Building a 100’ long Hoop House for under $300

By Darius Van d'Rhys (darius) August 13, 2008

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Why build a hoop house? As gardeners, we are always looking for ways to get a jump-start on spring planting, hoping we won’t have a late freeze. Mother Nature sometimes has her own ideas, and we are not always lucky. Finally we think it is safe and we plant out our precious seedlings. Unfortunately we are just as apt to catch the dreaded, unexpected weather forecast… and in sheer panic mode, we haul out all the extra sheets, blankets and anything else we can use to cover our plants.

With so many of us now growing a bigger garden to feed our families, we have passed the point of having enough blankets and sheets to protect all the plants in our larger gardens. Plus, some of us living in very short growing season areas are trying anything and everything to extend the season just a bit longer so our tomatoes ripen and the peppers and melons grow large enough to eat.

A late frost in spring (or an early fall frost) affects market gardeners too… local gardeners who depend on their income from farmer’s markets. They especially want to protect their crops and start their growing season early for all the customers who wait anxiously for the first real tomato since last year. There is a segment of gardeners popping up who want to do what Eliot Coleman* has been doing in Maine for 20 years (he wrote a book about it)…  Four Season Harvest. To extend growing and harvesting to four seasons in northern climates like he does, you would need to read Eliot Coleman’s book for details, but I believe he uses a moveable hoop house dragged over his garden beds when it starts to get cold.

It would be lovely if we all had the money to build a 100 foot x 30 foot high-tunnel greenhouse/season-extender, with fancy roll-up sides for summer ventilation. Better yet, a heated greenhouse! However, few of us can afford to do that in today’s economy. So why not build an inexpensive hoop house?

In mid-March this year (2008) I had the opportunity to participate in building a low-cost 100’ x 13’ hoop house with some volunteers at Appalachian Sustainable Development in Abingdon, VA. This hoop house is primarily designed to extend the growing season here (zones 5-6) by a month or so on each end. However, it is easily adapted to withstand colder temperatures, which I will address later in this article.

Anthony Flaccavento is the Executive Director of ASD, and a market grower. A bunch of us assembled on a March Sunday afternoon at his farm… with dark threatening clouds and brisk cold winds assaulting us out in the open field. Nevertheless, about a dozen of us erected this hoop house in less than 2 hours. Since this was a low budget project, it could only be kept within the budget with volunteer help.

Tony had prepared a section of the field with beds earlier, since the interior width of this hoop house (13’) wouldn’t allow his large tractor anywhere inside except down the middle. He had prepared 3 rows ready for planting, covered with black plastic to help warm the soil. The first thing we did was measure 100’ and run a string line down each long side so we had a straight line. Then the men, using a sledge, hammered in the 3’ fiberglass pipes (ground pipes) along the line at 10’ intervals, driving the pipes roughly halfway into the dirt. These pipes would hold our hoops so they were canted slightly inward, along the imaginary line the hoops would follow. The fiberglass pipes had originally been manufactured for ax or sledgehammer handles, then became surplus. Tony bought them for 50¢ each and we used a total of 20.

Ground Pole fits into PVC pipe	Ground Pole in bell-end of PVC pipe	PVC over ground pole in place

Once the pipes were driven on place, we began placing the hoops. They were 20’ long, 1-1/4” PVC pipes with one bell end. We slipped one end over a pipe and the PVC swung wildly in the air like those foam bats kids use in swimming pools. It was quite comical to see a dozen or so adults, most of us past our prime, trying to control 20 feet of PVC swaying crazily above our heads in strong winds. Finally though, we were able to capture the loose ends and slip the bell end over the opposing pipe.  

Next was placing the frost cloth aka row cover. The fabric was unrolled down the 100’ length, with an extra 10’ or so at each end (to close off the ends). Then several people stationed themselves along each long side and started dragging the fabric across the top of the hoops and down the far side. Trust me, this is not a 2-person job. In calm weather, I’d suggest at least 4 sets of hands for the job. While most of us kept a firm grip on the fabric, a few men went down the first long side and anchored about a foot or more of fabric under a mound of dirt running the entire length.

20' PVC pipes in the wind	Hoops all anchored	Fabric (Row Cover) being stretched & tightened

After that, we all pulled the fabric tight while the dirt was mounded down the second long side. The far end “wall” was pulled tight and fastened in the same manner. The near end was merely pulled into a flap for access that Tony taped together. All that remained was to go inside (thankfully out of the cold wind!) and align the hoops somewhat parallel. These hoops could have been fastened together via a long series of PVC down the center but Tony hadn’t done that in his previous hoop house and it had worked just fine for him. He also said that when it became hot in summer, he would remove the fabric (but not the hoops) and store it until fall, when he would reapply it over the hoops to gain some extra fall growing time.

Costs:

PVC (20’ x 1-1/4”)  $12.29 each from a plumbing supply. Needed 10. Total $122.90. Fiberglass ground posts (handles) 3’ long, 50¢ each, needed 20, Total $10.00. Row cover 20’ x 120’, 1 oz*., 120’, Berry Hill $114.00 includes shipping although there is an advertised $150 minimum order. You might look for off-season specials. Total Cost: $282.90

*Note: the weight is per square yard of row cover fabric.

Options:

Berry Hill’s 1 oz. row cover (like we used) transmits 70% of the available light and protects down to 24ºF. To protect from cold a bit more, they offer Medium Row Cover, 1.2 oz. with 60% light transmission, good down to 22ºF. Or you could go for Heavy Row Cover, 1.5 oz, 50% light transmission, good to 20ºF.

I don’t really need a 100’ hoop house, but a 30’-50’ one would be very useful to extend my growing season. Using this type of construction, it can be affordable! Perhaps my neighbors and I can split the minimum fabric cost and share the labor.

*Eliot Coleman’s Four Season Farm http://www.fourseasonfarm.com/  See also: http://www.fourseasonfarm.com/main/articles/articles/mother2.html

All Photos are by the Author

About Darius Van d'Rhys   I have a 'growing my own food' obsession that comes fromf my overlapping interests in cooking, nutrition and gardening. I am also a "teacher", a writer, a builder… and a craftsperson and... and… and many other things, LOL. In fact, I guess I am a generalist, and a Seeker. I live in the southern Appalachian Mountains on a hillside with a creek in front, and drive a 15 year old truck I lovingly call “My Farmer’s Ferrari.”

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Subject: Neat

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Posted by phicks (from Lakeland, FL) on August 13, 2008 at 5:37 PM:

I think ill put one up Great Article Paul

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Posted by darius (from Marion, VA) on August 13, 2008 at 5:54 PM:

Thanks, Paul!

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Posted by ccove (from West Islip, NY) on August 13, 2008 at 11:29 AM:

Although I don't need one, i will file the info away just in case. Great article.

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Posted by darius (from Marion, VA) on August 13, 2008 at 12:03 PM:

Thanks! Two years ago I wouldn't have thought I might need one either, and now I'm serious about a shorter version for my garden.

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Posted by Syrumani (from San Antonio, TX) on August 13, 2008 at 2:26 PM:

I wonder if this could be adapted . . . I'm not worried about winter . . . it's summer I have an issue with! I have absolutely no shade in any part of my yard that I can use for gardening . . . full sun all the way around! I could do the hoop house (not 100', maybe 30'), and use some sort of shade cloth instead - and not close at the ends. Hmm . . .

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Posted by crimsontsavo (from Crossville, TN) on August 13, 2008 at 1:42 AM:

I am already thinking of ways to modify this for my own use.
Thank you so much!!

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Posted by Dutchlady1 (from Naples, FL) on August 13, 2008 at 6:42 AM:

Very impressive. Good article with clear descriptions.
As long as I will stay in SW Florida I will never need this... but good to know anyway!

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Posted by Bubba_MoCity (from Missouri City, TX) on August 13, 2008 at 8:39 AM:

Outstanding article, as usual.

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Posted by gardenwife (from Newark, OH) on August 13, 2008 at 8:40 AM:

Great article, Darius. You make this look doable. I could see doing a very small version alongside our shed sometime.

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Posted by chatnoir (from Downers Grove, IL) on August 13, 2008 at 9:23 AM:

Thanks Darius. This gives me the blueprint to do my own next spring.

I had a disappointing early vegetable season and am determined to have better results in the future. This is exactly what I was thinking about doing.

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Posted by crimsontsavo (from Crossville, TN) on August 13, 2008 at 9:23 AM:

beats GW. SMALL? NOoOooo go BIG! LOL

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Posted by Sundownr (from (Bev) Wytheville, VA) on August 13, 2008 at 10:56 AM:

Good article Darius! I'll have to do some calculating on my specific needs. My garden is so small that I might be able to make a little (collapsible) green house using the same materials.

Between all the hands available here, we may be able to get all of ours done in a weekend, if not a long day! Ooooh, sounds like a party, err..., a barn-raisin', hehe!

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Posted by gardenwife (from Newark, OH) on August 13, 2008 at 1:15 PM:

Tsavo, our whole lot is only 40x140'! And it only gets sun in a small portion of that! LOL

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Posted by darius (from Marion, VA) on August 13, 2008 at 1:46 PM:

I'm glad the article has sparked some ideas for all of you! Thanks. :)

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Posted by crimsontsavo (from Crossville, TN) on August 13, 2008 at 4:10 PM:

Ahhh so you'll have ta SMOOSHIFY the greenhouse hehe.

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 4:23 PM:

I had always wondered if something like this was possible using pvc pipe. Thanks for providing such clear instructions. I would never have come up with the very creative use of the recycled ax handles. I'm wondering if rebar steel in 3 ft lengths would also work (though it would be quite a bit more expensive) or smaller diameter pvc substituted for the ax handles?

Our winter temperatures here get down to only about 28 F for several hours on our coldest nights -- just enough to kill off some tropicals or freeze them back to the ground. I was able to bring my plumeria through this winter with no damage by building a frame (using wood) and pulling 8 mil translucent plastic (available at big box hardware stores) over the frame. That was sufficient to make the difference between the plumeria freezing or flourishing, and I'm happy to report, they did the latter!

Jeremy

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Posted by darius (from Marion, VA) on August 13, 2008 at 4:39 PM:

Jeremy, some years ago I built a 'summer house'... basically a screened enclosure with a top tarp over the frame of PVC. I didn't use large enough PVC and it soon collapsed. However I wasn't making a plant/garden enclosure, just an outside "room" free of mosquitoes so we could escape the heat of the non-AC house.

I found the fiberglass handles to be very strong The plastics company that had them also has a large outside area full of many other sizes and shapes of fiberglass, even hollow 2x2 and 4x4 tubes. I brought home several samples to play with when it becomes too cold to garden here. Who knows what inspiration will alight!

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 4:52 PM:

Thanks, darius, for the input! One year, I was able to just use one of the cheap aluminum pole garden tents and draped the sides with heavy mil plastic. That worked well for that winter, but I wanted something a little more permanent. I called the tent structure my "Shabby Sheik Harem Tent." Not so pretty to look at, but it worked! LOL

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 4:58 PM:

Here's the inside of the tent. I think I ended up holding the plastic on the outside with the over-sized hinged paper clips. Staples wouldn't hold the plastic together when the winds hit.

Jeremy

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Posted by darius (from Marion, VA) on August 13, 2008 at 4:59 PM:

Hey... it worked!... seems like I remember when you posted it, or something similar. My Dad lived in Jax, as did I several times when we were stationed there. Oldest brother lives out near Mayport and I know your weather well.

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 5:03 PM:

How great that you were once here in Jax! You probably know the beach at Hannah Park if you were stationed at Mayport with your family. It is still about the only natural beach area left in the state of Florida. Everything else is a stretch of sand by the ocean with high rises, hotels, and motels as close as possible to the surf line. Yep, our winters are generally fairly mild, except when one of those freakish cold spells hit when it can go down to about 14 F. We even had snow enough to accumulate for a few hours sometime back in the 1980's.

Jeremy

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Posted by tigerlily123 (from Raleigh, NC) on August 13, 2008 at 8:20 PM:

It looks like the hoops are moving/slanting a bit towards the ends some-if it rains alot, does the rain puddle in the middle, on top and pull the plastic inward?
Also-I am always worried about the weight of snow on my grhouse-how does this one handle snow? I would love to figure out some kind of cold frame my self! Thanks for the article!!

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Posted by darius (from Marion, VA) on August 13, 2008 at 9:26 PM:

tigerlily, this one wasn't designed for year 'round use... just a season extender.

I think that for snow load (or heavy rain) I'd install cross members evenly spaced between (and connecting) all the hoops, at least at the top center. I'll have some experience after I get mine built next year. We do get some snow here, but not much in the 2 winters I've lived here. I don't expect that to always be the case...

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 9:35 PM:

I've done quite a lot of "inventing" with pvc pipe. There is a pvc connector you don't see in use often, but it is a cross shape that allows four pvc pipes to connect together at one junction. That would be very useful for adding additional pvc pipes for reinforcement, but then you have to cut and glue the connectors to the pipe which makes the construction a lot more difficult.

Jeremy

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Posted by crimsontsavo (from Crossville, TN) on August 13, 2008 at 9:47 PM:

I helped my boss build a permanent greenhouse for bonsai outta plastic and PVC, it was awesome and larrgggeee. Pretty easy too, you should do another article darius, one like this but "permanent". You write so that it sounds easy and attainable!

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Posted by darius (from Marion, VA) on August 13, 2008 at 9:52 PM:

Jocie, Thanks. I will do more documentation when I build mine. I hadn't any thought of writing an article when we built this one back in March!

Jeremy, yes I am familiar with those connections and have glued several of them in various projects!

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 9:57 PM:

Aren't they great! They add a whole new dimension for building with pvc. I have found from near dismal experience though that pvc glue does not hold up well under even a little stress. The connections will usually pop if you go much past vertical or horizontal in running the pipe (true of pvc plumbing, too, from someone that has had to crawl under the house more than once to fix a connection that popped due to stress on the connection because I thought I could get away with a bit of an angle in the pipe ---- WRONG! LOL).

Jeremy

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Posted by darius (from Marion, VA) on August 13, 2008 at 10:33 PM:

Jeremy, try PEX when you need some leeway...

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Posted by JaxFlaGardener (from Jacksonville, FL) on August 13, 2008 at 11:56 PM:

Thanks, darius. I'll look up PEX. I've never heard of it.

Jeremy

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Posted by Sonoita (from Sonoita, AZ) on August 14, 2008 at 11:19 AM:

The timing of this article was perfect. I have been thinking about this very idea for 2 unrelated projects; an aviary and hay storage. I am off to buy the supplies now!

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Posted by darius (from Marion, VA) on August 14, 2008 at 1:00 PM:

Hey, Sonalita... what great ideas for adapting this method! Be sure and take pictures and post them, okay?

edited for typo

This message was edited Aug 14, 2008 1:01 PM

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Posted by Sonoita (from Sonoita, AZ) on August 14, 2008 at 4:56 PM:

Sure

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