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Greenhouse structures, construction and design

Article · January 2021

DOI: 10.22271/chemi.2021.v9.i1a.11417

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 International Journal of Chemical Studies 2020; SP-9(1): 40-45

P-ISSN: 2349–8528
E-ISSN: 2321–4902
www.chemijournal.com Greenhouse structures, construction and design
IJCS 2021; SP-9(1): 40-45
© 2021 IJCS
Received: 19-11-2020
Accepted: 28-12-2020
Dr. AD Ashok and Dr. E Sujitha

Dr. AD Ashok
DOI: https://doi.org/10.22271/chemi.2021.v9.i1a.11417
Institute of Agriculture, Tamil
Nadu Agricultural University, Abstract
Kumulur, Tiruchirappalli, Tamil Greenhouse is a frame structure that covers transparent materials such as glass, polyethylene and
Nadu, India polycarbonate, etc. It consists of two parts frame and covering material. The greenhouse covering
material acts as a barrier to the passage of air and traps energy inside the greenhouse, which heats both
Dr. E Sujitha the plants and the soil within it. This wall, like the air near the ground, raises the temperature within the
Institute of Agriculture, Tamil greenhouse. Greenhouses may be used for the cultivation of high-quality fruits, flowers, various crop
Nadu Agricultural University, nurseries, ornamental and medicinal plants. The benefits of greenhouses are high production per unit area
Kumulur, Tiruchirappalli, Tamil because the genetic potential of the crop can be completely exploited, vegetables and nurseries can be
Nadu, India
grown off-season that obtain high market prices, good quality products and it is easy to protect the crops
from pests, diseases and extreme climatic conditions. Greenhouse farming is a highly intensive industry
that needs considerable labour and capital inputs. Because of this, all factors important for a successful
enterprisers should be carefully considered by potential growers. Greenhouse vegetable processing is a
24-hour commitment in several respects. Constant vigilance is required for the maintenance, crop
production and handling of emergencies.

Keywords: Crop production factors, greenhouse, loads, orientation, site selection, and shapes

Introduction
The existence of root media can only be regulated by traditional agricultural practices by
tillage, manure, fertilizer application, irrigation etc. In open field cultivation, there is no
influence over sun, temperature, air composition, humidity, etc. (Tiwari, 2003) [1]. However,
greenhouse cultivation can be used as one of the solutions for these parameters. Some of the
benefits of greenhouse cultivation are efficient use of agro-chemicals by minimizing emission
of waste and recycling, efficient use of solar, wind and thermal energy, off season cultivation,
better insect and disease control, reduced use of pesticides, protect plants from environmental
hazards such as heavy rain, strong wind, excess solar radiation and extremes of temperature
and humidity, better quality of produce, higher productivity, high-income generation for small
land holdings (Fernández et al., 2018) [2].

Greenhouse Classifications
The greenhouses can be classified on the bases of cost, shape, size and environment control.
On the basis of cost the greenhouses can be classified as:

Low Cost
The low-cost greenhouses are constructed from locally available materials i.e. bamboo, wood
etc. is used for construction of frame and glazed with stabilized polyethylene sheet. There is no
environmental control in this type of greenhouses. The cost varies from Rs 250 to 300 per
square meter.

Medium Cost
In case of medium cost greenhouses the frame may be made from Galvanized Iron/Mild steel
pipes. But the problem associated with MS pipes is rusting after some time, which also
Corresponding Author: damages the covering sheet. These greenhouses are also glazed with UV stabilized
Dr. AD Ashok
Institute of Agriculture, Tamil
polyethylene sheet. The cost varies from Rs.800 to 1000 per square meter.
Nadu Agricultural University,
Kumulur, Tiruchirappalli, Tamil
Nadu, India

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High Cost The cost of this type of greenhouses is more than Rs 2000 per
The high- cost greenhouses are made from aluminum/GI square meter.
pipes, glazed with double layer poly ethylene sheet or poly On the basis of shape the greenhouses may be classified as
carbonate. The environment inside the greenhouses is fully Quonset, modified Quonset, gable/standard peak free standing
controlled and operation is also automated. There are sensors (even and uneven span), multi span gutter connected and lean
and controllers for temperature, humidity and soil moisture. to type figure 1.

a) Gable/standard peak/Solar style free standing b) Gambrel/Vinery freestanding c) Conventional freestanding

d) Conventional lean to e) Solar slope lean to f) Double slope lean to g) Single slope lean to

h) Quonset i) Gothic/Modified Quonset j) Spike tooth k) Multispan

Fig 1: Various shapes of greenhouses

Indian standards for greenhouse photosynthesis through which carbohydrates are formed.
The BIS has formulated following standards with respect to Considerable energy is required to reduce carbon that is
greenhouse technology (Waaijenberg, 2006) [3]. combined with oxygen in carbon dioxide to reach the state in
 IS14462:1997-Recommended for layout, design and which it exists in carbohydrate (José et al., 2020) [5]. The light
construction of greenhouse structures. energy thus utilized is trapped in the carbohydrate. Later, the
 IS14485:1998 – Recommendation for heating, cooling carbohydrate can be moved from the green stem and leaf cells
and ventilation of greenhouse. where photosynthesis occurs to the other parts of the plant.
The carbohydrate can be converted into all other compounds
On the bases of height of greenhouses these may be classified needed in the plant. Energy from the sun is utilized in all of
as portable low tunnels and high tunnels. The portable low these compounds. These processes result in plant growth.
tunnels are of height 1 m and used to raise the seedlings of Respiration occurs in all living organisms at all time. In fact,
various crops. most living organisms are ultimately dependent on light
On the basis of cooling system the greenhouses may be energy. The day length (i.e. photoperiod) also affects the plant
classified as growth. The relative day-night lengths may affect the rooting
1. Without cooling system of cuttings, initiation of flowers and fruits, bulb and tubes
2. Passive cooing system formation, advent and cessation of dormancy, etc.
a. Natural ventilation The intensity of incoming solar radiation is an important
b. Shading type parameter for influencing the photosynthetic activity of
3. Active cooling system plants. The light intensity varies from place to place but it
a. Forced ventilation and generally varies from zero at the beginning of the day to about
b. Evaporative cooling 100,000 to 150,000 lux (lumen/m2) around noontime. Light
intensity on cloudy days is quite low which leads to poor
The natural ventilated and use of shade nets for reducing photosynthetic process. Light intensity below 3200 lux and
inside temperature is the most preferred energy saving way of above 129,000 lux is not ideal for plant growth since the
reducing greenhouse temperature. optimum light intensity for plant is 32,000 lux. In this case,
solar radiation transmittance needs utmost attention while
Crop Production Factors considering controlled environment agriculture obtained in
The crop production inside the greenhouse is affected by greenhouse. It is also influenced by the orientation of
micro climate, fertilizers, quality of seeds, seed treatment, structure (greenhouse) and the sun elevation.
pest control, field preparation and irrigation. The plant growth
also depends on other factors that are well within one's reach b) Temperature
and control (Pritam and Yadav, 2015) [4]. The key All crops have certain temperature range in which they grow
environmental factors affecting plant growth are light better. Below this range, the process necessary for growth
intensity, temperature, humidity, carbon-dioxide stops. Under very high or extreme temperatures, enzymes
concentration, airflow etc. become inactive, causing necessary processes for plant's
development to stop. Thus, the temperature may affect the
a) Light intensity movement of minerals, water and food in roots, stems and
Visible light constitutes a source of energy for plants. Light leaves. This can affect the photosynthesis process
energy, carbon dioxide, water all enter into the process of significantly. Prolonged low temperature will result in loss of
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flowers and fruits; slowing their growth. On the other hand, most common method of CO2 supplementation is through
prolonged high temperature will result in loss of flowers, burning of carbon fuels.
fruits, burning of leaves and lowering in plant growth. Soil
temperature also affects the plant growth because it affects the e) Air Movement
absorption of water from the soil by the plant. Although air movement affects the plant growth, through its
effect on transpiration, evaporation of water from soil, CO2
availability, tearing of leaves, cooling effect, etc. The air
velocity affects the boundary layer thickness of the plant's
leaves through which the plant transpires and water vapour
diffuses into the outside air while the atmospheric. CO2
required for photosynthesis enters into the plant.

Procedure for Greenhouse Construction Site Selection

 The greenhouse should be so located that it is well
connected to market for getting input supplies as well as
Fig 2: Temperature measuring instruments for marketing its produce.
 The soil should be of good quality and well drained.
c) Humidity  There should be permanent source of water near
Humidity in the atmosphere has its own importance as it greenhouse, this is most important for meeting out water
governs most of the metabolic and photosynthesis activities of requirements of greenhouse crops.
the plants. It has been observed that a relative humidity  There must be no obstructions (shadow), which will
between 20 and 70 per cent is ideal for plant growth. This is restrict the supply of sunlight to greenhouse Locate the
so because, very high relative humidity will provide better greenhouse at -a distance of 2 times the height of any
environment for pathogenic organisms making the plant object that might cast a shadow on the greenhouse.
susceptible to diseases. Low humidity is also harmful for  The availability of uninterruptable electricity supply must
plants since it increases the evaporation rate, and at the same be ensured.
time, enhances the water requirement. In environmentally
controlled chambers, relative humidity between 55 to 65 per Greenhouse Orientation
cent and temperature between 20 to 25 °C is maintained. The most important and complicated decision that what
should be the orientation of greenhouse. The greenhouse
orientation should be such that: it receives maximum sunlight
in winter and prevailing winds should have the minimum
effect on greenhouse structure and other operations. The
maximum sunlight will be received in the winter if the long
side of the greenhouse is oriented from east to west as
compared to north south (Figure 4). However in case of the
multi-span greenhouse the gutter should be oriented east-west
Fig 3: Relative Humidity measuring instruments
to avoid the shadow of structural components. The long side
of the greenhouse should be so oriented that the wind exert
d) Carbon dioxide (CO2) minimum pressure on the greenhouse. It should be parallel to
The amount of CO2 present in the plant environment affects wind direction.
the plant growth considerably because it is essential for
photosynthesis. The amount of CO2 required for optimum Size of Greenhouse
plant growth depends on the plant type, state of development, The size of greenhouse depends upon: production required
temperature, light intensity, leaf area, air, velocity, humidity, from greenhouse, land available and the capital investment.
water stress etc. But the CO2 requirement differs for various
plants. Research has shown that controlled environments,
such as closed greenhouse system, offers ample opportunity
to improve production through the elevation of CO2 levels.
Carbon dioxide, which comprises about 0.03 percent (300
ppm) of ambient air, is essential for plant growth. This level
of carbon dioxide in atmospheric air is sufficient to meet the
photosynthetic requirement of open field crops. In closed
conditions, the level of carbon dioxide rises to nearly 1000
ppm, because respired carbon dioxide remains trapped
overnight. As sunlight becomes available, photosynthesis
process begins and carbon dioxide from greenhouse air gets
depleted. As a result, the CO2 level in the greenhouse even
goes below 300 ppm before noontime. If the greenhouse air
does not receive additional carbon dioxide from any other
source, the plant would be deficient of carbon dioxide
resulting in poor growth. Reports have shown that crop yield
increased by 20-30 per cent when carbon dioxide level was
maintained from 1000-1500 ppm inside the greenhouse. The Fig 4: Greenhouse Orientation

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Greenhouse Frameworks additives are incorporated into the polymer matrix to provide
The greenhouse frame can be constructed from different types a longer lifetime in case of greenhouse films. These additives
of material. The selection of right framing material will are known as U.V. Stabilizers, when used along with anti-
depend upon capital investment, size of greenhouse, height of oxidants, protect the poly film from photo as well as thermal
greenhouse and availability of material. The most common degradation. The main types of LDPE films used for
materials for greenhouse frameworks are bamboo, wood, mild greenhouse covering are: cross laminated, clear, multi-layered
steel (MS) pipes, galvanized pipe and aluminium. The (different layers having different properties). The different
framework should be strong enough to bear wind, snow and variant of multi-layered sheets are available such as: anti-dip,
dead load including the load required for training of plants as anti-dust, diffused, thermic, anti sulphur, UV blocking,
well as for hanging of plant pots. It should allow the thermic etc.
maximum amount of light to reach the plants. It should Different types of chemicals are blended into the material
require little maintenance. Avoid the use of MS pipes as it when manufacturing these films. The two main types of U.V.
will require frequent painting and its rusting will damage the Stabilizer systems being used are: HALS (Hindered Amine
greenhouse cover (Lilly Cao, 2020) [6]. Light Stabilizer) + UV absorber Films based on the above
package are colorless / translucent in appearance, stabilizes
Greenhouse frame material the harmful U.V. radiation form entering in to the Greenhouse
Wood, Bamboo, Steel, Galvanized iron pipe, Aluminum and and allow maximum transmission of light. For chemical
Reinforced concrete (RCC), Glass, Polyethylene film, PVC resistance against halogens or Sulphur, it is necessary to
film, TefzelT2, Polyvinyl chloride rigid panel, FRP rigid include a co-stabilizer in this system. Nickel-quencher + UV
panel, Acrylic and polycarbonate rigid panel absorber Films stabilized with above package are greenish /
yellowish in appearance. This shade gives a slightly hazy
Greenhouse glazing effect thus reducing the intensity of direct light transmission.
The covering of the greenhouse is referred to as the glazing. This stabilization system gives excellent U.V. Stabilization
The considerations in choosing a glazing material include also provides good protection against action of CPC's. This
durability, light transmission, cost, and heating and cooling property is also sometimes termed as Anti-Sulphur.
costs. The solar radiation spectrum can be divided in several Proper light transmission filtering, out the harmful Ultra
specific wavebands, which are defined by their range of Violet (U.V.) radiation is very essential for optimized growth
wavelengths or energy content (e.g., radio and TV radiation, of the crops inside the Greenhouse. The photosynthesis
microwave radiation, visible light, etc.). The higher the activity in plants is directly proportional to the amount of
wavelength, the smaller the energy content. Typically, the light. Higher light transmission enhances the growth of plants.
wavelength of light used by plants is expressed in the units of Therefore it is crucial to select the right combination of
nanometer (rim). Not all components of sunlight are useful for polymer and specialty additives, to get maximum light
plant growth and development. In general, ultraviolet (UV; transmission. This is more significant for greenhouses located
less than 380 nm) and excessive infrared (IR; above 770 nm) in colder climates where availability of daylight is limited.
or heat radiation can be harmful to plants and should be The ultra violet radiation is harmful for the plants growth. As
avoided. Plants use Photosynthetically Active Radiation well as when the protective polyethylene films are exposed to
(PAR; 400-700 nm), as their energy source for the process of outdoors environment for longer duration are prone to,
photosynthesis. Therefore, greenhouse structures and degradation as a combined effect of sunlight, heat and
especially the glazing material should have a high oxidation. Interaction with the Sulphur or halogen based crop
transmittance of PAR radiation (John W. Bartok, 2013) [7]. protection chemicals (cpc), further accelerates this
The common materials for greenhouse glazing (covering) are: degradation process.
glass, plastic films and rigid plastics (poly carbonate and Special chemical additives are incorporated into the polymer
acrylic). matrix to provide a longer lifetime in case of greenhouse
films. These additives are known as U.V. stabilizers, when
Glass used along with anti-oxidants, protect the film from photo as
Glass has the highest light transmission, lasts the longest and well as thermal degradation. At the same time helps in proper
is the most expensive. However the single layer glass and maximum light transmission. The selection of film will
covering have relatively high heat transfer coefficient. depend upon the type plants grown inside the greenhouse and
properties of glazing cover required. The film thickness is
Plastic films specified in microns or weight density, 200 microns thick or
The use of plastic films as greenhouse glazing is very popular 120-150 GSM (grams per square meter, weight density)
across the globe. The advantages offered by them such as sheets are uses for greenhouse covering.
lightweight, translucency, flexibility, toughness, hydrophobic
nature and durability, make plastics films the most preferred Rigid plastics
material for cladding of greenhouses. Different types of The rigid plastics (e.g., polycarbonate and acrylic) are less
plastic materials such as Poly Vinyl Chloride (PVC), Poly expensive than glass and last seven to 20 years. They are
Carbonate (PC) and Low Density Polyethylene (LDPE) are usually manufactured as twin-walled sheets. The air space
commonly used for cladding of greenhouse structures. LDPE between the two walls acts as an insulator. Light transmission
remains the most popular of all plastic material because of its through rigid plastics is very good, although it usually
features, ease in availability and economics. decreases over time as the plastics age and turn yellow due to
Polyethylene films when exposed to outdoor environment for the amount of UV radiation contained in sunlight. The large
longer duration are prone to degradation as a combined effect sheets are much lighter than glass and require fewer support
of sunlight, heat and oxidation. Interaction with the Sulphur bars to attach them to the greenhouse frame. However, these
or Halogen based Crop Protection Chemicals (CPC), further rigid panels are not so easy to install on curved roofs.
accelerates this degradation process. Special chemical
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International Journal of Chemical Studies http://www.chemijournal.com

Procedure for construction

The greenhouse glazing should properly secure with Site layout

greenhouse for its long-life. The properly constructed Facilities master plan
greenhouse with quality construction material will last many A master plan provides a framework for orderly construction
years (Montero et al., 2009) [8]. of the buildings and should be based on a sound business
a. Dead load: Weight of all permanent construction, plan. The plan starts with a survey of any existing facilities,
cladding, heating and cooling equipment, water pipes and evaluates the benefits and constraints of the site and
all fixed service equipments to the frame. establishes where new facilities should be built. A good
b. Live load: Weights super imposed by use (include arrangement is to plan a core area which contains the
hanging baskets, shelves and persons working on roof). propagation and production greenhouses, head house, storage
The green house has to be designed for a maximum of 15 and parking. Outdoor production areas should be located
kg per square meter live load. Each member of roof nearby for efficient plant movement and shipping. Expansion
should be capable of supporting 45 kg of concentrated space should be planned for all areas. It is best to do the
load when applied at its centre. planning on paper so that several alternatives can be
c. Wind load: It depends on wind action and creates evaluated.
upward thrust. ANSI code a 25 year of mean recurrence
interval is taken. It depends upon the height of the Parking and Access
building and location of the structure like urban, rural, Good, all weather vehicular access to the buildings and
open area etc. growing areas should be provided. Parking for employees and
customers, convenient to the core area is desirable. An
Calculation of wind load adequate number of parking spaces for retail sales may be
Effective pressure of wind (q) = 2.37 (v2/105) needed to meet the zoning code. A paved surface is usually
required. Other areas and driveways can be unpaved. Surface
where, can be bank-run gravel, pea stone, crushed stone or trap rock.
q = wind pressure (pa) Driveways and parking areas should slope to provide
v = wind velocity (m/s). drainage. Swales or underground piping is necessary to carry
Load factor (W) = q*qp the water away from the area. Swales should be grassed and
qp= external pressure acting at the level area slope at least ¼"/ft.

Table 1: Minimum values of GH design loads Storage

Minimum load An area for storage of materials including soil mix,
Load containers, chemicals and equipment is needed. Indoor
(kg/cm2)
1. Dead Load storage for some items is desirable for easy access and
i. Pipe frames 10 protection from weather. This can be in a head house or
ii. Cladding materials 25 separate building. An outdoor area is usually provided for
iii. Crops (Tomato, Cucumber, Capsicum etc.) 20 – 25 growing mix. Space for an equipment storage shed with a
2.Live Load 15 -25 shop for maintenance should be planned. A clear span pole
3.Snow load 75 building is a low-cost alternative.
4.Wind load Site Specific
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Outdoor Production Areas

Prime space should be allocated to plant production including
growing beds, shade houses and overwintering structures.
Good light, drainage and proximity to water are needed.
Production areas should be laid out in rectangular blocks of
1000 to 2000sq ft. Within the blocks, 6' to 8' wide beds are
placed adjacent to 2' wide walkways. Generally an
arrangement with shorter length walkways across the block is
preferred over ones with walkways that run the length of the
block. Roadways are placed between blocks to transport and
maintain plants. These should be 15' to 20' wide to allow
movement of trucks or tractors. Gravel or stone on the surface
requires a minimum of maintenance.

Reference
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Contreras J et al. Current trends in protected cultivation in
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305.
3. Waaijenberg D. Design, construction and maintenance of
greenhouse structures. Acta Hortic 2006;710:31-42. DOI:
10.17660/ActaHortic.2006.710.1
4. Pritam K, Yadav RK. Enhancing small farmers’ income
through Off-season vegetable production under temporary
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Felices, Isabel M. Román-Sánchez. An Analysis of Global
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translucent-cladding-how-to-design-a-greenhouse> ISSN
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