhaust fan
wired so that low speed is always on,
except when room is occupied. High
speed is activated by light switch.
Four tube 4' fluorescent light fixtures
Fire Extinguisher
2A 10 BC
Floor to Ceiling Shelves
10"
Screened
Louver
Bag
Storage
Floor Drain
Barrel
Storage
Equipment
Storage
Sink
5' long
counter
with
storage
under &
overhead
10'
10'
1. Exterior walls and ceiling should be insulated.
Insulate interior walls if building is unheated.
2. Use chemical resistant paint on exterior walls.
3. Sink should drain to 1,000 gal. holding tank.
4. Provide heat to keep room temperature above
freezing.
5. Store pesticides by group (herbicide,
insecticide, fungicide, etc.) to prevent
accidental use and contamination.
135
Figure 6–28. Separate pesticide storage building. Adapted from USDA Plan No. 6346.
locking hardware, which automatically locks from
the outside when closed, for each door is required
to ensure that the building is secured when left
unattended.
Walls should be insulated to avoid temperature
extremes. A polyethylene vapor barrier placed
on the inside, covered with exterior plywood and
painted with a chemical-resistant paint makes a
good wall surface.
Minimize toxic or flammable vapors and dust buildup
by using a forced-air ventilation system. Install
louvers near the ceiling just above the front entrance
to the building and a two-speed electrically shielded
centrifugal fan above the back entrance. The system
should provide approximately 6 air changes per
hour at all times. When the interior lights are
switched on, fan speed must increase to provide
approximately 20 air changes per hour, assuring a
safe working environment.
Install a deluge shower and eye wash fountain for
emergency use. Always maintain access to safety
equipment by keeping surroundings clear at all
times.
Vacuum breakers must be installed on sink faucets
and water lines to prevent contamination of potable
water. A stainless steel wash basin and drain board
should be located within the building. This area
should be used for initial mixing of pesticides and
for washing utensils.
Wherever large quantities of pesticides are stored, a
fire or smoke detection system should be installed.
PLAN
12' 20'
12' 8"
3'
11' 4" x 13'
5' 0" x 11' 4"
Bulk Storage
Counter &
Cabinets
Mixing and
cleanup room
Concrete slab for
cleaning eqiupment
Provide outside
house bibb
Ridge ventilator
End Elevation Side Elevation
Exhaust Fans
136
An automatic sprinkler system hung from the ceiling
will provide additional protection in the event of
fire.
For nursery, vegetable, orchard, or golf course
operations, a sprayer washdown area is desirable.
This can be a concrete slab, 6 in. thick, and
sloped 1/4 in./ft. to a drain. It is used as an area
to complete the preparation of pesticide spray
mixes and for washing equipment used in the spray
operation. Its size will depend on the needs and
type of equipment. Spray rigs and other pesticide
application equipment should be washed down in
the area (field) where the application was made.
Incorporate a waste system to collect all materials
from the interior sink and the exterior wash area.
A waste system collection tank of up to 1,000 gal.
capacity can be used to store pesticide solutions
generated as a result of washing application and
safety equipment. However, the tank should
not be used for storing excess pesticides or tank
mixes. Waste water can be pumped to a pesticide
evaporation and degradation system (Plan #6409) or
disposed of through a commercial pesticide hauler.
If proper equipment calibration is done, very little
excess pesticide mix will be left in the tank after
spraying.
References
Bickford, E.D. and S. Denn. 1972. Lighting for Plant
Growth. The Kent State University Press, Kent,
OH.
Bloom, T. and F. Ingratta. 1979. Using Carbon Dioxide
in Greenhouses. Canadian Ministry of Food and
Agric.,Vineland Station, Ontario.
Cathey, H.M., L.E. Campbell and R.W. Thimijan.
1982. The Basics of Light. USDA-SEA, Beltsville,
MD 20705.
Daum, D.R. and T.F. Reed. 1983. Boom Sprayers.
Natural Resource, Agriculture, and Engineering
Service, Cornell University, Ithaca, NY 14853.
NRAES-19.
Kammel, D.W, et. al. 1991. Designing Facilities for
Pesticide and Fertilizer Containment. Midwest
Plan Service. Iowa State Univ. Ames, IA. 50011.
MWPS-37.
Poot, J. 1984. Application of Growlight in Greenhouses.
Poot Lichetnegie b.V. Westlander 42, 2636 CZ
Schipluiden, The Netherlands.
Ross, D.S, et. al. 1991. Trickle Irrigation in the Eastern
U.S. Natural Resource, Agriculture, and
Engineering Service, Cornell Univ., Ithaca, NY
14853. NRAES-4.
Stolze, J.A.B., I.J. Muedenbelt and J. Poot. 1988.
Application of Growlight in Greenhouses. PL
Lightsystems Canada, Im. St. Catherines,
Ontario L2M 7M8.
———. 1982. Fundamentals of Machine Operation—
Crop Chemicals. John Deere Co., Moline, IL
61265.
137
Chapter 7:
Remodeling Greenhouses
Figure 7–1. Plot plan of greenhouse range in a remodeling
and expansion program. The market is wholesale to retail
flower shops and garden centers.
Introduction
Many greenhouses in the U.S. and Canada were
built 50–85 years ago. Many have been maintained
in reasonable structural condition but have become
functionally obsolete due to changes in heating and
ventilation systems, introduction of new materials
handling equipment and systems, and changes in
production systems and plant material produced.
Many older ranges were developed with minimal
planning for efficient movement of materials, so
labor remains a major production cost. Examples
are individual houses placed on different levels
requiring steps or ramps for access or headhouses
with narrow aisles and doorways that restrict use of
labor-saving equipment (carts or wheelbarrows).
There are no specific guidelines to indicate when a
greenhouse should be renovated or removed. Each
operation must be evaluated in relation to the goals
and objectives of the operator. Most facilities have
low salvage value because of the time required
for removal and reconstruction. In some cases,
the historical or architectural value is sufficient to
warrant renovation. This is more often the case for
public facilities than for commercial operations.
Site Criteria
The building site can make a significant difference
in the functional and environmental operation
of the greenhouse. Ground slope for drainage
and building orientation is an important factor. A
southerly facing slope is good for winter light and
protection from northerly winter winds. Drainage
for both surface and subsurface water is critical.
Customer and service vehicle access and parking
must be convenient and should not interfere with
daily operations. Allow for expansion and possible
future changes in the operation. Figure 7–1 shows
a range for expansion and rebuilding some of the
greenhouses.
Expansion
Area
Movable
Benches
Movable
Benches
Access Road
Aisle Aisle
72' 144'
160'
Right
of Way
Proposed
Gutter-
Connected
Range
Gas Line
Aisle
50'
40'
Parking
Head
House
Receiving & Shipping
Existing greenhouses
to be removed
These glass greenhouses
in poor condition to be
replaced by new range
Present
greenhouse
range
South End Road
138
Function
Functional planning considers space allocation and
use, materials handling, labor efficiency, and other
factors. Provide sufficient space for the planned
production, arranged to permit efficient use of
materials handling equipment to maximize labor
efficiency. This may require removal of obstructions
such as internal posts and/or heating fluid
distribution lines. It also may require installation
of movable benches, monorails, or pallets for bulk
handling.
Structure
A thorough examination of all parts of the structure
should be made to locate possible problem areas and
determine changes needed to meet new demands.
Uneven plate lines or out-of-plumb walls indicate
foundation problems that need attention. Steel
columns may be corroded at ground level and
seriously weakened. Steel and aluminum frames
above ground will perform satisfactorily for many
years if reasonably maintained. Internal posts can
be removed in some steel-framed greenhouses by
the addition of members to form a truss. Figure
7–2 shows an example of column removal by truss
construction.
Many older glass glazed greenhouses have 16 or
20 in. wide panes on wood sash bars. A change
to wider float glass panes or to tempered glass panes
will result in fewer bars and more light reaching the
plants. The use of extruded plastic panels, fiberglassreinforced
plastic panels, or large film plastic
sheets may permit removal of additional framing
members and increase the light available to plants.
In any reglazing, the load carrying capacity of the
Figure 7–2. Frame remodeled to remove interior pipe columns.
A. Original frame with wood sash bars and glass
B. Truss fabricated in place to permit column
removal. Wood sash bars and glass remained in
place during remodeling.
40'
9' 22' 9'
7'1"
5'6" 5'6"
12
6
1
2
3
4
5
1/2" dia.
steel rod 3/4" dia. steel pipe
5/8" x 3" steel
strap rafter,
8'6" O.C.
2'6" conc.
wall
2" dia. steel pipe columns
8'6" O.C.
2" dia. steel pipe
3/4" x 3"
steel strap
post, 8'6" O.C.
5/16" x 2" x 1-1/2"
steel angle purlins
4' 0" O.C.
Cast steel gusset
at joints 1, 2, 3, 4, 5
Lateral bracing for
upper chord 2'0" O.C.
in lower panel only
7'1"
40'
Lower chord 5/8" x 1-1/2" steel strap
welded to 5/8" x 3" steel strap rafter
2" dia. steel
post cut and
welded to strap
1/2" dia. steel
rod welded top
and bottom
139
basic frame must be estimated and structural safety
maintained. See Chapter 2 for alternatives to glass
glazed greenhouses.
Floors under benches or for on-floor flats can be
gravel, but hard-surfaced aisles make materials
handling easier. Portland cement/gravel concrete
or porous concrete can be used. Porous concrete
provides a hard surface without water puddles or
slippery spots. Heated floors can be provided by
either the flooded floor technique or by embedding
piping for warm water circulation.
Environmental Control
HEATING
Increases in prices for fossil fuels have resulted in
concern over heating system operation. Alternate
fuels such as wood and coal have been investigated
and equipment developed or upgraded to use them.
Renovation may mean replacement of a furnace
or boiler to obtain higher efficiencies and better
temperature control.
A hot water sytem can provide excellent
temperature control if planned and installed
correctly. Hot water distribution lines can be used
as rails for materials handling equipment. If the
greenhouse range has a bench system, warm air can
be distributed through low ducts to supply heat
at plant level. See Chapter 5 for alternate heating
systems.
VENTILATION
Most older glass houses are equipped with side
and top vents. Cooling takes place using wind and
differences in temperature. Manual vent systems
require close supervision by the greenhouse
operator, especially during the spring and fall when
adjustments may have to be made many times a
day. Thermostatically controlled vent motors can be
installed to provide some automation.
Today’s modern greenhouses usually require more
precise control of plant zone temperature, which
can only be achieved with an exhaust fan system. A
typical system has a fan capacity of 8 cfm for each
square foot of floor area. Intake louvers located
at the opposite end or sidewall should have a free
area of 1.25 times the fan area. A vent opening the
full length of the side opposite the fan(s) will result
in uniform air distribution. More than one stage of
ventilation is desirable to reduce energy costs and
maintain more uniform temperature control. This
can be provided with multiple fans or, in small
houses, with a two-speed fan motor.
When ridge vents are not in place, cool season
ventilation generally employs perforated
polyethylene ventilation tubes suspended in the
ridge of the greenhouse. The colder ventilation air
is mixed with the warmer greenhouse air before
reaching plant level.
Air circulation is important to reduce humidity,
increase CO2 availability to plants, and reduce
temperature stratification. Fan-jet or more efficient
horizontal air flow (HAF) systems can be used.
Energy Conservation
Systems and Methods
Thermal energy for heat and electrical energy for
motors, lights, and controls is needed to operate
a greenhouse. With energy being 15–40% of plant
production cost, special attention should be paid to
this area. With systems and techniques developed
during the past few years, most older greenhouses
can be remodeled to be competitive with today’s
structures.
The type and condition of the glazing should
be checked. Adding a single or double layer of
polyethylene film over a glass house, although
reducing light levels 10–20%, can reduce heat loss
by as much as 50%. Other methods include fixed
or movable insulating blankets installed inside the
greenhouse.
Infiltration through gaps in vents, louvers, and
doors that don’t close tightly can also increase
heat needs significantly. Particular attention
should be paid to the top vents on older glass
houses. These tend to become warped, and the
gap created acts like a chimney, pulling heat from
below. Permanently sealing the vents and installing
thermostatically operated ventilating fans can
reduce infiltration loss.
140
Insulating sidewalls (to bench height), north
walls, and foundation perimeter are common
methods used to reduce heat loss. Polystyrene or
polyurethane foam board makes a good insulating
material.
Maintenance of heating, ventilating, lighting, and
other equipment in the greenhouse will also reduce
energy needs.
Utilities
ELECTRIC SERVICE
In many older greenhouse ranges, the electric
systems have not been upgraded since the original
construction even though additional motors and
lighting may have been added. The capacity and
condition of the service entrance should be checked
by a licensed electrician. The distribution system
within the greenhouse/headhouse area should meet
the National Electric Code and any local electric
codes. Watertight boxes, UF wire, and ground fault
interrupters may be required.
An alarm system to indicate when a power
interruption has occurred or environment control
system failed should also be installed. Back-up
power from an auxiliary generating system should
be available.
WATER SYSTEM
Plants require an adequate supply of moisture for
optimum growth and maximum production. If
greenhouses are to be used during the summer, the
system should be capable of supplying
500 gal./day/1,000 ft.2 of growing space. Depending
on whether manual or automatic watering is used,
the supply should also be adequate to meet the
peak use rate. Water quality, including chemical
content, hardness, and particulate content, should be
checked.
In many greenhouse ranges, considerable expansion
has taken place since the water system was installed.
The water system usually contains a pump,
pressure tank, and piping, unless municipal water is
available. The type, capacity, and age of the pump,
as well as the size and condition of the distribution
system, should be reviewed and changes made as
needed.
BENCHES
Most older greenhouses, except those used for
bedding plant production, were fitted with benches.
A typical arrangement oriented them the length
of the house with aisles between and cross aisles
at the ends. More efficient arrangements, such as
peninsula, movable, or pallet benches, can increase
space utilization and handling efficiency, both
important today when the alternative is to provide
additional greenhouse space and more labor.
Older benches were usually constructed of concrete,
redwood, and cedar. Condition of the bench
material and supports and their adaptability to the
proposed cropping system should be determined.
Expanded metal, pressure treated lumber, and
molded plastics are materials commonly used today.
141
Chapter 8:
Energy Conservation
Introduction
A greenhouse uses several forms of energy, with
thermal energy becoming most critical because of
the price and availability of fossil fuels. This chapter
discusses techniques for reducing fuel use, including
electricity, while maintaining a satisfactory plant
environment. Fuel consumption for environmental
control includes that used to maintain temperature
above a minimum during the heating season
and electricity used to keep temperature below a
maximum during the cooling season.
The average glass glazed greenhouse located
above 40° N latitude will use between 100,000 and
250,000 Btu/ft.2 of covered area per heating season.
Electricity use for summer cooling may vary from
1/3–1 Kwh/ft.2 per cooling season. The amount of
energy used depends on the cropping program and
weather.
Thermal Energy Use

Three ways to reduce thermal energy use are:
1) operate the greenhouse at air temperatures
lower than previously used, 2) increase the thermal
resistance of the greenhouse shell, and 3) reduce
the air exchange rate between inside and outside.
The first method is based on the temperature
requirements for satisfactory crop growth and may
require a change in plant selection. Table 8–1 shows
potential reduction in fuel use based on lowering the
inside air temperature (White and Aldrich, 1980).
Increasing the thermal resistance can reduce heat
loss but results in some loss in light intensity. Each
additional layer of light-transmitting glazing will
reduce light intensity by approximately 10%. There
must be a compromise between fuel conservation
and natural light availability.
INFILTRATION
A reduction in the rate of air exchange may reduce
fuel use as much as 10% but may also result in
high relative humidity. Management must decide
whether high relative humidities will cost more
than the fuel used to provide for relative humidity
control.
Infiltration can remove large amounts of heat.
A single layer lapped glass greenhouse in poor
condition can have an infiltration rate of four air
changes per hour with very little wind. A minimum
Table 8–1. Reduction in fuel use when greenhouse air temperature is lowered. (a)
OUTSIDE TEMPERATURE
Average
(°F)
GREENHOUSE AIR TEMPERATURE
°F lowered from A to B
A 65 60 55
B 60 55 50
Percent Reduction in Fuel Use
20 11 12 14
24 12 14 16
28 13 16 19
32 15 18 22
(a) Lowering the air temperature 10°F will double the tabular values.
142
air exchange rate is required to maintain ambient
carbon dioxide levels during daylight hours and
to remove excess moisture. The use of large plastic
film sheets and sealing glass laps and cracks will
reduce infiltration, although the reduction depends
on the prior condition of the greenhouse. The best
way to ensure minimum infiltration is through good
maintenance.
LAP SEAL
Lap seal is a transparent caulking compound which
stops infiltration heat loss through laps in single
glazed glass and fiberglass houses. After dirt and
moisture are removed from between the glass laps,
a clear, silicone-based sealant is injected by a high
pressure propellant. The material readily adheres
to clean glass and does not harden, so the seal is
maintained during glass expansion and contraction
and prevents glass slippage. This seal is permanent
because the sealant cannot be easily removed from
the lap area. If glass breakage occurs, a special knife
will cut the sealant to allow glass removal. Tubes
of sealant are available for hand sealing after glass
replacement (Figure 8–1).
Savings depend on greenhouse condition and
windiness of the location. Older glass greenhouses
with wooden frames in average or below-average
repair realize the most savings. It is usually not
profitable to seal a new glass greenhouse unless
done during construction.
CONDUCTION
Material in Chapter 4 on environmental control
shows that heat moves through the greenhouse shell
by conduction. The rate of heat transfer is affected
by thermal resistance, temperature difference, and
surface area. Once the greenhouse is constructed, it
is difficult to reduce the surface area, and thermal
resistance depends on the material and fabrication
system. Double glazing will reduce the heat loss
rate by up to one-half when compared to the rate
through single layer glazing. Table 8–2 opposite
shows estimated reduction in daily heat loss for
several glazing and energy conservation techniques.
Double Polyethylene Over Glass
Using the air-inflated technique, two layers of 4 or 6
mil greenhouse grade polyethylene film are installed
directly over a single glazed structure, usually
glass. Film lasts 2–3 years depending on its quality,
although film rated for a 2-year life is preferable
because effects of aging and darkening are reduced
by recovering every other year. Special attachment
devices, normally aluminum extrusions, carry loads
imposed on film by the air pressure used in the
covering system. Recovering large glass houses with
film is difficult, but growers with no other options
have experienced savings of about 50%.
The system does appreciably reduce light
transmission. In some cases, lower light has been
offset because the extra insulation keeps night
temperatures at the desired level. Without the film
covering, temperatures in a single glass house were
too low. Also, because the house is tighter, it has
less air exchange, causing more rapid depletion
of carbon dioxide and an increase in humidity. To
overcome the approximate 18% loss in light level,
cover only the north roof and all end and sidewalls,
and leave the south roof uncovered.
No snow load problems should occur with inflated
polyethylene over glass. A significant snow load
will collapse the poly on the glass to increase the
melting rate. Light snow will remain on the roof
longer, and cause some winter light loss.
Single Polyethylene Over Glass
A single layer polyethylene cover over glass
maintains higher light levels and, therefore, better
production than double poly over glass. It has about
the same heat loss as the double poly over glass.
The film may be stapled or attached to the structure
with batten strips. When the greenhouse has had lap
seal applied, a single layer film may be inflated with
Figure 8–1. A lap seal reduces infiltration in a lapped
glass glazed greenhouse.
Glass
Lap Seal
Glass
143
the benefits of double film glazing. Figure 8–2 shows
another method of holding a single film rigid over
glass to provide an insulating air film.
Costs for single layer are similar to double layer,
except only one film need be purchased. Glass
houses in poor repair required 40% less energy after
being covered with a single layer of polyethylene.
Perimeter Insulation
Insulation set into the ground around the perimeter
of the greenhouse will increase thermal resistance
and decrease heat loss. The percentage of heat loss
through the perimeter will be greater for relatively
small individual houses than for large gutterconnected
houses. Figure 2–3 (page 26) shows
details for perimeter rigid foam insulation. Rigid
foam insulation can also be used on sidewalls
below bench height and, in many greenhouses,
on the entire north wall. Two inches of foam
polyestyrene or 1.5 inches of foamed polyurethane
or isocyanurate will have a thermal resistance of
about 10 ft.2-hr-°F/Btu.
Steel and aluminum have very low thermal
resistance and are difficult to insulate. Gutters
and other metal members can be insulated with
materials that foam on mixing and adhere to the
member.
Blankets
Movable blankets add thermal resistance during
the night and are stored during the day. Most are
made of thin materials that will pleat and store in a
relatively small space. Several commercial systems
are on the market, and plans are available for
grower-installed units. Two systems are shown in
Figures 8–3 and 8–4 on the following pages. Thermal
blankets can be installed in any greenhouse, but
most easily in clear span units. There must be a good
seal around the edges to prevent warm air from
moving into the attic space created above blankets.
Heating pipes may have to be moved, and there
is generally some growing space lost to blanket
storage. A detailed analysis should be made for each
Figure 8–2. One method for covering a glass glazed
greenhouse with a single layer of polyethylene film.
Table 8–2. Heat loss reduction from increases in thermal resistance. (a)
COVERING SYSTEM
THERMAL
RESISTANCE
(ft.2-hr-°F/Btu)
DAILY HEAT LOSS
REDUCTION
(%)
Single layer lapped glass 0.91 0
Double layer glass 1.43 36
Single layer polyethylene 0.83 (Heat loss increased 10%)
Double layer polyethylene 1.25 27
Double polyethylene over glass 2.00 54
Double skin structural plastic panel (b) 1.70 46
Single layer lapped glass plus thermal blanket 1.78 36
Double layer polyethylene plus thermal blanket (c) 2.50 57
(a) Compared to single layer lapped glass.
(b) Thermal resistance is an average value for commercial panels.
(c) Thermal blanket in place during 15-hour night; thermal
resistance is an average from tests of several blanket materials.
Cutaway View
Hold tube in place with
cord or plastic band every
20' to 30'
Air Inflated
Polyethylene Tubing
to create air space
Single layer of
Polyethylene, fastened at
all edges
144
Figure 8–3. A track-supported thermal blanket stores against one endwall and works well for a free-standing
greenhouse.
Blanket clip
Blanket
Trolly
Track
Support wire
End
support
Support wire or strapping
Thermal blanket
Track
Heat seal
Heat pipes
Wall insulation
145
Figure 8–4. Curtain system for gutter-connected greenhouse.
Support Truss for
plants and equipment
Drive Cable
Curtain Drive System
Intermediate Support
Cables
INTERMEDIATE SUPPORT CABLES
Polypropylene Monofilament
Line
Cable Tightener Bracket
DETAILS
Double Pulley
Bracket
Continuous
Rectangular
Tubing
U-bolted to
each post
Pipe
Curtain Drive
Polyethylene Pipe slit
to fit over steel pipe
Cable
Tightener
Curtain Pipe
Drive Holder
Drive Shaft
Bracket
Bracket
CURTAIN DRIVE SYSTEM
Curtain
3/8" Pipe
Nylon Pipe
Holder
Curtain
Anchor
Guide
Cable Guide
2" Drive Shaft
Pipe
Drive Shaft
Mounting Bracket
bolted to posts
Drive Cable
Double Pulley
Bracket
12'–20' Bays typical
146
installation to determine the cost/benefit potential.
Table 8–3 illustrates potential savings for a typical
installation in the Northeast. Most studies have
shown the internal thermal blanket to be a good
investment.
It is not possible to predict the thermal resistance of
a material. Each must be tested and the resistance
calculated. A standard testing method used for all
samples allows comparison. Full-scale testing in a
typical greenhouse operation provides additional
performance data.
Table 8–3. Effect of energy conservation practices on fuel use and economics for a 40,000 ft.2 greenhouse in the
Northeast. (a)
Table 8–4. Overall heat transmission values for thin thermal blanket installed in three glass greenhouses.
Radiative properties are transmission, reflection,
absorption, and emission. A good reflector is a poor
absorber and poor emitter; a good absorber is a
poor reflector and a good emitter. All properties
are functions of the temperature of the radiating
source. An ideal material would have a highly
reflective surface facing the plants and a surface
with low emissivity (high reflectivity) facing the
outer greenhouse cover. An aluminized surface with
no protective coating has a high reflectivity and
low emissivity. A black surface has low reflectivity
and high emissivity. Table 8–4 gives overall heat
transmission values for several thin materials
installed in a single glazed glass house.
CONSTRUCTION SYSTEM
FUEL USE
REDUCTION
(%)
COST
REDUCTION
(%)
Single layer lapped glass 0 0
Single layer lapped glass plus thermal blanket 41 29
Double wall plastic structural panel 38 27
Double wall plastic structural panel plus thermal blanket 59 39
(a) Adapted from Rotz, C.A. and R.A. Aldrich. Computer predicted energy savings through fuel conservation systems in
greenhouses. Trans. of ASAE.
BLANKET MATERIAL
HEAT TRANSMISSION
VALUE
(Btu/hr.-°F-ft.2)
HEAT LOSS
REDUCTION (a)
(%)
Mobile air curtain (double layer polyethylene film) 0.68 20
Stationary air curtain (aluminized polyethylene tubes) 0.54 36
White-White spun bonded polyolefin film 0.51 40
Grey-White spun bonded polyolefin film (lightweight) 0.56 34
Clear polyethylene film 0.45 47
Black polyethylene film 0.48 44
Grey-White spun bonded polyolefin film (heavyweight) 0.43 49
Aluminum foil-clear vinyl film laminate 0.40 53
Aluminized fabric 0.39 54 (b)
Aluminum foil-black vinyl film laminate 0.63 26
Double layer spun bonded polyester (tobacco shade cloth) 0.53 38
(a) Compared to single glass for the same greenhouses for night time loss.
(b) Average of four years of test data.
147
Plastic Bead System
Polystyrene beads are pumped into the cavities in
double surface extruded plastic structural sheets to
produce a wall or roof with high thermal resistance.
The beads are pulled out at daylight and stored until
pumped back at dusk. The system has been used in
Japan and in Ohio to a limited extent. By controlling
which cavities are filled, the system can be effective
for summer shading.
Controls
Blankets may be opened and closed manually or
set automatically with a photocell or time clock.
Light activated operation is most desirable for crop
production, and requires no change in settings with
the seasons. A light level of 50 fc is a good threshold
point. At this level, blankets will remain open even
on dark, cloudy days. Time clocks are the most
common method of control, even though growers
must change the clock settings as seasons change.
If a blanket is opened rapidly, cold air from the
attic area will drain rapidly onto plants, many of
which are susceptible to damage from the cold. A
percentage timer opens blankets slowly over half an
hour to eliminate this problem. Another solution is
to wait for the sun to warm the attic before opening
the blankets, or partially open the blanket 6" for an
hour before opening the blanket completely.
In most snowy areas, blankets are left open during
snow storms to reduce potential structural damage
from accumulated snow. When the integrity of the
greenhouse structure depends upon melting the
snow with the heating system, consider installing
a snow alarm which will automatically open the
blanket. Provide a manual control option for all
systems in the event of a power or motor failure.
Blanket systems are more cost effective if additional
uses can be found, such as summer shading. Use a
white porous material, providing about 50% shade,
rather than a material providing the maximum
energy saving potential. Summer shading reduces
the radiant energy load on the crop, reduces leaf
temperatures, reduces the time fans must operate,
and provides a more comfortable temperature for
people working in the greenhouse. However, a
blanket may inhibit adequate summer ventilation in
naturally vented houses with ridge vents.
Black blankets which are light-tight on all edges
and corners are needed for photoperiodic control of
some crops. The blanket can also be used for energy
conservation if condensation can be drained away.
The drive and support systems for photoperiod
control curtains are identical to those for thermal
blankets and are normally controlled by time clocks.
Cost
The most expensive parts of a thermal blanket
system are the mechanical system, blanket sewing
and grommet insertion, and labor costs for
installation. The blanket material is probably the
least expensive part, so single- and multi-layer
blankets have similar costs.
Installation
Retrofitting older greenhouses can be difficult. Heat
pipes, irrigation lines, plant light, roof support
columns, and other obstructions may have to be
moved before a system can be installed. Blanket
ends and edges must be sealed tightly to reduce air
exchange between the growing area and the attic.
Figure 8–5 shows typical edge sealing methods. A
retracted blanket will partially shade the greenhouse
by as much as 10%. Storing it along the north wall
or under the gutter will minimize shading.
Figure 8–5. Blanket edge sealing methods.
Track is supported by
wires attached to the ceiling
Insulating blanket
Hinged board
Insulated
sidewall
Insulating
blanket
Insulation
board
Insulated
sidewall
Insulating
blanket
Insulated
bench
Uninsulated
sidewall
148
Alternate Fuels
Use of alternate fuels allows the grower to take
advantage of price and availability. Dual fuel
burners are available for some fuel combinations,
and, in large operations with central heating plants,
individual boilers may be fitted for specific fuels.
Table 8–5 lists heating values for fuels commonly
used for heating greenhouses, as well as heating
plant efficiencies.
Wood and coal are becoming important alternative
heat sources for greenhouses. Table 8–6 on the
opposite page compares the costs of various fuels
based on their heating equivalents as expressed in
price per MBtu. To use this chart, draw a vertical line
through the price of the fuel being considered to the
Heating Equipment Cost line, which shows the price
per MBtu. For example, fuel oil at $1.00/gal. has an
equivalent fuel cost of $9.80/MBtu.
WOOD
Wood wastes are sold by the ton or cord. A ton
of dry sawdust as received from a furniture
manufacturer will have a heat equivalent of 100
gal. of fuel oil (about 14 MBtu). If sawdust or chips
are green as they come from a sawmill or chipping
operation, their heat value is about 50 gal. of fuel oil
(7 MBtu) per ton. A cord of air-dried hardwood, cut
at least 12 months before use, equals 240 gal. or, if
fresh cut, about 150 gal. per ton (33.6 and 21 MBtu,
Table 8–5. Heating values and heating plant efficiencies for commonly used greenhouse fuels.
respectively). These are heat values before furnace
efficiency is considered. Prices vary widely and are
affected by heat value, distance hauled, availability,
and value for other uses.
While wood offers significant fuel cost savings,
substantial capital investment in new furnaces or
boilers, fuel handling equipment, storage buildings,
and pollution control devices may be needed.
Small furnaces and boilers of 100–300,000 Btu/hr.
output are available from stove shops and heating
contractors. Larger units are generally available
directly from the manufacturer (Figure 8–6, opposite
page). Costs are difficult to estimate because of the
wide variety of equipment options and the diversity
of individual installations.
In some cases, it may be possible to retrofit an
existing boiler originally designed for wood or
coal and now converted to oil. In all cases, first
discuss needs with firms that supply and install
this equipment. Tax credits and exemptions may
be available at both state and federal levels to help
offset some costs. Low cost loans are also available
in some areas. Contact the state energy office for
further information. Before making a final decision,
apply for a permit from your state department
responsible for environmental protection. Emissions
of particulate matter and smoke must be maintained
below specific levels and may require special
pollution control and monitoring equipment.
FUEL HEAT VALUE
HEATING PLANT EFFICIENCY
Maximum Typical
Fuel oil #2 140,000 Btu/gal. 80 70
Fuel oil #6 150,000 Btu/gal. 80 70
Natural gas 1,000 Btu/ft3 80 70
Propane gas 85,000 Btu/gal. 80 70
Coal, anthracite 13,000 Btu/lb. 70 50
Coal, bituminous 11,400 Btu/lb. 70 50
Wood, mixed hardwood 24,000,000 Btu/cord 70 50
149
30 40 50 60 70 80 90
Table 8–6. Fuel cost comparison.
Figure 8–6. Layout of a typical commercial woodchip/sawdust-fired boiler.
Heating Equivalent Cost, Dollars per Million Btu's
($/MBtu)
4 6 8 10 12 14 16 18
60 70 80 90 100 110 120 130 140 150
0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20
0.80 0.90 1.00 1.10 1.20 1.30 1.40 1.50 1.60
0.50 0.60 0.70 0.80 0.90 1.00
100
4 6 8 10 12 14 16 18
Heating Equivalent Cost, Dollars per Million Btu's
Coal: $/Ton
Natural Gas: $/therm
Fuel Oil: $/gal
Propane: $/gal
Green wood chips,
45% moisture: $/Ton
Assumptions:
COAL—13,000 Btu/lb. 60% efficiency. $/MBtu = $/Ton ÷ 13.8
NATURAL GAS—Therm = 100,000 Btu. 70% efficiency. $/MBtu = $/therm ÷ 14.3
FUEL OIL (Average #2 & #6)—145,000 Btu/gal. 70% efficiency. $/MBtu = $/gal x 9.8
PROPANE—85,000 Btu/gal. 70% efficiency. $/MBtu = $/gal. x 16.8
WOOD CHIPS (45% moisture)—3,800 Btu/lb. 75% efficiency. $/MBtu = $/Ton ÷ 5.7
Cool
Return
Water
Boiler
Aquastat
Hot Water Supply
Exhaust
Stack
Forced Draft
Fan
Stack Temp
Switch
Firebox
Igniter
Feed
Conveyor
Fuel Storage Bin
Conveyor
Drive
150
Operation and maintenance costs are considerably
greater for wood-fired units than comparable oilfired
units. Wood handling and ash removal require
extra personnel time, and larger units may require
night watchmen to oversee boiler operation.
COAL
Coal is solar energy that has been stored for 100–300
million years. Total identified reserves in the United
States amount to 1,600 billion tons, of which 475
billion tons are considered economical to mine at
today’s prices and present technology. With annual
consumption averaging 0.7 billion tons, the reserves
should last several hundred years.
Most of the coal used in the Northeast is anthracite
(hard) coal, mined in Eastern Pennsylvania and
shipped by truck or rail. Bituminous (soft) coal is
available in the Appalachian region, Mississippi
Valley, and Rocky Mountain areas, but is generally
used only in heating plants with pollution control
equipment that limits sulfur emissions.
Coal prices vary greatly, depending on the source,
quantity, and hauling distance. Although coal takes
up about one-third the space of wood and does not
absorb moisture, a covered bin area convenient to
truck access and the heating plant should be used.
One ton of coal has the equivalent heat value of
150–180 gallons of fuel oil (21–25 MBtu). Although
potential savings of converting to coal seem
significant, other factors must be considered. More
labor is required to burn coal than oil, even if an
automatic stoker is used. Most larger growers must
employ nightmen to oversee heating plants. Ash
removal and cleaning are also a necessary part of the
operation.
Although some older boilers that once used coal can
be reconverted, it is often best to install a modern
heating unit. These cost in the range of $1,000-
$2,000 per 100,000 Btu/hr. output. During the past
few years, several new manufacturers have started
marketing coal units, both furnaces and boilers.
A state’s environmental protection regulations may
require a permit to be obtained for most solid fuel
burning equipment used in greenhouses, except for
small units in individual greenhouses. Emission of
visible pollutants is limited by these regulations, as
is release into the air of particulate matter, namely
fly ash. Copies of the regulations are available from
the state’s environmental protection offices.
Operating a coal-fired unit is much more difficult
than setting the thermostat on an oil furnace
or boiler. Coal, with an ignition temperature of
800–900°F, is more difficult than wood to start and
keep burning, and a coal heating unit is different
from a wood heating unit. To get a deep bed of coal
with several layers and higher fire temperature, the
firebox must usually be taller than it is long.
A grate sized for the type of coal to be used is
necessary to support the fire and supply draft. More
draft (pressure required to move air) is needed to
burn coal because air is drawn through the tightly
packed ash layer and bed. A larger or taller chimney
may be needed or, in the case of high output units, a
forced draft can be used. The draft control system on
the heating unit should be designed to supply most
of the air as primary air below the grate, just the
opposite of the wood unit. One advantage to coal
as compared to wood is that no creosote is formed,
eliminating the potential for chimney fires.
Solid fuel units burn continuously, not
intermittently as do oil or gas units. For this
reason, particular attention should be paid to
the safety control features of the unit. On boilers,
pressure-temperature relief valves control draft
when water jacket temperature exceeds a set
limit, and a circulating pump control allows
water to circulate through the piping if the boiler
overheats. On furnaces, besides the damper control,
a blower is wired to operate continuously when
the duct temperature exceeds 250°F. A furnace or
boiler should be installed by a qualified installer
in accordance with National Fire Protection
Association standards, state codes, and the
manufacturer’s recommendations. In most states,
installation requirements are specified by the state
building code and a permit is needed.
151
Power Plant Waste Heat

Electricity generating plants produce vast
amounts of heat that must be disposed of in an
environmentally safe manner. One such process
produces warm water with temperatures ranging
from 80°F in summer to 100°F in winter. Water from
power plants which use river or lake water and
discharge it into the source is generally cooler than
water from plants with their own cooling ponds.
It is feasible to heat a greenhouse range with warm
water from a power plant if water temperature is
above 80°F. A flooded floor system or dry system
can be used for heat distribution. If a flooded floor
system is used, however, additional air heating is
necessary during the coldest part of the heating
season. A design capacity back-up heating source
is required for the range because electric power
generating plants cannot guarantee 100% continuous
operation and it cannot be predicted when a given
plant will be shut down for an extended time period.
An analysis of alternative systems showed a
potential reduction from 62% to 87% in energy
costs for waste heat systems compared with a
conventional oil-fired boiler system (Rotz, C.A.
and R.A. Aldrich, 1978). The same study showed a
simple pay-back period of 4–6 years. Several acres of
greenhouses in the U.S. are now heated with power
plant waste heat, and there is a potential for several
hundred acres more.
Geothermal Heat
There are areas where geothermal heat is available
at a reasonable cost. In some locations, hot water is
pumped from below ground to provide heat for the
greenhouse. In deep mine areas, warm air can be
pumped from the mines to heat greenhouses. There
are disadvantages to using both sources. Salts in the
water can precipitate out and foul heat distribution
equipment. Corrosive gaseous elements in the mine
air can create problems with equipment, structures,
and plants. There are a few greenhouses using
geothermal water, but expansion is limited.
Estimating Fuel Use

Annual reduction in fuel use with an increase in
heating system efficiency can be estimated by the
following equation:
FR = (EN – EO) 100
EN
where FR = reduction in fuel used, %
EN = new heating system efficiency
EO = original heating efficiency.
For example, if a heating system with an efficiency
of 70% is serviced to increase the efficiency to 80%,
the reduction in fuel use would be:
FR = (80 – 70) 100 = 12.5%
80
Heating degree days can be used to estimate
seasonal fuel requirements. One heating degree day
(HDD) is defined as a 24-hr. period when inside
temperature is 1°F above outside temperature. Most
published values for HDDs use 65°F as the base
inside temperature. If, in a 24-hr. period, the average
outside temperature was 40°F, there would be
65 – 40 = 25 HDDs for that day. Table 2, Appendix
IV, shows mean annual heating degree days for
selected locations. Consult a local weather station
for specific locations.
The example greenhouse will be used to estimate
seasonal fuel requirements. From Chapter 4, the
estimated heat loss for the greenhouse was 1,953,360
Btu/hr. If the greenhouse is located near Hartford,
CT, the mean annual heating degree days would be
6,235. The fuel required would be:
F = HDD (24) (ht)
CxExt
where F = fuel in trade units
HDD = mean annual heating degree days
for the location
ht = heat loss for the greenhouse,
Btu/hr.
t = temperature difference for ht, °F
C = heat content of fuel, Btu/trade unit
for fuel
E = efficiency of heating system in
decimal form
152
For the example, using No. 2 fuel oil and rounding
the heat loss value to 1,950,000:
F = 6,235 °F/yr. (24 hr.) (1,950,000 Btu/hr.)
(140,000 Btu/gal.)(0.80)(60°F)
= 43,433 gal./yr.
Approximately 80% of the greenhouse heating load
is at night, with temperatures at or below 60°F.
Therefore, heating degree days should be adjusted
to account for inside conditions different from those
in a building with high thermal mass. If the example
greenhouse had a night temperature of 55°F, the
heating degree days would be:
HDD = 6,235 (0.80) (55°F/65°F) + 6,235 (0.2)
= 4,221 + 1,247
= 5,468 HDD
The fuel requirement would be:
5,468 HDD (43,433 gal./yr.) = 38,090 gal./yr.
6,235 HDD
This represents a reduction of over 5,000 gal. of oil.
If a thermal blanket was installed in the greenhouse
to cover only the glass area, the U value for night
would be 0.5 Btu/hr.-°F-ft.2, and infiltration would
be reduced to one-half air exchange per hour. Heat
loss during the night would then be:
ht = 0.5 (1,643,664) + 0.5 (243,302) + 66,528 Btu/hr.
1.1
= 547,888 + 121,651 + 66,528
= 736,067 Btu/hr.
(See Worksheet No. 4, Appendix XII, for detailed
calculations of heat loss.)
Heat loss during the day would be
≈ 1,950,000 Btu/hr. for a 60°F difference in
temperature. The fuel requirement would then be:
F = 4,221 (24) (736,000) + 1,247 (24) (1,950,000)
140,000 (0.80) (50°F) 140,000 (0.80) (60°F)
= 13,314 + 8,864
= 21,998 gal./yr., a 49% percent reduction.
Solar Energy Systems

Solar energy systems have been successfully
designed and studied, but most have not saved
enough fuel to yield a reasonable economic return.
The energy saving options previously discussed
significantly decrease the quantity of fossil fuel
required to heat greenhouses. Once these options
have been installed, it is difficult to pay for solar
equipment, since fuel use has been drastically
reduced.
The Rutgers University Solar Energy System
combines three components: a porous concrete floor
over water storage, an energy saving blanket system,
and the solar collector shown in Figure 8–7. Although
the collector is inexpensive and uninsulated, it
collected an average of 50% of the available solar
energy during five years of research. Based on
construction costs, the entire system has a simple
pay-back of ten years. This period may be too long
to justify such an installation. Commercial solar heat
collectors require a much higher investment and have
much longer pay-back periods.
Figure 8–7. Rutgers’s solar collector.
Concrete Footing
Pipe
B Iowers to
Inflate Tubes
Brace
2" x 4"
Framing
Members
Inner
Tube
Scaffold Plank
Cat Walk
Black film
between tubes
Outer Tube
Gutter
Pipe
153
Heating System
Maintenance
Keeping the greenhouse heating system in good
repair and proper operating condition can save
money in several ways. Fuel consumption may be
reduced as much as 10–20%. Heat distribution may
be more uniform, permitting a lower thermostat
setting and better plant growth. The system is less
likely to fail and cause crop losses.
A competent service person should clean and
adjust all furnaces and heaters at least once a year,
preferably in the fall before the winter heating
season begins. The following checklist reviews the
most important factors to consider:
Use the proper fuel—The use of the wrong grade
or type of fuel can result in carbon accumulations,
decreasing heat transfer.
Protect fuel oil tanks—Twenty percent of service
calls result from dirty fuel. Tanks should be away
from dusty locations and watertight fittings should
be used.
Remove soot from inside the furnace—A 1/8-
in. soot deposit can increase fuel consumption as
much as 10%. Surfaces should be wire-brushed and
vacuumed or special cleaning compounds used.
Change fuel filters—Uniformly clean fuel delivered
to the burner results in more efficient combustion.
Fuel supply line connections should be tight.
Clean and adjust controls—Check gas valves,
thermostats, and ignition mechanisms for clean,
smooth operation.
Oil bearings on motors and pumps—Periodic
lubrication of bearings increases their lives.
Water must be clean—Drain off dirty water through
drain cocks in steam and hot water systems. Flush
steam boilers to remove scale and lime deposits.
Check combustion efficiency—A low stack
temperature means low oil consumption, and a high
carbon dioxide content in the stack means more
completely burned oil. (See next section for test
procedures.)
Replace burned oxygen—In polyethylene filmcovered,
tight glass, and structural panel houses,
install an air intake from outside to near the heater.
Allow 1 in.2 of intake area for each 2,000 Btu/hr.
furnace capacity.
Chimney must be high enough—A chimney
should extend at least 2 ft. above the ridge of the
greenhouse. The chimney top should be at least 8–12
ft. above the furnace to develop sufficient draft. Use
a chimney cap if necessary to prevent back drafts
and possible air pollution injury to plants.
Chimney must be tight—Any air leaks will chill the
gases and reduce the draft.
Chimney must be the correct size—Too small a
cross section or a chimney lined with soot will
reduce the draft; too large a diameter will cool the
gases quickly.
Draft control is necessary—Draft variations due
to atmospheric conditions can be stabilized by
installation of a barometric draft regulator.
Install baffles—Turbulators or baffles installed
in boiler tubes slow down and direct the flow of
gases so that more heat can be transferred to the
distribution fluid. Savings in fuel consumption of
10–15% can be achieved.
Blower timing—In forced warm air systems,
blowers should operate until the furnace is cooled
to 100–120°F or continuously where air circulation is
desired.
Valves—Repack leaky valves and replace defective
ones.
Clean all heat transfer devices—Dust and dirt
reduce heat transfer and increase fuel consumption.
Insulate distribution lines—In unheated and
underground areas, insulate pipes and ducts to
reduce heat loss.
154
Thermostat placement—Locate thermostats at plant
height away from heat pipes and hot air streams.
Shade and aspirate thermostats for most accurate
Furnace and ventilation fan thermostat
differential—Set ventilation fan thermostat at least
10°F above heater thermostat setting to prevent
simultaneous operation and possible back draft.
Inspection record—Keep a record of furnace
maintenance and repairs for future reference.
FURNACE OR BOILER
EFFICIENCY TESTS
Efficiency testing a furnace or boiler involves a
simple 10-min. procedure and, if done on a regular
basis, can indicate when problems are beginning
to develop. Records of temperature and carbon
dioxide (CO2) levels of flue gases taken at weekly
periods may indicate that carbon is building up on
heat transfer surfaces or air leaks are developing in
the combustion chamber. Efficiency may change
from day-to-day with the weather. It is especially
important to test after each fuel delivery.
Efficiency tests will also indicate when excess air
is being supplied to the fire. Adjusting the burner
to obtain 1–2% greater efficiency can result in a
significant reduction in fuel use over the heating
season. For example, a 2% increase in efficiency
in a 10 gal./hr. burner operating 3,300 hr. from
September to May will result in savings of 650 gal.
This increase in efficiency is quite realistic based
on tests of furnaces in a number of greenhouses in
Connecticut during one year.
The equipment needed to conduct an efficiency
test usually comes as a kit containing a stack
thermometer that will read to 1,000°F, a CO2
indicator with sampling tube and calculator, a
smoke tester and scale, and a draft gauge with
remote tube. Manufacturers include Bacharach
Instrument Company, Dwyer Instruments, Inc., and
Lynn Products Company. These kits are available
from some greenhouse equipment suppliers and
heating equipment retailers at reasonable prices.
Before the heating season begins, the furnace or
boiler should be cleaned and serviced. The burner
blast tube, fan housing, and blower wheel should
be free of dirt and lint. Leaks into the combustion
chamber, especially joints between cast iron boiler
sections and around the fire door, should be sealed.
The oil filter should also be replaced. Manufacturer’s
recommendations should be followed in replacing
the nozzle and in adjusting ignition electrodes.
Combustion Test
1) Operate the burner for a few minutes until
operation has stabilized and furnace or boiler is
warm.
2) Set draft—Check draft reading over the fire
with the draft gauge through a 1/4-in. hole drilled
in the fire or inspection door. Adjust barometric
draft regulator on the flue to the draft recommended
by the manufacturer. If no recommendations are
available, a setting of 0.02 in. of water column
negative pressure is usually used. Where it is
not possible to measure the draft at the fire box,
a reading can be taken in the flue pipe near the
furnace. An acceptable reading in the flue pipe is
0.04–0.06 in. of water column.
3) Smoke test—Make a smoke measurement in
the flue, following the smoke tester instructions.
Compare the spot on the test paper to the smoke
scale supplied with the kit. A reading of 1 or 2 is
acceptable; readings of 3 or 4 indicate sooting, and
the furnace will require cleaning more than once a
year. Tests have shown that a 1/8-in. soot layer on
heating surfaces can increase fuel consumption more
than 8%.
4) Efficiency test—Measure stack temperatures
and CO2 level following instructions with the
test kit. Record these readings and the resulting
combustion efficiency obtained from the chart or
graph. Reduce the air gate opening on the blower
slightly and repeat the efficiency test. This should
also increase efficiency. Check the smoke level to
see if it is still acceptable. Repeat the test to obtain
the highest efficiency while still maintaining an
acceptable smoke level.
155
On older units, the efficiency achieved should
be greater than 75% for small burners and 80%
for larger burners. With flame retention burners,
efficiencies of 80% or greater should be obtained.
If the efficiency recorded is much below the above
recommended levels, consideration should be given
to replacing the burner or possibly the furnace or
boiler. The increased efficiency of a new unit with
the continual increase in fuel prices may result in a
relatively short pay-back period.
Energy Conservation
Checklist
The following are ways in which heat loss can be
reduced with an accompanying reduction in fuel
use:
REDUCE AIR LEAKS
— Keep doors closed; use door closer or springs.
— Weatherstrip doors, vents and fan openings.
— Lubricate bearings frequently so doors and vents
close tightly. A partially open louver may allow
several air changes per hour. Additional fuel is
needed to heat this air.
— Repair broken glass or holes in the plastic
covering.
— Close holes under the foundation of plastic
houses.
DOUBLE COVERING
— Line sidewalls and ends of greenhouse inside
with polyethylene or fiberglass.
— Use a double layer of film plastic, air separated
to gain an extra layer.
— Add a single or double layer of plastic over glass
and fiberglass houses and air separate.
— Line houses with plastic to get double covering.
(In heavy snow areas, caution should be
exercised in lining roof because snow will not
melt as quickly, resulting in heavier roof loads.)
BLANKET SYSTEMS
— Tight closures should be maintained where
blankets meet sidewalls or gutters. Use a
U-shaped heat trap.
— Heat and water lines should be insulated or
placed below the blanket.
FOUNDATION AND SIDEWALL
INSULATION
— Place 1–2 in. polyurethane, isocyanurate, or
polystyrene board to 18 in. below the foundation
to reduce heat loss. This can increase the soil
temperature near the sidewall as much as 10°F
during the winter.
— Use 1–2 in. of insulation board on concrete walls
of glass greenhouses.
— Use aluminum-faced building paper behind heat
pipes to reduce radiation losses, but leave air
space next to wall to prevent wall freezing.
SITE LOCATION
— Locate new greenhouses in sheltered areas to
reduce wind-induced heat loss, if this does not
reduce available light.
— Use windbreaks on the north and northwest
sides of the greenhouse area.
HEATING EQUIPMENT
— Clean and adjust furnaces annually.
— Use thermostats with -1°F accuracy.
— Aspirate thermostats for more uniform
— Check the boiler, burner, and back-up systems
to make sure they are operating at peak
efficiency.
— Clean heating pipes and other radiation surfaces
often.
— Use horizontal air flow (HAF) or fan tube
systems for more even heat distribution.
— Insulate distribution pipes in areas where heat
is not required. Insulate the boiler itself if it isn’t
heating a work area. Check and repair leaks in
valves or pipes.
WIRING SYSTEM
— Have the wiring system inspected by a
competent electrician for overloading, corroded
parts, and faulty insulation.
— Losses of electric energy for heating the wires
can be reduced by using larger wire sizes.
156
MOTORS
— Motor size and type should be selected based
on the requirements of the equipment it is to
operate.
— Turn motors off when they are not needed.
— Keep proper belt tension and alignment. Use
larger diameter fans with smaller motors—for
example, a 36-in. fan with 1/3 hp motor can
give the same output as a 30-in. fan with 1/2 hp
motor, with a savings in electricity of
30 kwh/month. Both have 7,800 cfm output.
— A power company voltage reduction of 8% will
not affect most motors if the line supplying
the motor is an adequate size and is not
overloaded. A combined voltage drop due to
power company reductions and line losses of
more than 10% can cause motor overheating
and damage. Motors with thermal overloaded
protection should be used.
LIGHTING
— Keep light bulbs and fixtures clean.
— Use the correct size light bulb for the job.
— Turn lights off when not needed.
— Use fluorescent lights.
WATER
— A large supply of water is needed to operate a
greenhouse. The cost of this, whether it be in the
form of a monthly water bill or operation charge
of an individual water system, adds to the
production cost of plants. Conservation of water
as well as the energy to move it can be made in
several ways.
PUMPS
— Service the pump at least twice each year.
— Provide adequate wire size for the pump motor
to reduce heat loss from the wire and to provide
sufficient voltage at the motor.
TANKS
— Use large pressure tanks to eliminate frequent
starting of the pump motor.
— Drain tanks when needed to avoid a “waterlogged”
condition.
— Hot water tanks should be located as close as
possible to the most frequent hot water use.
— Heat water to the lowest temperature that is
needed for the job. Thermostats on most water
heaters should be set at 120°F.
PIPES
— Use pipe large enough to supply necessary
water at minimum pipe friction loss.
— Insulate hot water pipes to reduce heat loss.
— Eliminate all water leaks. A faucet dripping at
60 drops per minute will waste 113 gallons per
month.
GASOLINE AND DIESEL ENGINES
Gasoline and diesel fuel are essential to operate
the trucks, tractors, and other engine-powered
equipment used in the greenhouse operation.
Savings can be made by observing the following:
— Keep motors tuned and in good repair.
— Shut off engines rather than let them idle.
— Use the smallest size motor that will do the job
properly.
MEDIA PASTEURIZING
Treating root media with aerated steam, either in
beds or by a batch method in flat or pot system,
will save energy. About 180,000 Btu are required to
sterilize one cubic yard of a 1:1:1 soil mix at 212°F
and hold it at that temperature for 30 minutes. If
the same mix is pasteurized at 160°F (heated and
held at 160°F for 30 min.), about 120,000 Btu are
required. Table 8–7, opposite, shows heat required
for pasteurization at different temperatures.
157
TREATING
TEMPERATURE
(°F)
STEAM
REQUIRED
(lb.)
AIR
REQUIRED
(ft.3)
TOTAL HEAT
SUPPLIED
(Btu)
140 83 7,400 95,460
160 116 4,640 119,250
180 123 2,525 143,280
212 171 —
181,490
References
Poole, H.A. and P.C. Badger. 1980. Management
Practices to Conserve Energy in Ohio Greenhouses.
Ohio State University, Columbus, OH. Ext Bul.
668.
Bartok, J.W., Jr., W.J. Roberts, E.E. Fabian, and
J. Simpkins. 1989. Energy Conservation for
Commercial Greenhouses. Natural Resource,
Agriculture, and Engineering Service, Cornell
University, Ithaca, NY 14853. NRAES-3.
Rotz, C.A., R.A. Aldrich and J.W. White. 1979.
Computer Predicted Energy Savings Through Fuel
Conservation Systems in Greenhouses. Trans. of
Am. Soc. Agr. Engr. Vol. 22, No. 2. St. Joseph, MI
49085.
White, J.W. and R.A. Aldrich. 1980. Greenhouse
Energy Conservation. The Pennsylvania State
University, University Park, PA 16902.
———. 1984. Guidebook for Industrial/Commercial
Wood Energy Conservation. J.P.R. Associates,
Stowe, VT 05672.
Table 8–7. Heat required to warm one cubic yard of 1:1:1 soil:peat:perlite mix from 60°F.
159
Appendix I
REFERENCES
This list is not intended to be all-inclusive. Consult your Extension Specialist for additional
titles.
GENERAL REFERENCES
Greenhouse Design Standards. National Greenhouse Manufacturers Association.
Greenhouse Operation and Management. P.V. Nelson. 1991. Prentice Hall, Englewood Cliffs,
NJ 07632.
Energy Conservation for Commercial Greenhouses. Natural Resource, Agriculture,
and Engineering Service, PO Box 4557, Ithaca, NY 14852-4557. NRAES-3.
Floor Heating & Bench Heating for Greenhouses. W.J. Roberts and D.R. Mears. Bio. and
Agricultural Engineering Department, Cook College, P.O. Box 231, New Brunswick,
NJ 08903.
Heating & Ventilating Greenhouses. W.J. Roberts and D.R. Mears. Bio. and Agricultural
Engineering Department, Cook College, P.O. Box 231, New Brunswick, NJ 08903.
TRADE MAGAZINES
Flowers, Teleflora Plaza, Suite 260, 12233 W. Olympic Blvd., Los Angeles, CA 90064.
Greenhouse Grower, 37841 Euclid Avenue, Willoughby, OH 44094.
Greenhouse Manager, P.O. Box 1868, Fort Worth, TX 76101.
Grower Talks, 250 Town Road, West Chicago, IL 60185.
Nursery Business, P.O. Drawer 22389, Tampa International Airport, FL 33623.
Pacific Coast Nurseryman, 832 S. Baldwin Avenue, Arcadia, CA 91006.
Nursery Manager, P.O. Box 1868, Fort Worth, TX 76101.
Florist’s Review, 111 North Canal Street, Suite 545, Chicago, IL 60606.
Floral & Nursery Times, 328 Linden Avenue, Wilmette, IL 60096.
160
Appendix II
GREENHOUSE CONSTRUCTION AND SUPPLY COMPANIES
M —————– Manufacturer or supplier of commerical greenhouses
S ———— Supplies or Parts
E –––––– Equipment
E Acme Engineering & Manufacturing Corp., Box 978, Muskogee, OK 74402.
M Agra Tech, Inc., 2131 Piedmont Way, Pittsburg, CA 94565.
E American Coolair Corp., Box 2300, Jacksonville, FL 32203.
S E American Horticultural Supply, Inc., 4045 Via Pescador, Camarillo, CA 93010.
E Argus Control Systems Ltd., 10-1480 Foster St., White Buck, BC, V4B 3X7, Canada.
S Armin Plastics, 18901 E. Railroad St., City of Industry, CA 91748.
M Atlas America, 5 Glen Road, Manchester, CT 06040.
M E Atlas Greenhouse Systems, Inc., Rt. 1, Box 339, Alapaha, GA 31622.
M Attico Greenhouse Inc., 5243 Stillesboro, Kennesaw, GA 30144.
M S E B & K Installations Co., Inc., 246 4th Avenue S.W., Homestead, FL 33030.
M Ball Seed Co., P.O. Box 335, West Chicago, IL 60185.
M S Beck Manufacturing Co., Box 2014, Auburn, AL 36830.
E Berry Seeder Col, 1231 Salem Church Rd., Elizabeth City, NC 27909.
S BE Supply, Hemlock Road, Langdon P.O. Box 0, Charlestown, NH 03603.
S E BFG Supply Co., 14500 Kinsman Road, Burton, OH 44021.
E Bio-Energy Systems, Inc., P.O. Box 191, Ellenville, NY 12428.
E BioTherm Hydronic, Inc., P.O. Box 750967, Petaluma, CA 94975.
E Blackmore Co., 10800 Blackmore Ave., Belleville, MI 48111.
E Bouldin & Lawson, Inc., Box 208, McMinnville, TN 37110.
M S E Brighton By-Products Co., Inc., Box 23, New Brighton, PA 15066.
M S E Carolina Greenhouses, 1504 Cunningham Rd., Kingston, NC 28501.
M S E Caves Enterprises, Inc., 2464 Pumpkin Center Road, Hammond, LA 70403.
E Chapin Watermatics, Inc., 740 Water St., Watertown, NY 13901-0490.
M S E Clover Garden Products, Inc., Box 789, Smyrna, TN 37167.
M S E Conley’s Mfg. and Sales, 4344 Mission Blvd., Pomona, CA 91766.
S Continental Products, Inc., 1150 East 222nd St., Euclid, OH 44117.
E Cravo Equipment Ltd., RR #1, Brantford, Ontario N3T 5L4.
M S E CropKing, Inc., 5050 Greenwich Rd., Seville, OH 44273.
S CTFilm, 1355 Tercell Mill Rd., Bldg. 1474, Marietta, GA 30057.
S E D & L Grower Supplies, Inc., 33 Hess Rd, P.O. Box 241, Leola, PA 17540-0241.
M E Dace, Inc., 1937 High St., Longwood, FL 32750.
M E Dalsem Greenhouses USA, Inc., P.O. Box 54039, Jacksonville, FL 32245.
S E Darbco, Inc. 25 Almeida Ave., East Providence, RI 02914.
E Delta T Sales, Inc., 540 S. Andreasen Dr., Suite K, Escondido, CA 92029.
E Dramm Corp., P.O. Box 1960, Manitowoc, WI 54221-1960.
S Duragreen Marketing, Inc., P.O. Box 1486, Mount Dora, FL 32757.
M E Evergreen Enterprises, P.O. Box 128, Phippsburg, ME 04562.
S E Florist Products, Inc., 2242 N. Palmer Drive, Schaumburg, IL 60173.
E Gardener’s Supply Co., 128 Intervale Rd, Burlington, VT 05401.
161
S Garland Company, 3800 E. 91st Street, Cleveland, OH 44105.
M S E Geiger, E.C., Box 285, Harleysville, PA 19438.
E Gleason Equipment, 28055 S.W. Boberg Rd., Wilsonville, OR 97070.
S Greenhouse Supply Inc., P.O. Box 97, Orono, ME 04473.
S Green-Tek, Inc., 407 N. Main St., Edgerton, WI 53534.
M E Griffin Greenhouse Supplies, Inc., 1619 Main Street, Tewksbury, MA 01876.
S E George K. Groff, Inc., 224 Maple Ave., Bird-in-Hand, PA 17505.
S E Gro-Tech Supply, Inc., 1704 Henry G. Lane, Maryville, TN 37801.
M E Growell Greenhouses, 476 Coleman Road, Cheshire, CT 06410. 272-8147.
M S E Growers International, Inc., Box 10, Schulenberg, TX 78956.
M Grow-It Wholesale Greenhouses, P.O. Box 26037, West Haven, CT 06516.
E Growth Zone Systems, 1735 Cedardale Rd., Mt. Vernon, WA 98273.
M Harnois Industries, 1044 Principale, St. Thomas of Jolietta, Quebec J0K 3L0, Canada.
M S E Horticultural Products & Supplies, Inc., 1307 West Morehead, Charlotte, NC 28208.
M S E Hummert International, 2746 Chouteau Avenue, St. Louis, MO 63103.
M E Jaderloon Co., Inc., Box 685, Irmo, SC 29063.
E Javo USA, Inc., 1900 Albritton Dr., Kennesaw, GA 30144.
M Keeler-Glasgow Co., Inc., Box 158, Hartford, MI 49057.
S Klerk’s Plastic Products, 546 L & C Distribution Park, Richburg, SC 29729.
M S E Ludy Greenhouse Mfg. Co., Box 141, New Madison, OH 45346.
S E McCalif Growers Supplies Inc., P.O. Box 310, Ceres, CA 95307.
M S E McConkey Co., P.O. Box 1690, Sumner, WA 98390.
S Midwest Growers Supply, Inc., 918 Paramount Parkway, Batavia, IL 60510.
M S E Milikowski, William H., 75 Chestnut Hill, Stafford Springs, CT 06076.
E Modine Manufacturing Co., 1500 DeKoven Ave., Racine, WI 53403
E Nepco Inc., P.O. Box 33918, Seattle, WA 98133.
M E Nexus Greenhouse, 10983 Leroy Drive, Northglenn, CO 80233.
M E Oehmsen Midwest Inc., P.O. Box 585, George, IA 51237.
S E Penn State Seed Co., Box 390, Dallas, PA 18612.
M E Poly-Growers, Inc., Box 359, Muncy, PA 17756.
M Poly-Tex, Inc., P.O. Box 458, Castle Rock, MN 55010.
S E Premium Seed & Hort. Supply Co., Inc., 915 E. Jefferson, Louisville, KY 40206.
E Priva Computers, Inc., 3468 S. Service Rd., Vineland Sta, ON L0R 2E0, Canada.
E Q-Com, Inc., 17782 Cowan St., Irvine, CA 92714.
E Radiant Systems, P.O. Box 33666, Raleigh, NC 27636.
S Replex Plastics, P.O. Box 967, Mt. Vernon, OH 43050.
E Resnor, 1555 Lynnfield Rd., Memphis, TN 38119.
M S E Rough Brothers, Box 16010, Cincinnati, OH 45216.
E Seed E-Z Seeder Co., Rt. 1, E11290, Prairie Du Sac, WI 53578.
S E Sharp Distribution, P.O. Box 10, Schulenburg, TX 78956.
E Siebring Manufacturing Co., George, IA 51237.
M S E Smith, X.S., Inc., Drawer X, Red Bank, NJ 07701.
S E Southwest Growers Supply, 1015 Linda Vista, Bldg. B, San Marcos, CA 92069.
E Speedy Seeder, Inc., W11912 County Hwy V, Lodi, WI 53555.
M E Sterling Structures, Ltd., N. Hwy 59, Oakland, IA 51560.
162
M S E Stuppy Greenhouse Mfg. Co., 120 E. 12th Ave. North, Kansas City, MO 64116.
E Sunderman Mfg. Co., Rt. 1, Box 14, Baltic, SD 57003.
S E Transplant Systems, Inc., P.O. Box 983. Kingston, NC 28501.
M E United Greenhouse Systems, 708 Washington St., Edgerton, WI 53534.
M S E V & V Noordland, Inc., Box 739, Medford, NY 11763.
S VJ Growers Supply, 4041 Chastin Ave., Charlotte, NC 28219.
M E Van Wingerden Greenhouses, 4078 Haywood Rd., Horse Shoe, NC 28742.
M E Verbakel/Bomkas Co., 1900 The Exchange, Suite 220, Atlanta, GA 30339.
E Wadsworth Control Systems, Inc., 5541 Marshall St., Arvada, CO 80002.
S E Waldo & Assoc., Inc., 28214 Glenwood Road, Perrysburg, OH 43551.
M S E Westbrook Greenhouse Systems, Ltd., Box 99, Grimsby, Ontario L3M 4G1.
M S E Western Ag Products, Box 961, Gridley, CA 95948.
M E Winandy Greenhouse Co., Inc., 2211 Peacock Road, Richmond, IN 47374.
163
GREENHOUSE ERECTORS
Agra Tech Inc., 2131 Piedmont Way, Pittsburg, CA 94565. 415/432-3399.
Agricultural Construction Corp., Rochester, NY 14602. 716/454-2873.
American Greenhouse Bldg. & Maint. Co., 147 S. Delsea Dr., Vineland, NJ 08360. 609/692-7500.
Atlas America, 5 Glen Road, Manchester, CT 06040. 203/699-6024.
B & K Installations, Inc., 246 Southwest 4th Ave., Homestead, FL 33030. 305/245-6968.
Carl Bjorklynd, Greenhouse Repairs, Inc., East Brookfield, MA 01515. 617/867-6564.
Creamy Acres Farms, Ron Ambruster, Mullica Hill, NJ. 609/478-2942.
General Greenhouse Construction, P.O. Box 753, Millville, NJ 08332. 609/327-1314.
J & M Greenhouse Co., Inc., 2211 Peacock Rd., Richmond, IN 47374. 617/685-6069.
Albert J. Lauer, Inc., 16700 Chippendale Ave., W. Rosemount, MN 55068. 612/423-1651.
Ludy Greenhouse Mfg. Corp., Box 141, New Madison, OH 45346.
Chris Miller Construction, 3097 Allendale Parkway, Blasdell, NY 14219.
New England Greenhouse Construction Co., P.O. Box 187, Winchester, MA 01890.
New World Maintenance Co., 3 Fourth St., New Brunswick, NJ 08901. 201/545-3849.
Charles E. Nurnberger, 18 Hillside Ave., Woborn, MA 01801. 617/935-0717.
Bill Orlando, Westborough, MA 01581. 617/366-4212.
Professional Greenhouse Service, RD #2, Box 288, Mohawk, NY 13407. 315/823-1708.
RAF Greenhouse Erectors, Freehold, NJ 07728. 201/462-0834.
Rough Brothers, Inc., Box 16010, Cincinnati, OH 45217.
Sharp & Son, 19219 62nd Ave. S., Kent, WA 98032.
Specialty Products & Services Corp., P.O. Box 20909, San Jose, CA 95160.
Peter H. Winandy Sons, Inc., 1102 Washington, Glenview, IL 60025. 312/724-4721.
Winandy Greenhouse Co., Inc., 2211 Peacock Road, Richmond, IN 47374.
HYDROPONIC SYSTEMS, EQUIPMENT, & SUPPLY SOURCES
AgroDynamics, 12 Elkins Road, Brunswick, NJ 08816.
Alternative Garden Supply Inc., 297 N. Barrington Blvd, Streamwood, IL 60107.
American Produce, P.O. Box 123, Arcola, VA 22010.
Aquaculture, 700 West 1st Street, Tempe, AZ 85281.
Clover Garden Products, Inc., Box 874, Smyrna, TN 37167.
CropKing Inc., P.O. Box 310, Medina, OH 44258.
Genova, 7034 East Court Street, Box 309, Davison, MI 48423
GVI System—Van Duyne Tech. Prod., 3042 Holiday Ave., Apopka, FL 32703.
Hydrofarm, 3135 Kerner Blvd, San Rafael, CA 94901.
Hydrofarms, Box 3460, Syracuse, NY 13220.
Hydro-Gardens, Inc., P.O. Box 25845, Colorado Springs, CO 80936.
Hydro-Mart, 3841 Main St., Rowlett, TX 75088.
Northern Lights and Hydroponics, 4 Mahoning Ave., New Castle, PA 16102.
Smithers-Oasis, Box 118, Kent, OH 44240.
Troy Hygro Systems, Inc., 4096 Hwy ES, East Troy, WI 53120.
164
Appendix III
PLANS FOR GREENHOUSES
The plans listed are examples of those developed to aid commercial growers and are available from the
Agricultural Engineering Department, University of Connecticut. Contact your Extension Agricultural
Engineer for additional information and/or plans.
Plan No. Description

239 Twenty-Six Foot Wide, Slant-Leg Greenhouse—Covered with single or double layer
polyethylene. Designed for bedding plants. Can be built in multiples of 4 ft. Uses treated
wood posts for footings.
810 Straight-Leg Rigid Frame Greenhouse—23 ft. x 48 ft. or multiples of 4 ft. Can be covered
with polyethylene or fiberglass. Post or pier foundation.
243 Thirty-Four Foot, Rigid-Frame Greenhouse—This clear span building was designed to
meet the requirements of the commercial bedding plant and greenhouse vegetable growers.
It is covered with polyethylene fabric.
SP 498 Twenty Foot Wide Pipe Frame Greenhouse—Hoop house using 1-in. galvanized water
pipe. Can be built in multiples of 3 ft. Uses 32’ wide polyethylene covering.
6064 Shade House—This 23 ft. x 48 ft. rigid frame structure can be used for winter storage or
nursery stock or as a retail sales area.
SP 544 Jig for Bending Pipe Arches, 15 ft. wide—Wood block jig can be set up on wood floor or
trailer bed. Can be adapted to other sizes.
Plan No. 239
2” x 2” end
frame only
Frame for Fan
or Louvers
2” x 4” ridge
2” x 8” rafter
4” x 4” x 14”
2” x 3”
2” x 4” eave
26’-3/8”
8’0”
4’0”
7’0”
Plan No. SP 498
Plan No. 6185
10’ 0”
20’ 0”
2” x 4” Frame endwalls to suit individual needs
1” galv. pipe−1-1/2 lengths approx. 31 ft.
6 mil plastic
1” x 3” furring
strip
2” x 6” pressure treated
3/8” U-bolt
1-3/8” or 1-1/2” ID x 42” long
pipe driven into ground 36”
6
12
4’–0”
TYP.
ROOF TRUSS 6’–0” O.C.
FASTEN FILM HERE.
(SEE DETAIL)
EXHAUST
FAN
FILM PLASTIC COVER DOUBLE LAYER–AIR
SEPARATED ONE 40’ SHEET FROM TOP OF
VENT TO TOP OF VENT. FASTEN AT ENDS
& USE 1/20 HP. CENT. BOWER TO KEEP
LAYERS SEPARATED.
FASTEN FILM HERE−SEE DETAIL
2x3 SIDEWALL GIRTS
1½” POLYURETHANE CEMENT
ASBESTOS COVERED PANEL
1’–6” VENT OPENING. HINGE
AT TOP−COVER 2”X2” FRAME
W/ FILIM ON EACH SIDE
ACME TUBE MODEL DA
18” DIA. W/ RC 18 E 6 FAN
JET 3120 C.F.M. 120,000
BTU. HEATER
BENCH TOP 3” B–GRADE
CRUSHED STONE
6” COARSE GRAVEL
EARTH
28’–0”
4”x4” POST 6’–0” O.C. ¾”x¾” STOP FOR VENT
2”x3”x4’ BRACE, NAIL TO POST & UPPER CHORD W/ GALV. NAILS
IF FIBERGLASS PANELS ARE USED INSTEAD OF FILM,
FASTEN TO PURLINS W/ RING SHANK ALUM. NAILS WITH
NEOPRENE WASHERS.
NOTE:
12”x12”x6” CONC.
FOOTING
3’–0”
2’–6” 3’–0”
7’–0”
NOTE:
CARRY FOOTINGS
BELOW FROST LINE
CROSS SECTION
SCALE: ¼” = 1’–0”
CROSS SECTION
STEEL FRAME
SCALE: ¼” = 1’–0”
GRADE LINE
6”x6” CONC. PIER
3/8” DIA. RE–BAR
2” GALV. STEEL PIPE 6’–0” O.C.
WIND BRACE 3/16”x1” STRAP EACH SIDE OF
COL. & TRUSS (FIELD WELD IN PLACE)
28’–0”
EXHAUST
FAN METAL ROOF
TRUSS
12”x12”x6” THICK CONC. FOOTING
1/8”x1½”x1½” STEEL
ANGLE PURLINS
STEEL ANGLE CLIP AT
EACH PURLIN
1’–6” VENT OPENING. HINGE
AT TOP−COVER W/ FILM ON
EACH SIDE OF 2”x2” FRAME
2’–0”
1’–0”
6” 2’–0” 1’–0” 6’–0”
166
Appendix IV
HEATING AND COOLING DATA
Table 1. Heat Content of Fuels.
Fuel Heat Content
(Btu/lb.)
Bituminous Coal 11,000
Sub-bituminous Coal 9,000
Lignite Coal 7,100
Anthracite Coal 12,000
Charcoal 13,500
Peat (30% water, dry wt. basis) 6,000
Peat (12% water, dry wt. basis) 8,000
Petroleum coke (5% S) 14,100
High temperature coke 12,500
Oil shale (as mined) 2,800
Oil shale (as refined) 18,400
Birch (green—5,130 lb./cord) 5,300
Elm (green—4,850 lb./cord) 4,575
Oak, white (green—5,670 lb./cord) 5,060
Maple, red (green—4,500 lb./cord) 5,270
Pine, white (green—3,240 lb./cord) 5,340
Corn with cob 8,200
Flax straw 8,200
Wheat straw 8,500
(Btu/gal.)
Ethyl alcohol 84,300
Kerosene 134,000
No. 2 Diesel 138,700
No. 2 Fuel oil 140,000
No. 6 Fuel oil (2.7% S) 152,000
No. 6 Fuel oil (0.3% S) 143,000
Coal Tar 153,500
Asphalt 155,500
Butane (liquified) 103,000
Propane (liquified) 91,600
(Btu/ft.3)
Manufactured gas 525
Natural gas 1,000
Biogas 600
(Btu/cord)
Mixed hardwood 24,000,000
Mixed softwood 15,000,000
One cord = 128 ft.3
One barrel = 42 gallons
167
Table 2. Average yearly heating degree days for selected locations.(a)
LOCATION HEATING DEGREE DAYS (HDD)
day (b) + night (c) = total day (d) + night (e) = total
65°F 65°F 65°F 55°F
Denver, CO 1,257 5,026 6,283 1,257 4,253 5,510
Hartford, CT 1,247 4,988 6,235 1,247 4,221 5,468
Atlanta, GA 592 2,369 2,961 592 2,005 2,597
Springfield, IL 1,086 4,343 5,429 1,086 3,675 4,761
Lexington, KY 937 3,746 4,683 937 3,170 4,107
Baltimore, MD 931 3,723 4,654 931 3,150 4,081
Worchester, MA 1,394 5,575 6,969 1,394 4,717 6,111
Lansing, MI 1,382 5,527 6,909 1,382 4,677 6,059
Minneapolis, MN 1,676 6,706 8,382 1,676 5,674 7,350
Newark, NJ 918 3,671 4,589 918 3,106 4,024
Albany, NY 1,375 5,500 6,875 1,375 4,654 6,029
Raleigh, NC 679 2,714 3,393 679 2,297 2,976
Columbus, OH 1,132 4,528 5,660 1,132 3,831 4,963
Harrisburg, PA 1,050 4,201 5,251 1,050 3,555 4,605
Richmond, VA 773 3,092 3,865 773 2,616 3,389
Seattle, WA 1,029 4,116 5,145 1,029 3,483 4,512
(a) Adapted from ASHRAE Fundamentals 1981.
(b) Day HDD = 0.2 total
(c) Night HDD = 0.8 total
(d) Day HDD is same, since day temperature remains at 65°F
(e) Night HDD at 55°F = (55/65) of the night HDD at 65°F
Table 3. Sizing PE convection tubes(a) for cooling application. (Air flow based on 2 cfm/ft.2 of floor area.)
House Length (ft)
50 100 150 200 250
House Tube Fan Tube Fan Tube Fan Tube Fan Tube Fan
Width Des. Cap. Des. Cap. Des. Cap. Des. Cap. Des. Cap.
(ft.) (cfm) (cfm) (cfm) (cfm) (cfm)
15 A 1,500 A 3,000 A 5,000 B 6,000 B 7,500
20 A 2,000 A 4,000 B 6,000 C 8,000 D 10,000
25 A 2,500 A 5,000 B 7,000 D 10,000 E 12,500
30 B 3,000 B 6,000 C 9,000 D 12,000 F 15,000
35 B 3,500 B 7,000 C 10,500 E 14,000 G 17,500
40 B 4,000 B 8,000 D 12,000 F 16,000 H 20,000
Number of tubes used with the diameter shown:
Tube Des. No. Used. Diameter (in.)
A 1 18
B 2 18
C 1 24
D 2 24
E 1 30
F 1 30 (inlet at each end)
G 2 30
H 2 30 (inlet at each end)
(a) Commercially available tubes have prepunched holes to provide uniform air distribution. The tabular information is
furnished as a rough guide. Consult a greenhouse supply farm for details.
168
Appendix V
CONTAINER CAPACITIES
Table 1. Number of containers filled per unit of rooting media.
Container Containers Containers Container Containers Containers
Size per bushel per yd.3 Size per bushel per yd.3
Pot, STD Round Pot, Hanging Basket
2.25” 320 6,900 6” 25 540
2.50” 260 5,600 8” 10 215
3.00” 150 3,240 10” 6 135
3.50” 100 2,160 12” 5 110
4.00” 60 1,300
4.50” 50 1,080
5.00” 35 750 Gallon Container
5.50” 25 540 1 gal. 11.7 252
6.00” 20 430 2 gal. 5.8 126
7.00” 12 270 3 gal. 3.9 84
8.00” 7 160 4 gal. 2.9 63
10.00” 4 80 5 gal. 2.3 50
Pot, Round Azalea 2.5” Deep Flats
4.0” 70 1,500 11” x 22” 3.5 77
4.5” 55 1,180 12” x 24” 3.1 67
5.0” 35 750 13” x 15” 4.4 95
5.5” 30 650 14” x 16” 3.8 83
6.0” 22 480 14” x 18” 3.4 74
6.5” 20 430 15” x 20” 2.8 62
7.0” 15 325 16” x 16” 3.3 72
7.5” 12 270 16” x 21” 2.5 55
8.0” 9 190 16” x 24” 2.2 48
10.0” 5 110
Pot, Square
2.25” 444 9,600 Note: Pot numbers are approximate and
3.00” 160 3,450 may vary with soil type, fill level, and
4.00” 70 1,510 manufacturer.
169
Appendix VI
LABOR OUTPUT AND MACHINE CAPACITIES
Table 1. Labor requirements for typical growing tasks.
Growing Task Labor Required
Soil Mixing
Mortar mixer 1-1/2–2 yd.3/worker/hour
Transit mixer 3–5 “
Shredder-tractor w/bucket loader 15–20 “
Drum mixer—feeder bins 15–20 “
Flat Filling
Hand 60–100 flats/worker/hr.
Machine 150–300 “
Transplanting—bedding plants
Hand 8–15 flats/worker/hr.
Cell transplants, production line conveyor 30–50 “
Canning—1 gallon
Assembly of materials, hand filling & planting,
moving to field by trailer 120–150 cans/worker /hr.
Assembly of materials, machine canning,
moving to field by trailer 160–400 “
Canning—5 gallon
Assembly of materials, hand filling & planting,
moving to field by trailer 25–35 cans/worker/hr.
Assembly of materials, machine canning,
moving to field by trailer 30–60 “
Potting—1 gallon nursery stock
On ground—in place 400–500 plants/worker/day
In trailer 400–500 “
On assembly conveyor 600–800 “
170
Table 2. Typical equipment capacities and output.
MACHINE CAPACITY OUTPUT
Mixers
Batch 1 yd. bin with spiral agitator 6–8 yd.3/hr.
Batch 2 yd. bin with spiral agitator 10–12 “
Continuous Feeder bins with drum mixer ≤ 50 “
Flat/Pot Fillers
Carousel Semi-automatic 1–4 operators, pots/tubs 400–2,500/hr.
Potting Machine Pot dispenser/dibble—1–2 operators, pots/cans ≤ 3,000 “
Belt Pots held in template 9,000 “
Belt Flats 900–1200 “
Pot Separator 5-1/2–13-in. dia. ≤ 5000/hr.
Plug Extractor Removes plugs from tray ≤ 20,000/hr.
Precision Seeders 4–8 flats/hr.
Soil Bagger 4 yd. hopper 500–1,000 bags/hr.
Nursery Stock Balling
Machine 8–15-in. dia. balls 800–1,200/day
Bare Root Bagger 3 operators 4,000/day
Shredder 3 HP engine 8 yd.3/hr.
5 HP 12 “
24 HP 40 “
171
Appendix VII
ELECTRICAL DATA
Electrical Requirements for AC Motors
Table 1. Full-load currents for single-phase and three-phase AC motors. (a)
Single-Phase AC Motors Three-Phase AC Motors
115 volts 230 volts
Motor 125% 125% Motor 125%
Horse- Full Full Full Full Horse- Full Full
power Load Load Load Load power Load Load
(amps) (amps) (amps) (amps) (amps) (amps)
1/6 4.4 5.5 2.2 2.8 1/2 2.0 2.5
1/4 5.8 7.2 2.9 3.6 3/4 2.8 3.5
1/3 7.2 9.0 3.6 4.5 1 3.6 4.5
1/2 9.8 12.2 4.9 6.1 1-1/2 5.2 6.5
3/4 13.8 17.2 6.9 8.6 2 6.8 8.5
1 16.0 20.0 8.0 10.0 3 9.6 12.0
1-1/2 20.0 25.0 10.0 12.5 5 15.2 19.0
2 24.0 30.0 12.0 15.0 7-1/2 22.0 28.0
3 34.0 42.0 17.0 21.0 10 28.0 35.0
5 56.0 70.0 28.0 35.0 15 42.0 52.0
7-1/2 40.0 50.0 20 54.0 68.0
10 50.0 62.0 25 68.0 85.0
30 80.0 100.0
40 104.0 130.0
50 130.0 162.0
(a) To obtain full load currents for 208-volt motors, 60 154.0 192.0
increase corresponding 230-volt motor load by 10%. 75 192.0 240.0
100 248.0 310.0
125 312.0 390.0
172
Table 2. Starting and running requirements for commonly used 60-cycle, single-phase motors.
Approximate Watts required (a) Watts required
Motor amps to start to run
Horse- (full load) Split Cap. (full load)
power 120 V 240V phase start (b)
1/6 4.4 860 215
1/4 5.8 1,500 1,200 300
1/3 7.2 2,000 1,600 400
1/2 9.8 4.9 2,300 575
3/4 13.8 6.9 3,345 835
1 8.0 4,000 1,000
1-1/2 10.0 6,000 1,500
2 12.0 8,000 2,000
3 17.0 12,000 3,000
5 28.0 18,000 4,500
7-1/2 40.0 15,100 (c) ≤ 28,000 7,000
10 50.0 81,900 (c) ≤36,000 9,000
(a) Adapted from Cornell Extension Bulletin 879.
(b) Reduce 25% for repulsion induction motors.
(c) Soft start motors.
Table 3. Sizes of copper wire for single-phase, 115–120-volt motors, and a 2% voltage drop. (a)
Min. Wire Size Length of wire to motor in ft.
Load (Wire in cable 20 30 40 50 60 80 100 120 160 200 250 300 400 500
conduit or earth)
Types Types Bare or Wire size (AWG or MCM) (c)
R, T, RH, RHW, covered, ( Note: Compare the size shown below with the size shown in the
TW THW overhead in column to the left and use the larger size.)
air (b)
5 12 12 10 12 12 12 12 12 12 12 12 10 10 8 8 6 6
6 12 12 10 12 12 12 12 12 12 12 12 10 8 8 8 6 4
7 12 12 10 12 12 12 12 12 12 12 10 10 8 8 6 6 4
9 12 12 10 12 12 12 12 12 12 10 10 8 8 6 6 4 4
10 12 12 10 12 12 12 12 12 10 10 8 8 6 6 4 4 3
12 12 12 10 12 12 12 12 12 10 8 8 6 6 4 4 3 2
14 12 12 10 12 12 12 12 10 10 8 8 6 6 4 4 3 2
16 12 12 10 12 12 12 10 10 8 8 6 6 4 4 3 2 1
18 12 12 10 12 12 12 10 10 8 8 6 6 4 4 3 2 1
20 12 12 10 12 12 10 10 8 8 6 6 4 4 3 2 1 0
25 10 10 10 12 10 10 8 8 6 6 4 4 3 2 1 0 00
30 10 10 10 12 10 8 8 8 6 4 4 3 2 1 1 00 000
35 8 8 10 12 10 8 8 6 6 4 4 3 2 1 0 00 000
40 8 8 10 10 8 8 6 6 4 4 3 2 1 0 00 000 0000
50 6 6 10 10 8 6 6 4 4 3 2 1 0 00 000 0000 250
60 4 6 8 8 8 6 4 4 3 2 2 0 00 000 000 250 300
70 4 4 8 8 6 6 4 4 3 2 1 0 00 000 0000 300 350
(a) Use 125% of motor nameplate current for single motors.
(b) The wire size in overhead spans must be at least #10 for spans up to 50’ and #8 for longer spans.
(c) AWG is American Wire Gauge, and MCM is thousand circular mil.
173
Table 4. Sizes of copper wire for single-phase, 230–240-volt motors and a 2% voltage drop. (a)
(amps) conduit or earth)
air (b)
2 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 12 12
3 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 12 10
4 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 10 10
5 12 12 10 12 12 12 12 12 12 12 12 12 12 12 10 10 8
6 12 12 10 12 12 12 12 12 12 12 12 12 12 10 10 8 8
8 12 12 10 12 12 12 12 12 12 12 12 12 10 10 8 8 6
10 12 12 10 12 12 12 12 12 12 12 12 10 10 8 8 6 6
12 12 12 10 12 12 12 12 12 12 12 12 10 8 8 8 6 4
14 12 12 10 12 12 12 12 12 12 12 10 10 8 8 6 6 4
17 12 12 10 12 12 12 12 12 12 10 10 8 8 6 6 4 4
20 12 12 10 12 12 12 12 12 10 10 8 8 6 6 4 4 3
25 10 10 10 12 12 12 12 10 10 8 8 6 6 4 4 3 2
30 10 10 10 12 12 12 10 10 8 8 8 6 4 4 4 2 1
35 8 8 10 12 12 12 10 10 8 8 6 6 4 4 3 2 1
40 8 8 10 12 12 10 10 8 8 6 6 4 4 3 2 1 0
45 6 8 10 12 12 10 10 8 8 6 6 4 4 3 2 1 0
50 6 6 10 12 10 10 8 8 6 6 4 4 3 2 1 0 00
60 4 6 8 12 10 8 8 8 6 4 4 3 2 1 1 00 000
70 4 4 8 12 10 8 8 6 6 4 4 3 2 1 0 00 000
80 2 4 6 10 8 8 6 6 4 4 3 2 1 0 00 000 0000
100 1 3 6 10 8 6 6 4 4 3 2 1 0 00 000 0000 250
174
Table 5. Sizes of copper wire for three-phase, 230–240-volt motors and a 2% voltage drop. (a)
(amps) conduit or earth)
air (b)
2 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 12 12
3 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 12 12
4 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 12 10
5 12 12 10 12 12 12 12 12 12 12 12 12 12 12 12 10 10
6 12 12 10 12 12 12 12 12 12 12 12 12 12 12 10 10 8
8 12 12 10 12 12 12 12 12 12 12 12 12 12 10 10 8 8
10 12 12 10 12 12 12 12 12 12 12 12 12 10 10 8 8 6
12 12 12 10 12 12 12 12 12 12 12 12 10 10 8 8 6 6
15 12 12 10 12 12 12 12 12 12 12 10 10 8 8 6 6 4
20 12 12 10 12 12 10 12 12 12 10 10 8 8 6 6 4 4
25 10 10 10 12 12 12 12 12 10 10 8 8 6 6 4 4 3
30 10 10 10 12 12 12 12 10 10 8 8 6 6 4 4 3 2
35 8 8 10 12 12 12 10 10 8 8 8 6 4 4 4 2 1
40 8 8 10 12 12 12 10 10 8 8 6 6 4 4 3 2 1
45 6 8 10 12 12 10 10 8 8 6 6 4 4 3 2 1 0
50 6 6 10 12 12 10 10 8 8 6 6 4 4 3 2 1 0
60 4 6 8 12 10 10 8 8 6 6 4 4 3 2 1 0 00
70 4 4 8 12 10 8 8 8 6 4 4 3 2 1 1 00 000
80 3 4 6 12 10 8 8 6 6 4 4 3 2 1 0 00 000
100 1 3 6 10 8 8 6 6 4 4 3 2 1 0 00 000 0000
120 0 1 4 10 8 6 6 4 4 3 2 1 0 00 000 0000 250
150 000 0 3 8 6 6 4 4 3 2 1 0 00 000 0000 250 300
180 0000 000 1 8 6 4 4 3 2 1 0 00 000 0000 250 300 400
210 250 0000 0 8 6 4 4 3 2 1 0 00 000 0000 250 350 500
240 300 250 00 6 4 4 3 2 1 0 00 000 0000 250 300 400 500
Table 6. Wire size and fuse rating for single-phase 60-cycle AC motors. (a)
115V Circuit 230V Circuit
Motor Fuse Wire Size Motor Fuse Length of Run
Size Size 50 100 150 200 Size Size 50 100 150 200
(HP) (amps) (ft.) (HP) (amps) (ft.)
1/4 15 14 12 10 8 1/4 15 14 14 14 14
1/3 20 14 12 8 8 1/3 15 14 14 14 14
1/2 25 12 10 8 6 1/2 15 14 14 14 12
3/4 30 12 8 6 6 3/4 15 14 14 12 12
1 20 14 14 12 10
1-1/2 25 14 12 10 10
2 30 14 12 10 8
3 45 10 10 8 8
5 70 8 8 6 6
(a) The above values are based on 2% voltage drop in the wire and 125% of the name-plate current (in amps) wire
carrying
capacity.
175
Appendix VIII
MOVABLE BENCH DATA
Table 1. Dimensions for movable bench systems layout.
Bench Top Width Aisle Width X Y
4 ft. 16 in. 22 in. 32 in.
18 in. 20 in. 31 in.
20 in. not recommended
4.5 ft. 16 in. 28 in. 38 in.
18 in. 25 in. 36 in.
20 in. 22 in. 34 in.
5 ft. 16 in. 32 in. 42 in.
18 in. 30 in. 41 in.
20 in. 28 in. 40 in.
22 in. 25 in. 38 in.
5.5 ft. 16 in. 32 in. 42 in.
18 in. 32 in. 43 in.
20 in. 32 in. 44 in.
22 in. 32 in. 45 in.
24 in. 28 in. 46 in.
6 ft. 16 in. 32 in. 42 in.
18 in. 32 in. 43 in.
20 in. 32 in. 44 in.
22 in. 32 in. 45 in.
24 in. 32 in 46 in.
Bench Top Width
Roller Spacing
“X”
Support Frame Length
“Y”
176
Appendix IX
LIGHTING CONVERSION DATA
Table 1. Conversion from foot-candles to W/m2
(for wavelengths of 400–850 nm.). (a)
Type of Light Multiply fc by:
Fluorescent
Cool white 0.032
Warm white 0.031
Grow Lux–plant light 0.069 1 foot-candle = 10.8 lux
Grow Lux–wide spectrum 0.047 1 kilowatt hour = 3,412 Btu
Agro-Lite 0.043
Vita-Lite 0.041
Discharge
Mercury 0.030
Metal halide 0.037
High pressure sodium 0.036
Low pressure sodium 0.023
Incandescent
Standard 0.093
Mercury 0.065
Daylight 0.060
(a) Adapted from Cathey, H.M., L.E. Campbell, and R.W. Thimijan. USDA-SEA, Beltsville, MD 20705.
177
Table 2. Recommendations for supplemental greenhouse plant lighting.*
MINIMUM
LIGHTING LEVEL DAYLENGTH
PLANT SPECIES CROP STAGE mW/sq. m fc hours
Alstromeria Cultivation 3,000 120 13
Anthirrhinum Propagation 9,000 370 16
Cultivation 4,500 180 24
Azalea Propagation 6,000 240 18
Forcing 3,000 120 16
Bedding Plants Seedlings 6,000 240 16
Begonia Stockplants/Prop. 6,000 240 14
Bromeliads Propagation 6,000 240 18
Forcing 4,500 180 24
Cacteae Propagation 9,000 370 18
Calceolaria Forcing 3,000 120 24
Camellia Cultivation 4,500 180 14
Chrysanthemum Stockplants 9,000 370 20
Rooting 6,000 240 20
Cut Flowers 4,500 180 18
Cyclamen Propagation 6,000 240 18
Gesneria Propagation 6,000 240 18
Cultivation 4,500 180 18
Kalanchoe Stockplants 6,000 240 18
Rooting/Prop. 6,000 240 16
Ferns Propagation 6,000 240 18
Foliage Cuttings/Prop. 6,000 240 16
Geranium Stockplants 7,000 650 16
Cuttings 9,000 370 16
Gerbera Stockplants/Prop. 6,000 240 16
Gladiolus Cut Flowers 8,000 740 16
Nursery Stock Rooting/Prop. 7,500 700 24
Orchids Production 9,000 370 16
Rose Cultivation 6,000 240 24
Sinningia (gloxinia) Propagation 6,000 240 18
Stephanotis Cultivation 4,500 485 18
Succulents Seedlings 9,000 370 16
Cucumber Propagation 4,500 485 16
Lettuce Seedlings (Growth Room) 25,000 2,300 24
Crop Production
(Greenhouse) 7,000 650 16
Strawberries Fruit Production 350 30 8
Tomatoes Seedlings 6,000 240 16
*Adapted from Application of Growlight in Greenhouses, PL Lightsystems, St. Catharines, Ontario and Philips Lighting
Application Guide, Philips Lighting Co., Somerset, NJ.
178
Table 3. Lighting systems and cost comparison worksheet. (a)
LIGHTING LIGHTING LIGHTING
SYSTEM 1 SYSTEM 2 SYSTEM 3
A. Crop Data
Crop _________ _________ _________
Growing area (ft.2) _________ _________ _________
Average annual crop value _________ _________ _________
Crop value/ft.2 _________ _________ _________
Percent yield increase with lighting _________ _________ _________
Estimated crop value with lighting _________ _________ _________
Estimated crop value/ft.2 with lighting _________ _________ _________
Estimated fuel saving with lighting _________ _________ _________
B. Lighting Installation Data
Type (photosynthetic, photoperiodic) _________ _________ _________
Where and when applied _________ _________ _________
Lamp watts/ft.2 required _________ _________ _________
Type of lamp _________ _________ _________
Number of lamps required _________ _________ _________
Fixture type _________ _________ _________
Lamps per fixture _________ _________ _________
Fixtures per row _________ _________ _________
Number of rows _________ _________ _________
Total fixtures _________ _________ _________
Watts/fixture (including ballast, etc.) _________ _________ _________
Burning hours per year _________ _________ _________
Useful lamp life _________ _________ _________
Fixture life _________ _________ _________
Current demand (115V, 230V, etc.) _________ _________ _________
Control devices
(time switches, photocontrols) _________ _________ _________
C. Initial Capital Cost
Lamp cost _________ _________ _________
Fixture cost _________ _________ _________
Control device cost _________ _________ _________
Installation cost (labor, wiring, etc.) _________ _________ _________
Total initial cost _________ _________ _________
LIGHTING LIGHTING LIGHTING
SYSTEM 1 SYSTEM 2 SYSTEM 3
C. Initial Capital Cost (Continued)
Initial cost/ft.2 _________ _________ _________
Initial cost/fixture _________ _________ _________
Total cost/year of life _________ _________ _________
D. Annual Operating and
Maintenance Cost
Energy cost
Total KWH _________ _________ _________
Average cost/KWH _________ _________ _________
Total annual energy cost _________ _________ _________
Lamp replacement cost
Total number of lamps replaced _________ _________ _________
Net cost per lamp _________ _________ _________
Labor for individual relamping _________ _________ _________
Percent lamp failures before group
replacement _________ _________ _________
Group replacement schedule _________ _________ _________
Labor for group replacement _________ _________ _________
Total lamp replacement cost _________ _________ _________
Replacement cost/ft.2 _________ _________ _________
Replacement cost/fixture _________ _________ _________
Cleaning cost
Number of cleanings _________ _________ _________
Labor cost per cleaning _________ _________ _________
Total cleaning cost _________ _________ _________
Repairs
Parts _________ _________ _________
Labor _________ _________ _________
Total repair cost _________ _________ _________
Other fixed costs
Interest on investment _________ _________ _________
Depreciation _________ _________ _________
Taxes _________ _________ _________
Insurance _________ _________ _________
(a) From Lighting for Plant Growth. E.D. Bickford and S. Dunn.
179
Appendix X
HYDRAULICS — CONVERSIONS, PIPE FRICTION, ETC.
Table 1. Engineering data & conversion factors.
Volume Weight
1 U.S. Gal. = 231 in.3 1 U.S. Gallon = 8.33 lb.
1 Acre-in. = 3,630 ft.3 1 ft.3 of water = 62.35 lb.
= 27,100 gal. 1 Imperial Gallon = 10.00 lb.
1 Acre-ft. = 43,560 ft.3
= 325,829 gal.
Capacity Length
1 ft.3/sec. = 449 gpm 1 in. = 2.54 cm.
10,000 gal./day = 6.95 gpm 1 meter = 3.28 ft.
1 mile = 5,280 ft.
Head Horespower
1 lb./in.2 (psi) = 2.31 ft. head of water 1 H.P. = 33,000 ft.lb./min.
1 ft. of water = 0.433 psi = 550 ft. lb./sec.
Table 2. Basic hydraulic terms and explanations.
P.S.I. (psi) Pounds per square inch. A measure of force per unit area.
Static Pressure The force exerted in all directions in a water volume expressed in force per unit
area (psi), e.g., the pressure exerted on a water tower by the water within its
walls.
Available Pressure Pressure available at a point under a certain set of circumstances.
Working Pressure Actual pressure at any point of a working irrigation system. A result of the static
pressure, minus friction losses, plus or minus pressure changes due to elevation
changes.
Friction Loss A measurable pressure drop due to the movement of water through pipes,
valves, and fittings.
Pressure Changes For every foot of elevation change, there will be a pressure
due to Elevation change of ± 0.433 psi.
180
Pounds/Sq. In. (PSI) per 100 Ft. of Pipe C = 100
Flow
GPM 1/2" 3/4"
PIPE SIZE Flow
1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" GPM
1 0.91 1
2 3.30 0.84 0.26 2
3 6.80 1.80 0.55 3
4 11.80 3.10 0.93 0.24 0.12 4
5 17.80 4.60 1.40 0.37 0.37 5
6 24.90 6.40 2.00 0.52 0.24 6
7 8.50 2.60 0.69 0.32 7
8 10.80 3.30 0.88 0.42 0.12 8
9 13.50 4.20 1.10 0.52 0.15 9
10 16.40 5.10 1.30 0.63 0.19 10
11 19.50 6.10 1.60 0.75 0.22 11
12 23.00 7.10 1.90 0.88 0.26 0.11 12
13 8.20 2.20 1.00 0.30 0.13 13
14 9.40 2.50 1.20 0.35 0.15 14
15 10.70 2.80 1.30 0.40 0.17 15
16 12.10 3.20 1.50 0.45 0.19 16
17 13.50 3.60 1.70 0.50 0.21 17
18 15.00 4.00 1.90 0.56 0.23 18
19 16.60 4.40 2.10 0.61 0.25 19
20 18.20 4.80 2.30 0.67 0.28 0.10 20
22 21.80 5.70 2.70 0.81 0.34 0.12 22
24 25.60 6.70 3.20 0.96 0.40 0.14 24
25 27.60 7.30 3.40 1.00 0.43 0.15 25
26 7.80 3.70 1.10 0.46 0.16 26
28 9.00 4.20 1.30 0.53 0.18 28
30 10.20 4.80 1.40 0.60 0.21 0.06 30
35 13.50 6.40 1.90 0.80 0.28 0.07 35
40 17.30 8.20 2.40 1.00 0.35 0.10 40
45 21.60 10.20 3.00 1.30 0.44 0.12 45
50 26.20 12.30 3.70 1.60 0.54 0.14 50
60 17.30 5.20 2.20 0.75 0.20 60
70 23.00 6.90 2.90 1.00 0.27 70
80 8.80 3.70 1.30 0.34 80
90 10.90 4.60 1.60 0.42 90
100 13.20 5.60 1.90 0.52 100
120 18.50 7.80 2.70 0.72 120
140 24.60 10.40 3.60 0.96 140
160 13.30 4.60 1.20 160
180 16.50 5.70 1.50 180
200 20.10 7.00 1.90 200
220
Note: Values below horizontal lines are
at velocities over 5 ft./sec. and should
be selected with caution.
23.90 8.30 2.20 220
240 9.80 2.60 240
260 11.30 3.00 260
280 13.00 3.50 280
300 14.80 4.10 300
Table 3. Friction loss in standard iron or steel pipe.
181
Table 4. Friction loss in plastic pipe having standard I.D.
Pounds/Sq. In. (PSI) per 100 Ft. of Pipe C = 140
Flow
GPM 1/2" 3/4"
PIPE SIZE Flow
1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4" GPM
1 0.49 1
2 1.80 0.45 0.14 2
3 3.70 0.95 0.30 3
4 6.40 1.60 0.50 0.13 0.07 4
5 9.60 2.50 0.75 0.20 0.10 5
6 13.40 3.40 1.10 0.28 0.13 6
7 4.60 1.40 0.37 0.17 7
8 5.80 1.80 0.48 0.23 0.07 8
9 7.30 2.20 0.59 0.28 0.08 9
10 8.80 2.70 0.72 0.34 0.10 10
11 10.50 3.30 0.85 0.41 0.12 11
12 12.40 3.80 1.00 0.48 0.14 0.06 12
13 4.40 1.20 0.55 0.16 0.07 13
14 5.10 1.30 0.63 0.19 0.08 14
15 5.80 1.50 0.72 0.22 0.09 15
16 6.50 1.70 0.81 0.24 0.10 16
17 7.30 1.90 0.91 0.27 0.11 17
18 8.10 2.10 1.00 0.30 0.12 18
19 9.00 2.40 1.10 0.33 0.13 19
20 9.80 2.60 1.20 0.36 0.15 0.06 20
22 11.80 3.10 1.50 0.44 0.18 0.07 22
24 13.80 3.60 1.80 0.52 0.22 0.08 24
25 14.90 3.90 1.90 0.56 0.23 0.08 25
26 4.30 2.00 0.59 0.25 0.09 26
28 4.80 2.30 0.68 0.29 0.10 28
30 5.50 2.60 0.77 0.32 0.11 30
35 7.30 3.50 1.00 0.43 0.15 35
40 9.30 4.40 1.30 0.54 1.90 0.06 40
45 11.60 5.50 1.60 0.70 0.24 0.07 45
50 14.10 6.60 2.00 0.83 0.29 0.08 50
60 9.30 2.80 1.20 0.40 0.11 60
70 12.40 3.70 1.60 0.54 0.15 70
80 4.70 2.00 0.69 0.19 80
90 5.90 2.50 0.86 0.23 90
100 7.10 3.00 1.00 0.28 100
120 10.00 4.20 1.50 0.39 120
140 13.30 5.60 1.90 0.52 140
160 7.20 2.50 0.66 160
180 8.90 3.10 0.83 180
200 10.80 3.80 1.00 200
220
Note: Values below horizontal lines are
at velocities over 5 ft./sec. and should
be selected with caution.
4.50 1.20 220
240 5.30 1.40 240
260 6.10 1.60 260
280 7.00 1.90 280
300 8.00 2.10 300
182
Table 5. Friction loss in ordinary rubber hose.
Table 6. Quantity of water available from a city service line (for a 50-ft. long service line). (a)
Pounds/Sq. In. (PSI) per 100 Ft. of Hose
Flow
GPM 1/2" 5/8"
HOSE SIZE Flow
3/4" 1" 1-1/4" 1-1/2" 2" GPM
0.5 0.40 0.5
1.5 3.02 1.01 0.42 1.5
2.5 7.75 2.58 1.08 2.5
5 27.80 9.37 3.86 0.95 0.32 0.13 5
10 99.50 33.20 13.80 3.38 1.14 0.47 0.12 10
15 71.00 29.60 7.25 2.45 1.01 0.25 15
20 121.00 50.30 12.40 4.15 1.71 0.42 20
25 76.50 18.70 6.34 2.60 0.64 25
30 108.00 26.50 8.96 3.68 0.90 30
35 142.00 34.80 11.80 4.83 1.18 35
40 44.70 15.10 6.20 1.52 40
45 55.00 18.60 7.65 1.87 45
50 67.50 22.80 9.35 2.28 50
60 94.30 31.80 13.10 3.19 60
70 126.00 42.50 17.50 4.25 70
80 54.60 22.50 5.48 80
90 67.50 27.80 6.80 90
100 81.50 33.50 8.19 100
125 124.00 50.60 12.40 125
150 72.10 17.60 150
175 94.50 23.10 175
200 122.00 29.60 200
225 36.80 225
250 44.60 250
275 53.30 275
300 62.50 300
325 72.50 325
350 83.20 350
375 94.50 375
400 107.00 400
Size of Size of Gallons per
Service Line Meter Minute Available
(in. diameter) (in.) (gpm)
3/4 5/8 10
3/4 3/4 12 (a) This information is intended only as
1 3/4 18 a guide in determining the approximate
1 1 22 water supply available. The information is
1-1/4 1 30 based on a pressure drop of approximately
1-1/2 1 35 10 psi from the city main through the
1-1/2 1-1/2 45 service line and meter. For example, if the
2 1-1/2 60 static pressure in the city main is 60 psi,
2 2 75 then a 50-ft. service line with a 1-in. dia.
3 3 160 and a 3/4-in. meter should be capable of
delivering 18 gpm at 50 psi.
183
Appendix XI
CROP STORAGE AND NIGHT TEMPERATURES
Table 1. Storage conditions for selected cut flowers , greens, and nursery stocks.(a)
COMMODITY STORAGE TEMPERATURE APPROXIMATE METHOD OF
(°F) STORAGE LIFE HOLDING
Cut Flowers
Calla lily 40 1 wk. dry
Camelia 45 3–6 days dry
Carnation 31–32 2–4 wks. dry
Chrysanthemum 31–32 2–4 wks. dry
Daffodil (Narcissus) 32–33 1–3 wks. dry
Dahlia 40 3–5 days dry
Gardenia 32–33 2 wks. dry
Gladiolus 40–42 1 wk. dry
Iris, tight buds 31–32 2 wks. dry
Lily, Easter 32–35 2–3 wks. dry
Lily-of-the-Valley 31–32 2–3 wks. dry
Orchid 55 1–2 wks. water
Peony, tight buds 32–35 4–6 wks. dry
Rose, tight buds 32 1–2 wks. dry
Snapdragon 40–42 1–2 wks. dry
Sweet peas 31–32 2 wks. dry
Tulips 31–32 4–8 wks. dry
Greens
Asparagus (Plumosus) 32–40 4–5 mos. polyliner
Eucalyptus 35–40 2–3 mos. dry
Fern, dagger and wood 30–32 4–5 wks. dry
Holly 32 4–5 wks. dry
Huckleberry 32 1–4 wks. dry
Laurel 32 1–4 wks. dry
Magnolia 35–40 1–4 wks. dry
Rhododendron 32 1–4 wks. dry
Salad 32 1–4 wks. dry
Bulbs
Amaryllis 38–45 5 mos. dry
Caladium 70 2–4 mos.
Crocus 48–63 2–3 mos.
Dahlia 40–45 5 mos. dry
Gladiolus 38–50 8 mos. dry
Hyacinth 55–70 2–5 mos.
Iris, Dutch, Spanish 80–85 4 mos. dry
Lily
Gloriosa 63 3–4 mos. polyliner
Candidum, Regal 31–33 1–6 mos. polyliner & peat
Croft 31–33 1–6 mos. polyliner & peat
Longiforum (Easter) 31–33 1–10 mos. polyliner & peat
Speciosum (Japanese) 31–33 1–6 mos. polyliner & peat
Peony 33–35 5 mos. dry
Tuberose 40–45 4 mos. dry
Tulip (for outdoors) 31–32 5–6 mos. dry
Tulip (for forcing) 40–50 2–4 mos. dry
(a) From ASHRAE Handbook–Applications. 1982. American Society of Heating, Refrigeration, and Air Conditioning
Engineers, Atlanta, GA.
184
COMMODITY STORAGE TEMPERATURE APPROXIMATE METHOD OF
(°F) STORAGE LIFE HOLDING
Cuttings
Azalea, unrooted 31–40 4–10 wks.
Carnation, 31–33 5–6 mos.
rooted & unrooted
Chrysanthemum, rooted 31–35 5–6 wks.
Chrysanthemum, unrooted 31–33 5–6 wks.
Evergreens and other
woody ornamentals, rooted 31–35 5–6 mos.
Nursery Stock
Trees and shrubs 32–36 4–5 mos.
Rose bushes 32 4–5 mos. bare rooted with polyliner
Strawberry plants 30–32 8–10 mos. bare rooted with polyliner
Rooted cuttings 33–40 polywrap
Herbaceous perennials 27–35
185
Table 2. Standard night temperatures at which greenhouse crops are grown.
CROP SPECIES NIGHT TEMPERATURES REMARKS
(°F)
Aster
Callistephus chinensis 50–55 Long days during early stages
of growth
Azalea
Rhododendron species 60–65 Vegetative growth and forcing
specific temperatures required
for flower initiation and
development
Calceolaria
C. herbeohydrida 60 Vegetative growth,
50 flower initiation and
development; initiation also
occurs with long days and
high temperatures if radiant
flux is high
Calendula
C. officinallis 40–45
Calla
Zantedeschia species 55–60 Decrease to 55° as plants
bloom
Carnation
Dianthus caryophyllus 50–52 (winter) Night temperatures adjusted
seasonally 55 (spring) in
relation to radiant energy flux
55–60 (summer)
Chrysanthemum
C. morifolium 60 (cut flowers) Temperatures during flower
initiation especially
62–63 (pot plants) critical; uniform initiation
very important for pot mums;
cultivars classified on basis
of temperature development
Cineraria
Senecio cruentus 60 Vegetative growth
48–50 Flower initiation and
development; plant
quality best at low
temperatures
Crossandra
C. infundibuliformis 75–80 Germination
65 Growth and flowering
Cyclamen
C. indicum 60–65 Germination
55 Seedlings
50–52 Growth and flowering
186
(°F)
Foliage plants 65–70 Species differ in their
temperature and
radiant energy requirements
Fuschia
F. hydrida 52–55 Long days for flower initiation
Geranium
Pelargonium x hortorum 55–60 60–65° F for fast crops at high
radiant energy flux
Gardenia
G. grandiflora 60–62 Lower temperatures result in
iron chlorosis;
G. jasminoides higher temperatures increase
bud abscission
Gloxinia
Sinningia speciosa 65–70 Lower temperatures increase
bud brittleness
Hydrangea
H. macrophylla 55–60 Specific temperature for
flower initiation and
60–70 (forcing) development
Iris
L. tingitana (Wedgewood) 45–60 (forcing) Forcing temperature: 55–58°F
for 10/11 bulbs; 50–53°F for
9/10 bulbs
Kalanchoe
K. blossfeldiana 60 Temperatures influence rate of
flower development and
incidence of powdery
mildew
Lily
Lilium longiflorum 60 Temperatures manipulated to
alter rate of flower
development; specific
temperatures for flower
initiation
Orchid
Cattleya species 60 Temperature requirement of
Phalaenopsis species 55 hybrids related to parenta
Cymbidium species 50 species
Cypripedium 50–55
Poinsettia
Euphorbia pulcherrima 65 Vegetative growth
60–62 Photoperiod requirement
changes with temperature;
bract development influenced
by temperature
187
(°F)
Rose
Rosa species 60–62
Saintpaulia
S. ionantha 65–70 Below 60°F, growth is slow,
hard and brittle.
Snapdragon
Antirrhinum maias 48–50 Winter
55–60 Spring and Fall; Seedlings
benefit from
60–65°F temperatures
Stock
Matthiola incana 45–50 Buds fail to set if
temperatures are above
65°F for six or more hours per
day; grown mainly as field
crop in California and
Arizona
Tomato 60–66 70–80°F on sunny days
Lettuce 55 62–65°F cloudy days;
70–78°F sunny days
Cucumber 65 75°F cloudy days;
80°F sunny days
Source: Mastalerz, J.W. 1977. The Greenhouse Environment. John Wiley.
188
Appendix XII—Worksheets
WORKSHEET NO. 1—GREENHOUSE FACILITY PLANNING
General Specifications
Cropping System:
Bedding plants
Pot plants
Cut flowers
Woody ornamentals
Vegetables
Other
Production Unit:
Pots
Flats
Blooms
Other
Growing Media:
Soil, site mixed
Soil, purchased
Hydroponic
Marketing Period:
All year
Seasonal From to .
Growing Period:
All year
Part year
Growing System:
Floor
Fixed benches
Moving benches
Other
Annual Production:
Pots
Flats
Blooms
Other
Marketing System:
Wholesale only
Wholesale/retail
Retail only
Activity
Media Preparation:
Mixed on site As needed For season
Purchased As needed For season
Volume Required:
yds.3 / day yds.3 / season
Components: #1 #2 #3
Vol. req./day
Vol. req./season
189
Seeding/Germination:
Yes No Flat size
No. of flats: per day per week
Max. no. of seed flats germinating at one time:
Transplanting:
Yes No
Transplanting from:
Seed flats
Plugs
Cuttings
Other
Growing container: Type Size No./day No./week

Max. no. of growing containers in use at one time:
Marketing–Order Assembly:
Marketing Unit: Size
No./shipping container
No. containers/carrier
Maximum No. of shipping containers/day
Maximum No. of carriers at any one time
Production Areas:
Seeding: ft2 Conditioning: ft2
Germinating: ft2 Growing: ft2
Transplanting: ft2 Total Production Area: ft2
Ancillary Areas
Area (ft2)
Dry storage (flats, market packs, pots, labels, etc.)
Office
Employee (toilet, eating, etc.)
Chemicals (pesticides, fertilizers, etc.)
Central heating, mechanical service, fuel storage
Refrigeration (cold storage)
Parking: Employee
Public (receiving, shipping, visitors)
Total Antillary Areas:
190
SAMPLE WORKSHEET NO. 1—GREENHOUSE FACILITY PLANNING
General specifications
Cropping System:
Bedding plants X
Pot plants
Cut flowers
Woody ornamentals
Vegetables
Other
Production Unit:
Pots
Flats X
Blooms
Other
Growing Media:
Soil, site mixed X
Soil, purchased
Hydroponic
Marketing Period:
All year
Seasonal From to .
Growing Period:
All year
Part year X
Growing System
Floor X
Fixed benches
Moving benches
Other
Annual Production:
Pots
Flats 40,000
Blooms
Other
Marketing System:
Wholesale only
Wholesale/retail X
Retail only
Activity
Media Preparation:
Mixed on site X As needed For season
Purchased As needed For season
Volume Required:
yds.3 / day 6 yds.3 / season 360
Components: #1 soil #2 peat #3 perlite
Vol. req./day
Vol. req./season 132 yd.3 132 yd.3 132 yd.3
191
Seeding/Germination:
Yes X No Flat size 11.5" x 21.25"
No. of flats: per day 60 per week 300
Max. no. of seed flats germinating at one time: 380
Transplanting:
Yes X No
Transplanting from:
Seed flats X
Plugs
Cuttings
Other
Growing container: Type Size No./day No./week

6 pack flat 11.5" x 21.25" 740 3,700
Max. no. of growing containers in use at one time: 27,890
Marketing–Order Assembly:
Marketing Unit: flat Size 11.5" x 21.25"
No./shipping container 70
No. containers/carrier 14
Maximum No. of shipping containers/day 14
Maximum No. of carriers at any one time 1
Production Areas:
Seeding: ft2 200 Conditioning: ft2 1,860
Germinating: ft2 700 Growing: ft2 52,700
Transplanting: ft2 600 Total Production Area: ft2 56,060 *
* allow for walkway, etc.
Ancillary Areas
Area (ft2)
Dry storage (flats, market packs, pots, labels, etc.) 360
Office 160
Employee (toilet, eating, etc.) 1,000
Chemicals (pesticides, fertilizers, etc.) 120
Central heating, mechanical service, fuel storage 180
Refrigeration (cold storage) —
Parking: Employee 2,400
Public (receiving, shipping, visitors) 2,400
Total Antillary Areas: 6,620
192
WORKSHEET NO. 2—STORAGE & MECHANIZATION REQUIREMENTS
A. No. of containers to be filled/season containers/season
B. Length of production season days/season
C. Work hours/day hours/day
D. Daily output required = A ÷ B containers/day
E. Hourly output required = D ÷ C containers/hours
F. Volume of media required = A ÷ containers filled/cu. yd.
(see Appendix V and VI) yd.3
G. Storage floor area required for media = (F x 27) ÷ depth of media (ft.)
ft.2
H. Volume of media required/day = F ÷ B yd.3/day
I. Labor hours required to fill containers = A ÷ containers/labor hour
(see Appendix VI) hours
J. Hours per day filling containers = I ÷ B hours/day

K. Volume of media handled/hour = H ÷ J yd.3/hour
L. No. of tractor-trailer units required
Equipment Required1 Work Crew2
1 Does not include seeders, transplanters, waterers.
2 Work crew to operate equipment listed.
193
SAMPLE WORKSHEET NO. 2—STORAGE & MECHANIZATION REQUIREMENTS
Sample for a Bedding Plant Operation
A. No. of containers to be filled/season 10,000 (flats) containers/season
B. Length of production season 40 days/season
C. Work hours/day 7 hours/day
D. Daily output required = A ÷ B (10,000 ÷ 40) 250 flats/day containers/day
E. Hourly output required = D ÷ C (25 ÷ 7) 36 flats/hr containers/hours
(10,000 ÷ 95) 105 yd.3
(see Appendix V and VI, 13" x 15" flat, 95 filled/yd.3)
(105 x 27) ÷ 6 [assume media depth is 6ft.] 473 ft.2
H. Volume of media required/day = F ÷ B
(105 ÷ 40) 2.6 yd.3/day
(10,000 ÷ 60) 167 hours
(see Appendix VI, hand filling ≈ 60 flats/hour)
J. Hours per day filling containers = I ÷ B (167 ÷ 40) 4.2 hours/day

K. Volume of media handled/hour = H ÷ J (2.6 ÷ 4.2) 0.62 yd.3/hour
L. No. of tractor-trailer units required none
Mixer 1 person to load and unload mixer,
deliver and remove flats
194
SAMPLE WORKSHEET NO. 2—STORAGE & MECHANIZATION REQUIREMENTS
Sample for a Nursery Operation
Must can 500,000 gallon cans during a 50-day production season. Average production hours equal 7 hr./day.
Tractors pulling two trailers holding 200 cans each move plants to fields, requiring 20 minutes for each trip.
A. No. of containers to be filled/season 500,000 (1 gal. cans) containers/season

B. Length of production season 50 days/season
C. Work hours/day 7 hours/day
D. Daily output required = A ÷ B (500,000 ÷ 50) 10,000 cans containers/day
E. Hourly output required = D ÷ C (10,000 ÷ 7) 1,429 containers/hours
(500,000 ÷ 252) 1,985 yd.3
(see Appendix V, 252 one gal cans/yd.3)
(1,985 x 27) ÷ 6 [assume media depth is 6ft.] 8,932 ft.2
H. Volume of media required/day = F ÷ B (1,985 ÷ 50) 40 yd.3/day
(500,000 ÷ 1,429) 350 hours
J. Hours per day filling containers = I ÷ B (350 ÷ 50) 7 hours/day
K. Volume of media handled/hour = H ÷ J (40 ÷ 7) 5.7 yd.3/hour
L. No. of tractor-trailer units required 2
Front end loader Front end loader – 1
Mixer Pot filling – 2
Feeder bin Moving plants to growing beds – 4
Pot filler
Belt conveyor
2 tractors
4 trailers
195
WORKSHEET NO. 3—CALCULATING MACHINERY COSTS
Machine
Original cost
Estimated useful life years hours
Estimated hours of use per year
Salvage or trade-in value (if any)
Fixed Cost Annual Cost
Depreciation Original cost – Salvage value $
Estimated life (years)
Interest on Original cost + Salvage value x Interest Rate $
Investment 2
Taxes Original cost x 0.03 (or your actual rate) $
Insurance Actual cost to you $
Shelter Pro rated share of building cost on an annual $
basis if machine is stored under cover
Total Fixed Cost $
Variable Cost Annual Cost
Fuel Gallons/hour x price/gallons x hours of use/year $
Electricity Total kilowatts x price/kilowatt-hour x hours of use/year $
(See Table 2, Appendix VII for kilowatt usage of common motors.)
Oil Gallons used x Price/gallon $
Repair cost Estimated total lifetime cost $
(parts & labor) Estimated years of useful life
Labor Number of operators x Labor cost/hour (Including fringe benefits) $
x hours of use/year
Total Variable Cost $
Total Annual Cost = Total Fixed Cost + Total Variable Cost
Total Cost/Hour = Total Annual Cost ÷ Estimated hours of use/year
Total Cost/Day = Total Annual Cost ÷ Days of use/year
Total Cost/Production Unit = Total Annual Cost ÷ No. of units produced
196
SAMPLE WORKSHEET NO. 3—CALCULATING MACHINERY COSTS
Machine Flat/pot filling machine w/ supply hopper and belt conveyor. A bucket
loader is already owned.
Original cost $12,000
Estimated useful life 10 years
Estimated hours of use per year 15 flats/minute x 60 minutes/hour = 900 flats/hour
Yearly Production Hours of use
25,000 flats 28
50,000 56
75,000 84
100,000 112
Salvage or trade-in value (if any) $2,000
Fixed Cost Annual Cost
Depreciation 12,000 – 2,000 $ 1000.00
10
Interest on 12,000 + 2,000 x .08 $ 560.00
Investment 2
Taxes 12,000 x 0.03 $ 360.00
Insurance $ 30.00
Shelter $ 20.00
Total Fixed Cost $ 1,970.00
Variable Cost Annual Cost
Electricity 3.5 KW ($0.10) x 28 hours $ 10.00
Repair cost 5.5% of 12,000 $ 660.00
(parts & labor)
Labor 3 people ($5.00/hour) (28 hours use + 7 hours waiting and service time) $ 525.00
Total Variable Cost $ 1,195.00
Total Annual Cost = $1,970.00 + 1,195.00 = $3,165.00
Total Cost/Hour = $3,165 ÷ 28 hours = $113
Total Cost/Flat = $3,165 ÷ 25,000 flats = 13¢/flat
197
SUMMARY AND COMPARISON—WORKSHEET NO. 3 CONTINUED
Yearly Production—flats
25,000 50,000 75,000 100,000
Fixed Costs
Depreciation $1,000 $1,000 $1,000 $1,000
Interest on Invesment 560 560 560 560
Taxes 360 360 360 360
Insurance 30 30 30 30
Shelter 20 20 20 20
Total Fixed Costs $1,970 $1,970 $1,970 $1,970
Variable Costs
Electricity $10 $20 $30 $40
Repairs 660 660 700 750
Labor 525 1050 1575 2100
Total Variable Costs $1,195 $1,730 $2,305 $2,890
Total Annual Costs $3,165 $3,700 $4,275 $4,860
Total Cost/Hour $113 $66 $51 $43
Cost/Flat $0.13 $0.07 $0.06 $0.05
198
WORKSHEET NO. 4—GREENHOUSE HEAT LOSS CALCULATIONS
The dimensions defined in the diagrams are used
throughout the Heat Loss Calculations:
Step 1. List greenhouse dimensions in feet:
Wall height, A =
House width, B =
House length, C =
Rafter length, D =
Lower wall height, E =
Upper wall height F =
Gable height, G or H =
Step 2. Calculate the appropriate surface areas and
perimeter. N is the number of individual house sections
forming each greenhouse range.
N = 1 for a single house
Lower wall area:
2N(E x B) + (E x 2C) =
Upper wall area:
2N(F x B) + (F x 2C) =
Single material wall:
2N(A x B) + (A x 2C) =
Gable area:
NxBxG=
Curved end area:
1.3N x B x H =
Gable roof area:
2N x D x C =
Curved roof area:
NxDxC=
Perimeter:
2 [ (N x B) + C] =
Step 3. List construction materials and U factors for each
surface.
Location Construction Material U Factor
Lower wall U1 =
Upper wall U2 =
Single material wall U3 =
End area U4 =
Roof U5 =
Perimeter U6 =
Step 4. Calculate appropriate conduction heat loss, hc.
hc = Area x U x ΔT
T = Inside night temperature – minimum
outside temperature
Lower wall area x U1 x ΔT =
Upper wall area x U2 x ΔT =
Single wall area x U3 x ΔT =
Gable or curved end area x
U4 x ΔT =
Roof area x U5 x ΔT =
Perimeter length x U6 x ΔT =
Total = QC =
Step 5. Calculate greenhouse volume.
Gable house volume:
N [ (A x B x C) + (B x G x C/2) ] =
Single curved roof house volume:
2H x B x C/3 =
Multiple curved roof volume:
N [ (A x B x C) + (2H x B x C/3) ] =
Step 6. Calculate air infiltration losses, hinf.
hinf = 0.02 x ΔT x Volume x Air changes/hour
(Table 4–5, page 66)
=
Step 7. Calculate total heat loss, ht.
ht = hC + hinf =
H
B
C
D
H
A
B
C
D
A
B
C
D
E
F
G
199
WORKSHEET NO. 4—EXAMPLE
Wall height, A = 8
House width, B = 24
House length, C = 192
Rafter length, D = 13.4
Lower wall height, E = 1.5
Upper wall height F = 6.5
Gable height, G or H = 6
Step 2. Calculate the appropriate surface areas and
perimeter. N is the number of individual house sections
forming each greenhouse range.
N = 1 for a single house
Lower wall area:
2N(E x B) + (E x 2C) = (2)(4) [ (1.5)(24) + (1.5)(2)(192) ]
= 864 ft.2
Upper wall area:
2N(F x B) + (F x 2C) = (2)(4) [ (6.5)(24) + (6.5)(2)(192) ]
= 3,744 ft.2
Single material wall:
2N(A x B) + (A x 2C) =
Gable area:
N x B x G = (4)(24)(6) = 576 ft.2
Curved end area:
1.3N x B x H =
Gable roof area:
2N x D x C = (2)(4)(13.4)(192) = 20,582 ft.2
Curved roof area:
NxDxC=
Perimeter:
2 [ (N x B) + C] = 2 [ (4)(24) + 192 ] = 576 ft.
Step 3. List construction materials and U factors for each
surface.
Location Construction Material U Factor
Lower wall U1 = 0.75
Upper wall U2 = 1.1
Single material wall U3 =
End area U4 = 1.1
Roof U5 = 1.1
Perimeter U6 = 0.8
Step 4. Calculate appropriate conduction heat loss, hc.
hc = Area x U x ΔT
ΔT = Inside night temperature – minimum
outside temperature
Lower wall area x U1 x ΔT = 864(0.75)(60) = 38,880
Upper wall area x U2 x ΔT = 3,744(1.1)(60) = 247,104
Single wall area x U3 x ΔT =
Gable or curved end area x
U4 x ΔT = 576(1.1)(60) = 38,016
Roof area x U5 x ΔT = 20,582(1.1)(60) = 1,358,412
Perimeter length x U6 x ΔT = 576(0.8)(60) = 27,648
Total hC = 1,710,060 Btu/hr.
Step 5. Calculate greenhouse volume.
Gable house volume:
N [ (A x B x C) + (B x G x C/2) ] =
4 [ (8)(24)(192) + 24(6)(192)(½) ] = 202,752 cu.ft.
Single curved roof house volume:
2H x B x C/3 =
Multiple curved roof volume:
N [ (A x B x C) + (2H x B x C/3) ] =
Step 6. Calculate air infiltration losses, hinf.
hinf = 0.02 x ΔT x Volume x Air changes/hour
(Table 4–5, page 66)
= 0.02(60)(202,752)(1) = 243,300 Btu/hr.
Step 7. Calculate total heat loss, ht.
ht = hC + hinf = 1,710,060 + 243,300
= 1,953,360 Btu/hr.
A
B
C
D
E
F
G
N=4
ΔT = 60ºF
200
WORKSHEET NO. 5—GREENHOUSE COOLING CALCULATIONS
House width A = ft.
House length B = ft.
Step 2. Calculate ground area for each house:
A x B = ft.2
Step 3. Calculate air flow required for each house:
(Use 8 cfm/ft.2 of ground area)
A x B x 8 cfm/ft.2 = cfm of installed capacity
Step 4. Select fans from manufacturer's catalog to provide a minimum of three stages of
ventilation (provide 2 cfm/ft.2 for first stage).
Manufacturer Model No.
1) fan(s) at cfm
2) fan(s) at cfm
3) fan(s) at cfm
Total = cfm
Step 5. Size inlet louvers to be at least 10% larger than exhaust fan areas. If continuous
wall
vents are used, size to air speed ≈ 250 fpm through vents.
201
SAMPLE WORKSHEET NO. 5—GREENHOUSE COOLING CALCULATIONS
House width A = 96 ft.
House length B = 192 ft.
Step 2. Calculate ground area for each house:
A x B = 18,432 ft.2
Step 3. Calculate air flow required for each house:
(Use 8 cfm/ft.2 of ground area)
A x B x 8 cfm/ft.2 = 147,456 cfm of installed capacity
Step 4. Select fans from manufacturer's catalog to provide a minimum of three stages of
ventilation (provide 2 cfm/ft.2 for first stage).
Manufacturer Model No.
1) 2 fan(s) at 18,900 cfm
2) 2 fan(s) at 18,900 cfm
3) 4 fan(s) at 18,900 cfm
Total = 151,200 cfm
Step 5. Size inlet louvers to be at least 10% larger than exhaust fan areas. If continuous
wall
vents are used, size to air speed ≈ 250 fpm through vents.
202
WORKSHEET NO. 6—EVAPORATIVE (PAD) COOLING CALCULATIONS
Step 1. Calculate face area of pad:
Installed cfm divided by 250 for cellulose pads,
or divided by 150 for aspen shavings pads.
cfm/250 = ft.2
cfm/150 = ft.2
Step 2. Calculate pad height to extend full length of one wall:
ft.2/ ft. = ft. of pad height
Step 3. Calculate water flow rate and pump size:
ft. x 0.5 gpm/linear ft. of pad = gpm
Step 4. Calculate pump size:
ft.2 of pad x 0.75 gal./ft.2 = gal.
For a system in which pad-to-fan distance is less than 100 ft., increase installed fan
capacity
by the factor F = 10 , where D is the pad-to-fan distance.
D
203
SAMPLE WORKSHEET NO. 6—EVAPORATIVE (PAD) COOLING CALCULATIONS
Step 1. Calculate face area of pad:
Installed cfm divided by 250 for cellulose pads,
or divided by 150 for aspen shavings pads.
151,200 cfm/250 = 605 ft.2
cfm/150 = ft.2
Step 2. Calculate pad height to extend full length of one wall:
605 ft.2/ 192 ft. = 3.2 ft. of pad height
(use 3.0 ft.)
Step 3. Calculate water flow rate and pump size:
192 ft. x 0.5 gpm/linear ft. of pad = 96 gpm
Step 4. Calculate pump size:
576 ft.2 of pad x 0.75 gal./ft.2 = 432 gal.
For a system in which pad-to-fan distance is less than 100 ft., increase installed fan
capacity
by the factor F = 10 , where D is the pad-to-fan distance.
D
204
WORKSHEET NO. 7—AERATED STEAM HEATING SYSTEM
Type of container: No. filled/yd.3:
No. filled per hour: No. filled/day:
Mix ratio: : : : by volume
Mix ingredients:
Vol. of mix required: ft.3/hr ft.3/day
Media Specifications
Dry weight: lb./ft.3
Moisture content: %, dry weight basis
Specific heat: Btu/lb.-°F
Media depth in heating chamber: inches
Media depth in cooling chamber: inches
System Specifications
Heating temperature: °F
Media temperature at start °F
Air temperature, average °F
Boiler to blower efficiency %
Blower to media efficiency %
Heat available from saturated air Btu/ft.3 air (See Table 6–9, p.123)
Steam required to heat and saturate 70°F air lb./ft.3 air (See Table 6–9)
System Calculations
Wt. of dry media = ft.3 x lb./ft.3 = lbs. media
Wt. of water in media = lbs. media x % moisture content =
lbs. water
Heat required for dry media = lbs. media x Btu/lb.-°F x
Δt°F = Btu
Heat required for moisture = lbs. water x Δt°F = Btu
Total Heat required = Btu for dry media + Btu for moisture =
Btu Total Heat
Heat required in Btu/min to warm media in 30 minutes:
h = Btu = Btu/min
30 min x % eff
205
Air flow required to supply the heat:

M = Btu/min = ft.3 of air/min
Btu/ft.3 of air
Steam required to heat and saturate the air:
w = ft.3/min x lb. of steam/ft.3 or air
= lbs. of steam/min.
Boiler capacity to supply the steam:
N = lb. of steam/min = lb./min, lb./hr.
% efficiency
Heat bin area for 24 in. maximum depth:
A = ft. /hr = ft.2
2 ft.
System summary
Outbin size = ft.3/hr.
Bin size = ft. x ft. x ft. deep
(same size for heating and cooling)
Fan capacity = cfm at inches of water

(same specifications for heating and cooling)
Boiler capacity = lb./hr. (Boiler hp)

3
206
SAMPLE WORKSHEET NO. 7—AERATED STEAM HEATING SYSTEM
Type of container: 6" round std. No. filled/yd.3: 430
No. filled per hour: 1,500 No. filled/day: 12,000
Mix ratio: 1 : 1 : 1 : by volume
Mix ingredients: soil peat perlite
Vol. of mix required: ft.3/hr 81 ft.3/day 648
Media Specifications
Dry weight: 33 lb./ft.3
Moisture content: 40 %, dry weight basis
Specific heat: 0.27 Btu/lb.-°F
Media depth in heating chamber: 24 inches
Media depth in cooling chamber: 24 inches
System Specifications
Heating temperature: 160 °F
Media temperature at start 60 °F
Air temperature, average 60 °F
Boiler to blower efficiency 90 %
Blower to media efficiency 50 %
Heat available from saturated air 25.7 Btu/ft.3 air (See Table 6–9, p.123)
Steam required to heat and saturate 70°F air 0.0225 lb./ft.3 air (See Table 6–9)
System Calculations
Wt. of dry media = 81 ft.3 x 33 lb./ft.3 = 2,673 lbs. media
Wt. of water in media = 2,673 lbs. media x 0.4 % moisture content =
1,069 lbs. water
Heat required for dry media = 2,673 lbs. media x 0.27 Btu/lb.-°F x
100 Δt°F = 72.171 Btu
Heat required for moisture = 1,069 lbs. water x 100 Δt°F = 106,900 Btu
Total Heat required = 72,171 Btu for dry media + 106,900 Btu for moisture =
179,071 Btu Total Heat
Heat required in Btu/min to warm media in 30 minutes:
h = 179,071 Btu = 11,938 Btu/min
30 min x .5 blower eff
207
Air flow required to supply the heat:

M = 11,938 Btu/min = 464 ft.3 of air/min
25.7 Btu/ft.3 of air
Steam required to heat and saturate the air:
w = 464 ft.3/min x 0.0225 lb. of steam/ft.3 or air
= 10.44 lbs. of steam/min.
Boiler capacity to supply the steam:
N = 10.44 lb. of steam/min = 11.6 lb./min, 696 lb./hr.
0.9 boiler efficiency
Heat bin area for 24 in. maximum depth:
A = 81 ft. /hr = 40.5 ft.2
2 ft.
System summary
Outbin size = 81 ft.3/hr.
Bin size = 6 ft. x 7 ft. x 2 ft. deep
(same size for heating and cooling)
Fan capacity = 464 cfm at 20 inches of water

(same specifications for heating and cooling)
Boiler capacity = 696 lb./hr. (Boiler hp)

3
Appendix XIII
USEFUL CONVERSIONS
Type of
Measurement To convert: Into: Multiply by:
feet inches 12
Length yards inches 36
rods feet 16.5
miles feet 5,280
miles yards 1,760
millimeters inches 0.04
microns millimeters 0.001
square feet square inches 144
Area square feet square yards 0.111
square yards square inches 1,296
square yards square feet 9
acres square feet 43,560
acres square yards 4,840
sections acres 640
ounces grams 28.3495
Mass Weight pounds kilograms 0.4539
short tons megagrams (metric tons) 0.9078
grams ounces 0.3527
kilograms pounds 2.205
megagrams (metric tons) short tons 1.1016
cubic feet cubic inches 1,728
Volume cubic feet cubic yards 0.037
cubic feet bushels 0.804
cubic feet gallons 7.48
cubic yards cubic feet 27
cubic yards cubic inches 46,656
cubic yards bushels 21.71
barrels (dry) bushels 3.281
barrels (dry) quarts 105
barrels (dry) cubic inches 7,056
bushels cubic yards 21.7
bushels cubic feet 1.24
bushels cubic inches 2,150.4
gallons (dry) cubic inches 269
gallons (liquid) cubic inches 231
gallons (liquid) quarts 4
quarts (dry) cubic inches 67.2
quarts (liquid) cubic inches 57.7
pints (liquid) cubic inches 28.87
ounces (liquid) cubic inches 1.805
ounces (liquid) tablespoons 2
ounces (liquid) teaspoons 6
ounces (liquid) milliliters 29.57
208
209
[Useful Conversions continued]
Type of
Measurement To convert: Into: Multiply by:
ounces milliliters 29.59
Liquid Volume (cubic centimeters)
pints liters 0.4732
quarts liters 0.9463
gallons liters 3.785
milliliters ounces 0.0338
(cubic centimeters)
liters pints 2.113
liters quarts 1.057
liters gallons 0.2642
Parts Per Million
1 oz./gal. = 7,490 ppm
1oz./100 gal. = 75 ppm
To determine parts per million (ppm) of an element in a fertilizer, simply multiply the percent of
that element by 75. The answer will be the ppm of the element per ounce of the fertilizer in 100
gallons of water.
As an example, ammonium sulfate contains approximately 20% nitrogen. Multiply
20% (.20) by 75, which equals 15, the ppm of nitrogen in 1 oz. of ammonium sulfate/100 gal. of
water.
Temperature Conversions
To convert Fahrenheit to Celcius (Centigrade): Subtract 32 and multiply by .55 (≈ 5/9), thus:
(68°F – 32) x .55 = 20°C.
To convert Celcius to Fahrenheit: Multiply by 1.8 (≈ 9/5) and add 32, thus:
(60°C x 1.8) + 32 = 140°F.
Formulas: (°F – 32) x (5/9) = °C
(°C x (9/5)) + 32 = °F
210
Aerated Steam 123
Air Infiltration 65, 141
Air Movement 79
Air Pollution Injury 62
Air Speed 62
Air Supported or “Bubble House” 35
Alarm Systems 88
Bell 89
Light 90
Siren or horn 89
Alternate Fuels 148
Apron Space 60
Assembly Conveyor 42
Backflow Prevention 109
Belt Conveyors 54
Benches 44, 47
Blanket Systems 67, 143–146
Boilers 73
Bulb Storage 18
Cabinet Method of Shipping 55–56
Carbon Dioxide Enrichment 62, 118
Sources of 118
Equipment 119
Distribution 121
Carts and Wagons 55
Chlorine 105
Coal Fuel 150
Cold Frames and Hot Beds 15–18
Computers 87–88
Concrete or Steel Storage Tank 105
Conservation 141
Electricity 140
Energy 67, 139, 141
Water 140
Construction 22
Costs 37
Container Filling 53
Continuous Material Movement 42
Controls for Lighting Systems 102
Time control 87, 90
Daytime control 102
Computer control 102
Control Systems 83
Automatic control systems 84
Capacity 84
Differential 84
Lag coefficient 84
Precision 84
Range 84
Sensitivity 84
Sensors 84
Timers 87
Cooling (See Ventilation)
Degree Days 167
Design Load 22
Direct Fired Units 73
Double Glass Panels 32
Drainage 1
Dual Fuel Burners 148
Ebb and Flow Irrigation 112
Economics 56
Electric Wire Service 171–174
Energy Conservation 67, 141
Double poly over glass 142
Single poly over glass 142
Energy Supply 1
Environmental Control 63, 139
Equipment 52–55
Container filling 53
Conveying 54
Heating and cooling 73, 79
Mixing 52
Old and out-dated 44
Renting/leasing 44
Selection 44
To prevent bottlenecks 43
Evaporation Simulators 104
Evapotranspiration Rate 67
Fans 71, 79
Performance table 81
Aspirated 84
Fertilizer Injector 109
Fire Safety 36
Flashlighting 96
Flat Fillers 53
Floors 25
Flower Crops 61
Fluorescent Light 98
Fluorine 105
Foundations 24
Footing 24
Frame 27
Gothic arch frame 27
Materials 27
Primary greenhouse frame 24
Quonset type frame 27
Structural form 27
Wood frames 27
Index
211
Furnace
Sizing 65
Efficiency Tests 154
Selection 73
Garden Center 2
Geothermal Heat 151
Germination Cart 102
Glazing
Absorptivity 64
Application systems 32
Emissivity 64
Heat transfer 65
Transmissivity 64
Materials 29
Spectral transmission 31
Granular Applicators 124, 131
Gravel Floor 25
Gravity 43
Gravity conveyors 43
Greenhouse 1
Benches 140
Design load 22
Environment 61
Garden 14
Institution 8
Planning factors 1
Public park 14
Rehabilitation center 12
Remodeling 137
Retirement 11
Teaching 9
Growing Systems 7
Aeroponics 8
Bags 8
Beds 8
Nutrient film technique (NFT) 8
Other components 8
Sand/stone culture 7
Trays 8
Troughs and pipes 8
Growth Rooms 101
Hard Water 105
Headhouse 50
Layout 1, 4
Heat Content of Fuels 166
Heat Loss and Gain 65
Heat Requirements 70
Air infiltration 65
Conduction 65
Heating 139
Heating Equipment 73
Distribution of 74
Underfloor systems 74
Flooded floor systems 74
Bench heating systems 77
Electric resistance heaters 77
High Intensity Discharge Lighting (HID) 98
Horizontal Air Flow (HAF) 79
Humidity Control 69
Hydraulic Sprayers 124
Nozzles 127
Pumps 127
Strainers 126
Tank agitators 126
Tanks 125
Hydroponic Systems 6
Advantages 6
Crops 7
Disadvantages 7
Incandescent Light 97
Insect Screens 71
Lap Seal 142
Lateral Sprinkler Lines 114
Light 61, 87
Accumulators 103
Conversion data 176
Cost comparison worksheet 178
Measurement 94
Photometric quantity 93
Radiometric quantity 93
Sources 97
Supplemental Plant Lighting 177
Live Loads 22
Load Carrying Capacity of Fiberglass or
Double Plastic Panels 35
Loading Docks 56
Low-Volume Sprayers 129
Electrostatic sprayer 129
Mechanical fogger 131
Mist blower 129
Thermal foggers 130
Lumen 93
Machine Capabilities 169
Materials Handling 42–44
Mechanization 39
Media Pasteurizing 123, 156
Mercury Light 98
Metal Halide Light 99
Mist Control 114
Mixers 52
212
Motor Loads 171
Movable Benches 44, 175
Operations and Analysis 39
Operation (def.) 39–40
Operation process chart 39–41
Orientation 1
Overhead Conveyors 54
Overwintering Structures 15
Pallets 47
Perimeter Insulation 143
Pesticide Application Equipment 124
Pesticide Storage 132
Photoperiod 61
Photoperiodic Lighting 101
Photosynthesis 61
Piping 108
Flexible copper 109
Galvanized steel 108
Polyethylene (PE) 108
Polyvinyl chloride (PVC) 108
Rigid copper 109
Plan Layout 1–4, 40
Planning the Facilities 44
Plant Temperature 61
Plastic Film Materials 29
Fiberglass reinforced plastics (FRP) 32
Polyethylene film (PE) 29
Polyvinyl chloride (PVC) 32
Pollutants 62
Ponds (for watering) 105
Portable Watering Booms 114
Porous Concrete Floor 25
Preliminary Layout 1
Pressure Tanks 108
Process Charts 39–41
Pumps 106–108
Pesticide application equipment 124
Water 106
Refrigerated Storage 18
Relative Humidity 18, 61, 69
Control equipment 85
Respiration 61
Roller and Skate Wheel Conveyors 54
Saturated Air 124
Seeders 54
Hand or electric vibration type 54
Precision seeders 54
Shade Structures 15
Shipping 55
Site Selection 137
Smoke Test 154
Snow Load 22
Sodium Light, High Pressure (HPS) 99
Sodium Light, Low Pressure (LPS) 99
Soil Moisture Conductivity 104
Solar Heat 152
Solar Radiation 44
Space Requirements 44
Special Purpose Facilities 15
Standardizing Containers,
Mixes and Methods 43
Standby Generators 90
Storage of Materials 42
Supplemental Greenhouse Lighting 101
Temperature 61
Control 85
Sensors 85
Tensiometers 104
Testing Sprinkler Distribution 114
Thermal Blankets 143–146
Thermostats 85
Timers 87
Transplanting 54
Trickle Irrigation 110
Truck Bodies and Vans 56
Tungsten-Halogen Light 97
Ultraviolet Light 61
Utilities 4, 50
Electric service 4, 140
Water 6, 140
Water system 140
Ventilation 71, 139
Equipment 79
Fan and pad 83
Fog system 83
Walk-in Cooler 19
Waste Heat 151
Water 103
Distribution 114
Pumps 106
Quality 105
Quantity 104
Supply 6, 104, 108
Systems 105, 110, 116
Timing 103
Watering Boom 114
Watering Cart 114
Weight of Soil Moisture 104
Wind Load 24
Wood 148
Work Area 50
Zoning Regulations 1
www.sare.org or www.nraes.org, or call (607) 255-7654. Page 1 of this PDF has fair use information.__

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NRAES-33 Greenhouse Engineeering

By R. Aldrich and J. Bartok

Purchasing the Book

More information on NRAES is included at the end of this PDF.

Chapter 2. GREENHOUSE STRUCTURES 22

Chapter 3. MATERIALS HANDLING 39

Chapter 4. GREENHOUSE ENVIRONMENT 61

Chapter 5. EQUIPMENT FOR HEATING AND COOLING 73

Chapter 6. ENVIRONMENTAL MODIFICATION 92

Chapter 7. REMODELING GREENHOUSES 137

Chapter 8. ENERGY CONSERVATION 141

Special Purpose Facilities

Materials and Methods

GENERAL TYPE COMMENTS

Materials Handling Basics

Equipment Selection Basics

Planning the Facilities

Estimating Heating and

Water System Components

Carbon Dioxide Enrichment

Thermal Energy Use

Power Plant Waste Heat

Estimating Fuel Use

Solar Energy Systems

Plan No. Description

Growing container: Type Size No./day No./week

Growing container: Type Size No./day No./week

J. Hours per day filling containers = I ÷ B hours/day

J. Hours per day filling containers = I ÷ B (167 ÷ 40) 4.2 hours/day

A. No. of containers to be filled/season 500,000 (1 gal. cans) containers/season

Air flow required to supply the heat:

Fan capacity = cfm at inches of water

Boiler capacity = lb./hr. (Boiler hp)

Air flow required to supply the heat:

Fan capacity = 464 cfm at 20 inches of water

Boiler capacity = 696 lb./hr. (Boiler hp)

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