Indiana High Tunnel Handbook - Purdue Extension
Horticulture & Landscape Architectureag.purdue.edu/hlaHO-296Indiana High TunnelHandbookAnalena Bruce,Postdoctoral Research Fellow,Indiana UniversityElizabeth Maynard,Clinical EngagementAssistant Professor of Horticulture,Purdue UniversityJames Farmer,Associate Professor and Co-Directorof IU Campus Farm,Indiana UniversityJonas Carpenter,Bread and Roses Nursery, LLC
HO-296-WPhoto CreditsPhotos provided by Erin Bluhm, Analena Bruce, William Horan,Richard Kremer, Jon Leuck, Jonas Carpenter, andElizabeth MaynardAcknowledgementsThis publication was supported by the U.S. Departmentof Agriculture (USDA) Agricultural Marketing ServiceSpecialty Crop Block Grant #15-002. Its contents aresolely the responsibility of the authors and do notnecessarily represent the official views of the USDA.The patience and expertise of the farmers whoparticipated in the high tunnel study was essentialto the production of this book. We’d like to thank allparticipating farmers for their generosity and willingnessto share their experiences and advice with others.We also thank the reviewers: Wenjing Guan andPetrus Langenhoven from the Purdue Departmentof Horticulture and Landscape Architecture;Adam Heichelbech from the Indiana Natural ResourcesConservation Service (NRCS); and farmers Linda Chapman,Genesis McKiernan-Allen, and Richard Ritter, whocontributed to and strengthened this book.The authors assume responsibility for any errors or flaws.2
HO-296-WWhy High Tunnels?the cooler months and planting earlier in the spring(crops such as lettuce, spinach, and kale). Another halfonly use the structures in summer to improve the growthand production of warm-season crops like tomatoes,peppers, and cucumbers.High tunnel crop production has grown immenselyin the past decade, particularly among specialty cropgrowers who sell directly to consumers. High tunnels(also called hoop houses) are low-cost, plastic-coveredstructures used for growing plants that make use ofthe sun’s passive solar energy. The structures protectplants from weather-induced temperature extremes andadverse weather conditions (such as heavy rains, winds,and frosts), which safeguards crops for earlier planting,later harvesting, and protection from certain diseasesand pests. High tunnels are often defined as unheatedor passive solar greenhouses, but our survey revealedthat farmers use a continuum of practices.Indiana farmers report annually earning a totalrevenue of about 1.70 per square foot of high tunnelspace. Consequently, high tunnels are an increasinglyimportant piece of farm infrastructure. However,high tunnels can be labor-intensive and high tunnelproduction is vulnerable to a number of weather, disease,and pest-related challenges that require advancedpreparation and knowledge along with an adequateinvestment of time and money to manage successfully.In this publication, we define high tunnels as poly-filmcovered structures big enough to walk in that are usedfor growing plants — regardless of the heat systemthey use or don’t use. Most of the discussion refers tostructures without heat or with minimal heat. Hoophouse is a term used interchangeably with high tunnel.This publication is a resource for those who areconsidering high tunnel production or are relativebeginners. This resource describes: selecting the rightsize and type of high tunnel for your operation, choosinga site location, constructing a high tunnel, determiningplanting dates, laying out beds, spacing plants,understanding environmental factors, monitoring soilhealth, and managing pests and diseases. Furthermore,this publication features information from the livedexperience of farmers via survey data and on-farmcase studies. Our goal is to build upon important workhappening across the United States to better understandthe ins and outs of producing in high tunnels.Research has shown great potential for high tunnels toincrease the quality, yield, and shelf life of fresh fruitsand vegetables. We developed this handbook basedon a study of Indiana farmers’ use of high tunnels.We learned from more than 130 Hoosier farmers abouttheir experience growing in high tunnels throughmailed surveys and on-farm interviews.We hope you find the handbook useful and weappreciate hearing any feedback you have. Sendfeedback to James Farmer (jafarmer@indiana.edu)or Liz Maynard (emaynard@purdue.edu).High tunnels are a new variation on greenhouses.Growers are using this low-cost technology tostrengthen the viability of small-scale diversified farmsthat supply fresh produce for local food systems byfacilitating the production of high-quality vegetablesand fruits during the growing season — especiallyduring the cooler shoulder seasons.Table of Contents1. Opportunities and Challenges . 4Farmers indicated that installing and growing in ahigh tunnel:2. Considerations for New Users . 7 Improved their farms’ economic stability3. Site Selection and Preparation . 16 Improved harvest quality4. High Tunnel Construction . 19 Reduced some disease problems and weed pressure5. Planting Dates . 22 Increased product shelf life and yield6. Planting Arrangements and Spacing . 23 Protected produce from adverse weather7. Environmental Management . 258. Soil Management . 28Overall, we found that Indiana high tunnel growershave had positive experiences. In particular, they saidhigh tunnels helped extend the growing season andimprove product quality and yield year-round. Nearlyhalf of the growers we spoke to are now harvesting in9. Pest and Weed Management . 3110. Irrigation . 3311. Summary . 3412. Resources . 353
HO-296-W1. Opportunities and ChallengesA Way to DiversifySome farms use high tunnels to provide additionalrevenue streams on the side. In such cases, the primaryfocus might be field crops, an orchard, or field vegetableproduction. For these operations, the high tunnel is aside business, perhaps for their teenage kids or otherfamily members.High tunnel technology presents a unique opportunityfor farmers to increase their revenue per square foot,improve the quality and yield of their crops, and extendthe growing season of their operations (and therebyexpand market opportunities). Hoosier farmers are usinghigh tunnels in a variety of ways by adapting them tomeet their individual needs and farm business goals.Here are some advantages to using high tunnels todiversity your operation:Indiana farmers are using high tunnels as the center oftheir farm businesses, using them to diversify their existingoperations, or using them as a way to start farming. You can experiment with growing high-valuespecialty crops such as cut flowers, delicateperennials, or berriesThe Center of the Farm Business You can add a unique or popular product to attractcustomers at farmers’ markets or make your CSAmore competitiveSome farms have made high tunnel production thecenter of their business. These farms produce specialtycrops year-round in their high tunnels. They plant rootvegetables and winter greens in the late summer andearly fall and harvest them through the winter and earlyspring. They get a head start on early tomatoes andother summer fruiting crops that fetch a price premiumand continue producing into the fall. Farmers who havemade high tunnel production the center of their businesstypically keep their high tunnel in use year-round. You can add a side revenue stream (such as transplantor bedding plant production)Here are some advantages to centering your farm onhigh tunnel production: You can take advantage of off-season markets such aswinter farmers’ markets, restaurants, and winter CSAs You can demand a price premium for early andlate produce You can earn year-round incomeThe high tunnels shown here are behind open fields, whichmarks a diversified and integrated approach to growingunder cover. You can attract and keep great workers You can grow greenhouse-specific, high-yieldingvarietiesA Way to Start FarmingSome farms use high tunnels as a way to start small-scalevegetable operations geared for selling produce at localfarmers’ markets.Here are some advantages to using high tunnels as a wayto begin a farming operation: High tunnels are an opportunity for beginning farmerswith limited experience to increase their income asthey learn and grow High tunnels offer a strategy for maximizing incomeon limited or marginal landThis farm uses numerous high tunnels as a foundation fortheir specialty crop production business.4
HO-296-W The Natural Resources Conservation Service (NRCS)provides higher cost-share incentive payments tobeginning, socially disadvantaged, veteran, andlimited income farmers through the EnvironmentalQuality Incentives Program (EQIP). Advance EQIPpayments for high tunnels are also available.Learn from a Farmer: Harvest Moon Flower FarmSome farms construct DIY high tunnels while they are justgetting started with the technology or when they areinvolved in specialty crop production.Autumn flowers bloom in front of the high tunnels atHarvest Moon Flower Farm where high tunnels havebeen in use for decades.High tunnels present many opportunities, but thedecision to invest in a high tunnel should not be madelightly. High tunnels require you to significantly investtime and money to reap the benefits. The most commonexperience we heard from Indiana farmers growing withhigh tunnels was: “You get out what you put into it.”Harvest Moon Flower Farm is a small, sustainable,year-round operation in Owen County that hasbeen owned and operated for more than 30 yearsby Linda Chapman. Although growing and sellingflowers is their “bread and butter,” they also grow adiverse assortment of herbs, vegetables, and fruitcrops primarily grown for local chefs.In other words, receiving a significant return on yourhigh tunnel investment depends on how much laborand attention you give to managing your high tunnel.Farmers who invest more time and labor in their hightunnels are also obtaining a higher return. These farmerstypically manage at least two tunnels and have madethem the center of their farm businesses.To round out their year on both ends, they offer avery diverse selection of garden bedding plants inthe spring. For the fall and holiday seasons theycreate dried flower and evergreen wreaths, andother seasonal items.However, if you are already struggling to keep up withyour farm business, adding a high tunnel may be aburden if you don’t have the time to put into it. Likewise,if you don’t have the financial resources to invest in ahigh-quality high tunnel, you could be at higher risk oflosing your tunnel to strong winds or of experiencingstructural damage that requires more time and money tofix. Be sure you are ready before you buy and know whatyou’re getting into!Overall Management StrategyChapman said she is constantly cycling newflowers, herbs, salad mix, greens, and carrots inand out of the farm’s six high tunnels. Some of thetunnels are heated. There is no rest period and it’svery rare for there to be any bare ground that’s notplanted with something.5
HO-296-WRather than follow a set rotation of specific crops,the farm maintains a great deal of diversity andcomplexity in terms of plant varieties, timing ofplanting/harvesting, and rotations. Chapman said shefollows her intuition and experience of what specificflower varieties do best in which tunnels, but she alsogoes by what seedlings and space she has.“High tunnels have been fabulous for growing mybusiness as they allowed me to start doing wintermarket and having income in the winter,” Chapman said.“High tunnels have expanded my income substantially.They’ve allowed me to do weddings in November,December, and March. It’s been real sweet, not tomention I get to eat really good food all winter long,which is really important, too. Efficiently utilizing ourhoop houses has vastly improved the quality of whatwe do here and has generally allowed us to charge atleast a little more than most vendors — certainly for theflowers and even sometimes for the food (our salad mixparticularly). But our customers know that the quality isthere and they’re willing to buy it.”Harvest Moon Flower Farm considers its emphasis ondiversity to be a large contributor to its success andstrength. A diversity of crops grown with knowledgeand care ensures that customers get the quality thefarm has become known for — be it flower bouquets,herbs, micro-greens, vegetables, fruits, plants, wreaths,or wedding florals.Greens, salad mixes, kale, and spinach flourish in the raised beds of this well-used high tunnel.6
HO-296-W2. Considerations for New UsersIn this chapter, we examine several considerations thatare important when you plan to construct a high tunnel.While we discuss each factor separately, these factorsare related and can affect your structure’s longevity anddurability, as well as your overall high tunnel experience.In this section, we will examine: High tunnel selection Site selection and preparation Construction tips and considerationsHigh Tunnel SelectionHigh tunnel structures vary in shape and design. Whenyou’re selecting high tunnels, think of basic design, thinkof how permanent you want the structure to be, andthink about how large of a structure you need for thenext season and three to five years down the road.Basic DesignsHigh tunnels vary in structural complexity and strength.A. A caterpillar tunnel. B. A caterpillar tunnel with plasticheld in place by ropes. C. A Quonset-style tunnel with hoopsmade of PVC tubing and added wooden support beam.D. A Quonset-style tunnel with longer ground posts tocreate vertical sidewalls and simple vertical poly curtainend wall. E. A gothic-style tunnel with metal-framedpolycarbonate paneled end walls, a large roll-up curtaindoorway, and end-wall vents above the door. F. A gothicstyle tunnel with roof vent.The classic Quonset tunnel is a ground-to-groundhalf-circle. Some Quonsets are set on higher groundposts so there are straight sides before the half-circle.The gothic high tunnel design has a pointed roof thatrises diagonally from the sidewalls to form a peak.Single sections (or bays) of Quonset or gothic structurescan be connected side-by-side to form gutter-connectedmulti-bay structures. These are more commonly used asheated greenhouses than unheated high tunnels.Some multi-bay high tunnel designs are forthree-season production; the structure won’tsupport a snow load, so the plastic must beremoved in the winter. These designs oftencover a fairly large area; a small one mightcover 1/3 acre.Caterpillar tunnels are smaller, low-cost, lesspermanent structures. The plastic coveringis held down with ropes, giving them thesegmented appearance of a caterpillar.Lightweight hoops provide little structuralsupport and so they are usually less than14 feet wide. A caterpillar tunnel can be alow-cost entry point for individuals gettinginto tunnel production, but they also can playa role in a whole farm plan, as they do atFull Hand Farm (page 10).7
HO-296-WChoose the Right High Tunnel for Your Farm3. What Seasons Do You Want to Grow In?When you think about investing in a high tunnel, youshould carefully examine a number of things about yourgoals and your operation. In this section, we describe anumber of important factors you should consider (andthe questions you should be asking) before you decide.When you want to grow will also influence the tunnelstyle. Some styles work better for warm-season cropsand others are better for winter growing. Choose astructure based on the season and crops you intendto emphasize.General QuestionsFor instance, if you’re unsure that you’ll have the timeand energy to continue production through the falland winter, then choose a structure and add-ons basedon summer crops. If you are already busy during thesummer growing season and are investing in a tunnelto extend the season, consider options that supportcool-season production.When choosing a high tunnel, you should start withsome basic questions — here are six questions youshould consider.1. What Kind of Site Do You Have Available?Consider if your site can accommodate a high tunnel andstill avoid shade, sloped ground, and water seepage thatwould compromise the success of your high tunnel.2. What Crops Do You Want to Grow?What you plan to grow will affect the type of tunnel thatwill work best for you.Quonset-style tunnels typically cost less, but they havevery low headroom over the edge beds unless they havetall sidewalls. Low headroom would limit crops that growtall (like trellised tomatoes). Plus, low headroom can beuncomfortable for a person who is using a walk-behindseeder or tiller near a sidewall.The taller sides of gothic-style structures provide moreuseable space along the sides for working and cropproduction. If you plan to grow tomatoes, some trellissystems require greater height for interior and perimeterrows. Gothic-style tunnels typically have higher roll upsides, which provide better airflow over tall crops.This moveable high tunnel is held in place by cables andturnbuckles connected to ground anchors. Peppers(foreground) and basil are thriving.Key Considerations for Summer ProductionIf you plan to use a high tunnel for summer production: Be sure the structure has good ventilation andpossibly fans Consider a design with a taller roof and that includesvents in the roof or end walls. The vents allow hot air toescape and draw cool air into the structure, which willimprove airflow through side vents and out vents inroof or end walls. Look for designs with large doors or end walls that youcan completely remove to improve ventilation Remember that it is more difficult to get enoughcross-ventilation with very wide tunnels that just haveroll-up sidesThese trellised tomatoes are just starting to ripen.The high tunnel provides extra heat for an early crop.8
HO-296-W Know that the open roll-up sides on ground-to-groundQuonset-style tunnels can expose some of crops torain and other adverse weatherThe USDA-Agricultural Resource Service offers free“Virtual Grower” software you can use to estimateheating costs for many types of structures. Visit areid 309.The growers have prepared the beds with peppers andtomatoes to capitalize on the heat trapped in theseQuonset-style high tunnels in early spring. The tunnelshave 90-degree vertical sidewalls that reach about4 feet before the arch begins.Key Considerations for Fall/Winter ProductionIf you plan to use a high tunnel for fall or winterproduction, then remember:This spring mix flanked by kale has enjoyed a row cover usedto trap extra heat and buffer against cold temperatures thatotherwise would damage the profitable crop. A low structure will heat up more quickly than ataller one4. Do You Receive High Winds or Heavy Snows?If you have high winds or heavy snows in your area,then remember: A long, narrow structure will cool down more quicklythan a short, wide structure Low-profile structures with strong frame materialsand extra bracing and anchoring withstand highwinds better A gothic shape will be warmer than a Quonset shape Wide tunnels are easier to manage and keep heatedfor winter production Poly curtain end walls are particularly vulnerable towind damage — growers reported more problemswith that type of end wall. Sturdier end wall designsfare better in Indiana, unless you have goodwindbreaks to protect your tunnel. Double poly covering
and vegetables. We developed this handbook based on a study of Indiana farmers’ use of high tunnels. We learned from more than 130 Hoosier farmers about their experience growing in high tunnels through mailed surveys and on-farm interviews. High tunnels are a new variation on greenhouses. Growers are using this low-cost technology to
Indiana State University 2 5.0% University of Southern Indiana 0 0.0% Indiana University-Bloomington 6 15.0% Indiana University-East 0 0.0% Indiana University-Kokomo 1 2.5% Indiana University-Northwest 0 0.0% Indiana University-Purdue University-Indianapolis 4 10.0% Indiana University-South Bend 0 0.0% Indiana University-Southeast 1 2.5%
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