News » 07.07.2025 - Elevating growth literally with a raised greenhouse
For DC Farms grower Michael del Ciancio, the decision to raise the greenhouse was based on long-term thinking. "Over the years, I received consistent positive feedback from other local farms that had completed similar upgrades," he explains. "As I continued to reinvest in this structure, with upgrades like vent racks and fans, it became clear that keeping current is crucial; falling too far behind can make it difficult to catch up, just like with your crop."
The project marked the last major renovation needed for that particular growing range. Coordinating the raise with the installation of white polycarbonate sidewalls also laid the groundwork for future lighting infrastructure. "It made sense to time it all together. This isn't just about today, it's about staying flexible for next projects," he adds.
The project started in November 2024, and was led by Dool International, a greenhouse construction company known for precision engineering and tailored solutions.
The engineering behind the raise
Raising the structure was no small feat. The greenhouse, originally with a leg height of 440 cm (about 14.4 feet), was extended by 170 cm (roughly 5.6 feet) to reach a total leg height of 610 cm (20 feet), covering an area of over 13,200 square meters.
"The design was straightforward, but the execution required precision," explains Vincent van den Dool, General Manager at Dool International. "We extended 290 columns (272 interior and 18 path-side) with galvanized box profile, using clamps and matching steel to maintain integrity. Every piece was reinforced to ensure stability, and all extensions were provided by the client."
Sidewalls, fronts, and existing cross shores were also raised and reinforced with additional galvanized elements. "The challenge is ensuring structural continuity while minimizing disruption," he mentions. "We coordinate closely with the grower's timeline and operational flow."
Real-world benefits in the growing zone
The new height has already begun to show its value in crop management. "The higher ceiling improves environmental control significantly, especially when managing humidity during certain seasons," Michael says. "It also opens up the option to raise the crop wire and harvest from elevated carts, which could reduce labor."
Importantly, the raise now allows for the possibility of a well-designed lighting plan, something that wasn't feasible before. "Previously, the lights were too close to the crop canopy," he notes. "This new height gives us room to optimize that system without compromising the plant environment."
Dealing with past and future structural issues
While most of the process followed plan, there were unavoidable challenges. "Over the years, a few posts had settled, which created low points in the rain gutters and led to water entry during heavy rains which is clearly not ideal," Michael admits. "During the renovation, each affected post was custom-cut and leveled. We also added extra cross-bracing where needed. Since then, water drainage has improved dramatically."
Vincent adds, "These kinds of legacy issues are common. Our role is to make sure the grower ends up with a structure that not only meets current needs but performs reliably over the next decade or more."
Materials and method
The choice of materials was deliberate. "We used galvanized 4" x 4" columns to match the existing structure," Michael explains. "Galvanized steel is ideal in greenhouse environments because it resists corrosion and handles high humidity really well."
To ensure the safety of the structure during the raise, each column was lifted with precision. "The process involved jacks at every post, plus chains, straps, air hoses, and pumps along the hallways. It was an impressive operation, especially considering it took place in a cold, windy winter."
Navigating exclusions and additions
Despite detailed planning, there were some additions prompted by exclusions in the contract, like HVAC systems, wall purlins, and rerouting waterlines and electrical systems. "That said, the contractor was transparent throughout," Michael mentions. "We were able to communicate effectively and keep the project on track."
Van den Dool notes that clear boundaries and client collaboration are key to project success. "We set expectations from the start and our exclusions are transparent. That way, there's no confusion when systems like HVAC or computer wiring need to be adapted."
For DC Farms, the investment in structural modernization is already proving worthwhile. With a higher ceiling and improved drainage, and future-ready infrastructure, the greenhouse is well-positioned for the next growing seasons ahead.
"It's about staying ready for what's next," Michael concludes. "The structure now supports the kind of growing and environmental control we'll need moving forward, and that peace of mind is worth every bit of the effort."
Source: www.floraldaily.com
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