Category: Greenhouse

Propagation Room Construction

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The propagation room is coming along. I was able to get the last 6 fiber boards in place today. These fiber boards need to be taped to eliminate and leaks between the boards.

As you can see from this view, the boards are not completely fitted yet. I am going to have to make some cuts and adjust these boards properly. The 2×4’s are there to keep the boards from curling. I plan on getting this done completed this Saturday. I was able to get several 2×4 boards secured into the wall this week. You might ask why is it taking so long to build two simple walls, and that would be a great question. The answer would be, first of all I’ve been working part time 0500-1000 a.m.to help slow the burn rate of our saved funds that we are living on while off season. So I’m tired, pure and simple. I’ve been trying to get out to the farm as often as possible. Secondly, It has been very muddy on the farm. I had our excavator dump 25 tons of a material that he described as slag. It’s basically crushed stone and the powder associated with the rock. I rented a dingo and laid this material along where the access road are needed and a four foot wide path that leads to the garage door of the high tunnel. This greatly improves getting around on the property, and I’m no longer concerned with getting the truck or trailer stuck now. I really need another 25 tons delivered, but for now I need to remain focused on getting the propagation room completed in time for the hanging basket plugs to arrive in early February.

I bought a hoop bender back in December of last year. The intention of this hoop bender is to create my own hoops for 4 foot wide low tunnel raised beds. One of these beds is planned to run parallel of the high tunnel for the entire 60 feet of the high tunnel and four feet wide. In addition there are plans to have another pad dug just below the high tunnel. This pad will be one hundred twenty feet long, and hopefully I can get a minimum of 20 feet wide. This will allow for considerable growth as we need more growing space.

This pile of rock came from when the excavator dug our water line trench. As you can see this land is very rocky. This is one reason that we will be growing the majority of our plants in raised beds. So we are at a point now that these rocks need to be relocated. Initially my thoughts are that they will go behind the fire pit which you can see in the left side of the above image. The left side of the fire pit is where the hillside begins and the rock would make a good border along the grade change. It may also be a seating option for use of the fire pit. I am wanting to develop this space into at least one, possible two raised beds, then a grassy space with a fence along the entire frontage. So these are some of the short term projects that need to be addressed for the farm to be successful.

Finishing Up The Greenhouse Just in Time

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Well I am relieved that Derek and I were able to get the last end completed last week. It feels good to know that the greenhouse is pretty much enclosed. The man door that you can see in the image above is still open, and the garage door opening on the other end is without a door. My plan is to build the door for the man door out of the strut and hang it on hinges within the next week. The garage door I will probably wire a sheet of film in place for the winter. This will allow me to do the job right, and not rush through it just to be able to heat the greenhouse this winter.

Speaking of heating the greenhouse, I just signed a contract for Suburban Propane to be our propane supplier for the next year. This was an obvious choice considering that they have an office just four miles away on US-25. They will be delivering a 400 gallon storage tank on December 3, 2020. This causes more work!! I have purchased black iron pipe to run my gas lines for the two new heaters we will be using to start our market plants this Winter. Yes just like the water lines, I will be running my own gas lines. This, just like the water will be a first for me. The concept is actually straight forward, tape the threaded ends and connect them. It’s the same for any of the fittings. I have 1/2″ EMT clamps to mount the pipe inside of the house and along the outside where Suburban will be making their connection.

I have done quite a bit of research on heaters. Natural gas, propane, electric, wood burners, pellet shoves, and alternative methods such as compost heating. Natural gas is not available here so I didn’t do much with this type, electric is expensive, and we don’t currently have a pole set. I like the alternative methods, but I have no experience with this method and I need something that is proven and reliable out the gate. Wood and pellet burning looked to be the best for a couple of reasons. A pellet stove with a larger capacity hopper can burn for long periods of time without needing to be tended. A wood burning stove is a cheap means of heating, especially with all of the wood available on the farm. I have actually purchased a steel 55 gallon drum to build a drum stove. I would build a double drum stove which I have actually found the kit to build it. The issue I have with wood or pellet burning is running the stove pipe for venting. I really needed to finish up the ends, so for now I have put this idea on the back burner. Next Spring I can revisit this and build a gable so that I can pass the pipe through the film without melting anything. Propane heat proved to be the best method under the conditions and situations we have currently. So I have ordered the propane radiant heater pictured above. I did all of the research about radiant and convection heaters. So based on my research our primary heater will be a 22K BTU radiant heater. Now keep in mind we are not planning on heating the entire greenhouse. There is no need for this. I have done the calculations and the 22K BTU heater should be fine for the space we are planning on using for starting our early market baskets. We will be using a 320 sqft. area for basket production this Winter. The plants for the baskets require a 50F minimum temperature, so I assumed a 55F minimum in the calculations. We will need 20,429 BTU to maintain 55F if the temp outside stays above 15F.

That’s where this convection heater comes in. This heater is capable of heating the entire greenhouse. So you might ask, “Why not just use one heater?” Good question. The radiant heater above had a fuel burn rate of 0.274 gallons/hr, This convection heater burns 2.3- 3.7 lbs./hr with propane being 4.2#’s per gallon at 60F. So that’s 2-3 times more fuel than the radiant heater. The name of the game is provide heat at the best price. The radiant heater has a thermostat so it will run on a regular basis when heat is needed. If we have a winter event that requires more than the radiant heater can supply, then the convection heater can supplement the needed heat on a temporary basis. The best of both worlds. My long term plan is to implement thermal mass inside the greenhouse and insulate the floor to reduce heat loss through the ground. We will also use a double drum wood burning stove. The theory is to retain the heat by insulating the ground, to heat the air by burning wood which in turn heats the thermal mass. So what is this thermal mass you ask?

My thermal mass shall be several 275 gallon IBC tanks full of water. Water is a perfect substance to store heat, and water temperature fluctuates very slowly. What you wind up with is a buffering of the inside temperature. The water absorbs the heat all day long during growing season and gives it off at night which keeps temps quite stable. In the winter it absorbs the temps at night which is when you will be heating and buffers during the day. So year around the temperatures are rather stable. erratic temperature swings are really tough on plants that are actively growing, such as our hanging baskets for Mothers day which are trying to make it in February and March. So there is still a lot going on at the farm. We also have plants that need to be potted up for Spring sales. This will be another project over the Winter as we prepare for Spring 2021 sales.

The finish line is in sight

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I am very happy to report that we are very close to completing the greenhouse frame build. This has been an ongoing project from August of this year. This was a very ambitious for the family to take on. None of us have any construction experience going into this, just a commitment to the end result, a functional greenhouse.

Gina and I decided to spend the night at the cabin Friday night into Saturday morning instead of getting up early to get to the farm by 08:00. It was a long night with the generator droning on all night in order to keep the heater on. We are also not accustomed to going outside in order to use the restroom in a brisk 41 degrees Fahrenheit. Morning came as it does every day and we would soon embark on the job at hand

So I started a fire in the pit because who doesn’t like a good fire on a crisp Saturday morning? Derek and Meredith arrived at 08:00 and after a quick bite to eat we all got started pulling greenhouse film over a 26 foot wide, 60 foot long steel frame which we have been working on for almost 4 months now.

We worked on the greenhouse all day from sun up to sun down making really good progress. The ladies made a run to Dry Ridge to get us all something for lunch, but other than that we worked non stop until about 4:30. Mer and Der had another engagement that evening and I needed to get a role of greenhouse tape that I had back at the house before the sun went down. 

Just like us our greenhouse isn’t perfect. From the beginning I had concerns about the structure being in square, and I had concerns about getting the film attached to the structure. Now here we are and the structure isn’t perfectly square even though I probably measured each section at least six or seven time to ensure it was right. I had no idea if getting the film attached would be successful or not. There are so many things that could go wrong and this isn’t a one man job. God is good to us and the weather was perfect and family has come together even though we all have different things calling for our time to get this greenhouse built correctly. We have not cut any corners even though we were very tired and at times very hot working on this project. We have given all of our abilities to build this structure. 

I have been told in the past that I can be tough. This isn’t always a bad thing to not except less than your best. I must say that all of the work has paid off and our greenhouse looks very nice. Best of all it was a labor of love and passion for family. This structure is key to the success of our family farm. This structure brought us all together in a time that families don’t have time for each other, or in some cases don’t like each other. We are a family, and we care about each other. This is our greenhouse and our farm. This is our story and my legacy I’m leaving for them.

So we were able to get the top on and the end with the drive through door on which was a lot of work. Derek and I were very tired at the end of the day. The other end will get attached next Saturday providing the weather is good. 

This is the end that I will be working on this next Saturday. It isn’t going to be straightforward because I need to make places for vents and a place to run an exhaust pipe for a drum stove that I’m going to build. So there will be plywood on some sections of the end. I want our greenhouse to look professional so I am planning this out now. 

The Clock Is Ticking….

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I made a trip to the farm this afternoon relocate some plants and hopefully get some more of the wiggle worm bases attached to the frame. Unfortunately it was way too wet to work on the greenhouse pad. So I was only able unload plants at the farm. The good news is we are starting to get our yard back at our home! I have several benches that are now ready to make their trip to the farm. Gina and I are excited to get our backyard back, for many years this has been where I have grown all of my plants. Gina has been patient with me over not having a “normal” backyard. So this will be a nice change for us. I’ve been keeping my eyes on the weather forecast over the last several weeks because I am quite aware that time is running out to get the greenhouse complete. I am a bit anxious because there is rain in the forecast several times this week. With the cooler temps the farm doesn’t dry out very fast. I really need two days of dry windless days to finish, so I am praying for better weather conditions before the bottom drops out for the rest of the year.

Categories: Greenhouse

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All framed in… Finally

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It has been a long time in coming, but the greenhouse frame is complete. The damaged hoop replacement finally arrived last Thursday and I was able to bolt it all together and tie in the purlins. Yesterday (Tuesday October 13th) I went to the farm to connect the end wall that I prefabricated to find that the wind storm we had on Monday had knocked it over along with the scaffolding that was helping to hold it in place… at least I thought it would hold it. This was frustrating, but I was able to piece it all back together and connect it to the main structure.

This is what I’m referring to as the rear entrance. I intentionally spaced the entrance door to the left of the frame. I did this to gain maximum use of the rear wall space. If I would position it in the middle of the house, which is somewhat traditional spacing, then I would have to work around the door. This is my plan for the greenhouse.

As you can see in the top left corner is the entrance door. With this positioning I am able to have a wood burning stove and two 4’x8′ potting benches along the rear wall. If the door was positioned in the center this wouldn’t be possible.

This was my problem child, the end frame that I found on the ground. When deciding what to do with this end of the house, I wanted to allow full access to the inside of the house. So I pulled my truck into the house so I could determine how wide and how tall I might want the entrance to be. What I decided to do was create a door 9’2″ wide, and 7′-2″ tall. This size would allow me to pull a truck or my tractor inside of the greenhouse. This can be quite helpful when moving plants. It also allows for ventilation in the Summer when the house would get quite hot. This is my current plan for that end of the house.

As you can see I have a wide opening on this end of the house which will allow for good access inside the house. The main crop on this side of the house will be vegetables and herbs. So this large opening will allow for easy access to be able to load product ready for market.

So what’s next?

I am quite aware that the weather is changing quickly, and if we don’t get the film on soon we may not be able to do so until next Spring. This would be quite disastrous considering our order for hanging basket plants, and bedding plants have been ordered and are scheduled to arrive starting in late January. So with this said, getting the side boards and the wiggle worm bases installed is a priority. We really need to get the film installed on November 1st. This is our goal to be under film by November 1st.

Framing Up The Sides

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I was able to get out to the farm after selling at the Boone County Farmers Market today. Right now the priority is getting the greenhouse ends built. I was able to get half of one end build, the angle brackets for the rest of the vertical braces mounted, and the vertical drilled. The next visit I should be able to get the rest of the end frame completed.

The replacement hoop has been shipped and is expected to arrive on October 6th. So there is finally signs of completion in sight which is feeling really good. I have been nervous about this build from the beginning. The completion of this greenhouse is key to the success of the farm, it’s that important!

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One step closer to a functional greenhouse

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Well just as I predicted, we did not work at the farm on Saturday. We loaded up our trailer and set up at the Boone County Farmers Market at Camp Ernst Road and KY18. It was a great morning to be at the market and we sold over half of the mums we had available plus several perennials and one tropical. We did make it on Sunday, we actually made it to the farm early. We watched our Church service online and had breakfast before getting to work.

We normally wouldn’t work on a Sunday, but we unfortunately we have a time constrained to get our greenhouse build and covered before the strong winds of Fall kick up. Today was a very productive day! I was able to get the final six sections of center purlins installed. So the whole frame is done except for the last hoop which we are waiting for the manufacturer to replace. On the end of the frame you will notice all four purlins extended in the air beyond the frame. Once we receive the replacement hoop we will bolt it together and then bolt the purlins to the hoop and the frame is complete.

I’m hoping to get out to the farm tomorrow morning if it isn’t raining and get some grading done, lay the Geo fabric, then start building the end wall. We bought a complete frame which includes end walls. So I will get one wall build, so that once the replacement hoop arrives and is tied in we can build the other wall. I still want to get the greenhouse film on during the week of October 11th. I’m hoping the hoop ships and arrives as soon as possible.

Categories: Farm Update Greenhouse

Greenhouse frame is almost complete

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There has been several projects on the farm needing to be completed. The water line installation is finally complete, all of the rain we have had along with demands of the landscape business have caused this project to drag out too long. I am glad that water installation is behind us. Now all focus is on getting the greenhouse completed. I was able to break away from the landscape work and head to the farm today.

I’m going to guess that this isn’t an OSHA approved method to complete our project! The peak of the greenhouse comes in at about 12 feet, so this is the most efficient and effective means to get the top purlins connected. I have found that the tubes that were shipped to us wasn’t drilled out completely. I have had to use a punch to help line up the holes and a hammer to tap them through the holes. Needless to say this doesn’t help the threads too much, but we are making it work. The other option would be to drill the holes out so the bolts can pass through the holes properly. This seems like a lot more work considering that not all of the holes are undersized.

As you can see I was able to get quite a bit completed in about three house. I have been keeping in the back of my mind that the cold weather and strong winds of Fall will be upon us soon. So this project must be completed soon. The film for this greenhouse is 75 feet long and 50 feet wide. To successfully cover this house we need a day with winds less than 2 MPH, and it would be nice to have at least some sun to cause the film to expand so that when it is fastened onto the house it will contract as the weather cools and create a tight fit over winter.

So the plan is to finish up mowing tomorrow and then head back out to the farm to finish the last of the purlins, then possibly get the end wall built on this side of the greenhouse. Unfortunately a few of the poles were damaged in transit, so we are waiting for replacements to be fabricated and shipped to us. I would like to have the film on the house by the week of October 4th. In the mean time while we wait for the replacements we can get the baseboards on, and the wiggleworm bases attached. That was all that is left is to build the last end wall and attach the film. I will feel so much better once the film is successfully attached.

Greenhouse Construction Begins!

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We are so excited that construction on our first greenhouse has begun! I must say that this is the most precise thing I have ever done! I think I measured each of the four sides at least six times and the diagonal measurements four times before the first ground post went into the ground. The first side of the greenhouse ground posts are all in the ground, although they need to be driven to the same consistent height.

The plan is to get the opposing side set tomorrow, finish back filling the water lines next weekend, then come back and finish the greenhouse build on Labor day weekend. We would like to be under film by mid September at the latest. I have been seeing the geese getting restless flying here and there. Stirring geese is a reminder that Fall is quickly coming, and frost not too far away. So we want to get our greenhouse covered and ready for the cold weather as soon as possible. Once the house is up there is still a lot to be done to make it functional for 2021 production.

Categories: Farm Update Greenhouse