figure 23. screenshot annex 3.a 3d 20 cows module · 3.b 3d 80 cows module steel feed fence &...
TRANSCRIPT
page | 74
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 60
ANNEX 3: 3D PRESENTATIONS AND TECHNICAL DESIGN DRAWINGS
Three dimensional presentations of the 20 and 80 cow house modules are available in Google Sketchup format. These are accessible through the drop box and in pdfs that can be downloaded from the SNV Kenya website. In the drop box the Folder name is: “Annex 3: 3D Presentation”. The File names are: 3.a 3D 20 Cows module 3.b 3D 80 Cows module steel feed fence & stall dividers 3.c 3D 80 Cows module wood feed fence & stall dividers
Screenshot Annex 3.a 3D 20 Cows module
Figure 23. Screenshot Annex 3.c 3D 80 Cows module steel feed rail.
This Annex includes:
a) 3D presentations of the 20 and 80 cow house modulesb) Technical Design Drawings (TDs) of the 4 cow house modulesc) Technical Design Drawings (TDs) of biogas installations Biogas Energy calculation example diesel to biogas Biogas Energy calculation example Biogas BOQ example
Screenshot Annex 3.c 3D 80 Cows module steel feed rail.
Figure 23. Screenshot Annex 3.a 3D 20 Cows module
page | 76
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
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page | 77
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
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61
AN
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the
drop
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the
SNV
Ken
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page | 86
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
Pow
er
35 k
W
6 hr
s/da
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Ener
gy
210
kWh/
day
Conv
ersio
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ctor
kW
h to
MJ
3.6
Net
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31.1
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Biog
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lcul
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ampl
e D
iese
l to
Biog
as
page | 87
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
Power installed/required 5 [kW]
On-time 6 [hrs]
Energy produced 108 [MJ]
Calori�c value biogas 23 [MJ/m3]
Biogas requirement 4.70 [m3] net
E�ciency conversion 25%
Biogas requirement 18.78 [m3] gross
Speci�c biogas production dung 0.04 m3/kg
Dung requirement 470 kg
HRT 40
Digester volume 37.57 [m3]
Biogas Energy Calculation Example
page | 88
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
Modified Camartec domestic biogas installation 13m3
Bill of Quantities and pricing
qty unit rate household Company Total
1 General bulk materials
1.1 Sand 5.00 [m3] 900 4,500 4,500 1.2 Gravel 4.00 [m3] 54 216 216 1.3 Stones 3.00 [m3] 900 2,700 2,700 1.4 Cement 28 [bags 50 kg] 390 10,920 10,920 1.5 Bricks 1,550 [piece] 9 13,950 13,950 1.6 Lime 5 [bags 50 kg] 420 2,100 2,100 1.7 Acrylic emulsion paint 2 [ltr] 210 420 420 1.8 Chicken wire (1 mtr wide) 75 [mtr] 90 6,750 6,750 1.9 Welded / square mesh 1 [pcs] - - 1.10 Round bar 2 [length] 390 780 780 1.11 PVC pipe 4" 1 [length] 420 420 420 1.12 HDPE 3.4"class 6 100 [mtr] 240 24,000 24,000
2 Biogas materials
2.1 Dome pipe 1 [pcs] 600 600 600 2.2 Single biogas stove 1 [pcs] 900 900 900 2.3 Double biogas stove [pcs] - - 2.4 Biogas lamp 1 [pcs] - - - 2.5 Main gas valve 1 [pcs] 360 360 360 2.6 Stove tap [pcs] 270 - - 2.7 Lamp tap 1 [pcs] - - - 2.8 Water trap 1 [pcs] 60 60 60 2.9 Pressure meter 1 [pcs] 60 60 60 2.10 Fitting material & sundry 1 [set price] 300 300 300 2.11 Repair & maintenace set 1 [set price] 180 180 180
3 Labour
3.1 Unskilled labour 24 [persondays] 4 - 3.2 Skilled labour 12 [persondays] 8 - 3.3 Artiasan 2 [persondays] 10 -
Euro = ZWM 8.24Total costs per category Euro
Buidling material 21,366 45,390 66,756 8,101 Biogas materials - 2,460 2,460 299 Company fees 19,140 19,140 2,323
Grand total 66,990 88,356 10,723
Total costs per category productive biogas
Buidling material 66,756 750 Biogas materials 8,640
Company fees 40% 30,158
Grand total 105,554
40% of comp share in bldg materials
page | 89
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
Modified Camartec domestic biogas installation
Bill of Quantities and pricing
qty unit rate household company Total
1 General bulk materials
1.1 Sand 2.2 [m3] 900 1,980 1,9801.2 Gravel 1.2 [m3] 54 65 651.3 Stones 1 [m3] 900 900 9001.4 Cement 12 [bags 50 kg] 390 4,680 4,6801.5 Bricks 700 [piece] 9 6,300 6,3001.6 Lime 2 [bags 50 kg] 420 840 8401.7 Acrylic emulsion paint 1 [ltr] 210 210 2101.8 Chicken wire (1 mtr wide) 30 [mtr] 90 2,700 2,7001.9 Welded / square mesh 1 [pcs] - -1.10 Round bar 1 [length] 390 390 3901.11 PVC pipe 4" 1 [length] 420 420 4201.12 HDPE 3.4"class 6 50 [mtr] 240 12,000 12,000
2 Biogas materials
2.1 Dome pipe 1 [pcs] 600 600 6002.2 Single biogas stove 1 [pcs] 900 900 9002.3 Double biogas stove [pcs] - -2.4 Biogas lamp 1 [pcs] - - -2.5 Main gas valve 1 [pcs] 360 360 3602.6 Stove tap 1 [pcs] 270 270 2702.7 Lamp tap 1 [pcs] - - -2.8 Water trap 1 [pcs] 60 60 602.9 Pressure meter 1 [pcs] 60 60 602.10 Fitting material & sundry 1 [set price] 300 300 3002.11 Repair & maintenace set 1 [set price] 180 180 180
3 Labour
3.1 Unskilled labour 12 [persondays] 4 PM PM -3.2 Skilled labour 6 [persondays] 8 PM PM -3.3 Artiasan 2 [persondays] 10 PM PM -
Total costs per category
Buidling material 5,645 24,840 30,485 Biogas materials - 2,730 2,730 Company fees 40% of comp share in bldg materials 11,028 11,028
Grand total 38,598 44,243
4m3Modified Camartec domestic biogas installation
Bill of Quantities and pricing
qty unit rate household company Total
1 General bulk materials
1.1 Sand 2.2 [m3] 900 1,980 1,9801.2 Gravel 1.2 [m3] 54 65 651.3 Stones 1 [m3] 900 900 9001.4 Cement 12 [bags 50 kg] 390 4,680 4,6801.5 Bricks 700 [piece] 9 6,300 6,3001.6 Lime 2 [bags 50 kg] 420 840 8401.7 Acrylic emulsion paint 1 [ltr] 210 210 2101.8 Chicken wire (1 mtr wide) 30 [mtr] 90 2,700 2,7001.9 Welded / square mesh 1 [pcs] - -1.10 Round bar 1 [length] 390 390 3901.11 PVC pipe 4" 1 [length] 420 420 4201.12 HDPE 3.4"class 6 50 [mtr] 240 12,000 12,000
2 Biogas materials
2.1 Dome pipe 1 [pcs] 600 600 6002.2 Single biogas stove 1 [pcs] 900 900 9002.3 Double biogas stove [pcs] - -2.4 Biogas lamp 1 [pcs] - - -2.5 Main gas valve 1 [pcs] 360 360 3602.6 Stove tap 1 [pcs] 270 270 2702.7 Lamp tap 1 [pcs] - - -2.8 Water trap 1 [pcs] 60 60 602.9 Pressure meter 1 [pcs] 60 60 602.10 Fitting material & sundry 1 [set price] 300 300 3002.11 Repair & maintenace set 1 [set price] 180 180 180
3 Labour
3.1 Unskilled labour 12 [persondays] 4 PM PM -3.2 Skilled labour 6 [persondays] 8 PM PM -3.3 Artiasan 2 [persondays] 10 PM PM -
Total costs per category
Buidling material 5,645 24,840 30,485 Biogas materials - 2,730 2,730 Company fees 40% of comp share in bldg materials 11,028 11,028
Grand total 38,598 44,243
4m3
page | 91
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
Modified Camartec domestic biogas installation
Bill of Quantities and pricing
qty unit rate household company Programme
1 General bulk materials
1.1 Sand 4.00 [m3] 900 3,600 3,6001.2 Gravel 3.00 [m3] 54 162 1621.3 Stones 2.00 [m3] 900 1,800 1,8001.4 Cement 20 [bags 50 kg] 390 7,800 7,8001.5 Bricks 1,150 [piece] 9 10,350 10,3501.6 Lime 4 [bags 50 kg] 420 1,680 1,6801.7 Acrylic emulsion paint 2 [ltr] 210 420 4201.8 Chicken wire (1 mtr wide) 55 [mtr] 90 4,950 4,9501.9 Welded / square mesh 1 [pcs] - -1.10 Round bar 2 [length] 390 780 7801.11 PVC pipe 4" 1 [length] 420 420 4201.12 HDPE 3.4"class 6 100 [mtr] 240 24,000 24,000
2 Biogas materials
2.1 Dome pipe 1 [pcs] 600 600 6002.2 Single biogas stove [pcs] 900 - -2.3 Double biogas stove 1 [pcs] - -2.4 Biogas lamp 1 [pcs] - - -2.5 Main gas valve 1 [pcs] 360 360 3602.6 Stove tap [pcs] 270 - -2.7 Lamp tap 1 [pcs] - - -2.8 Water trap 1 [pcs] 60 60 602.9 Pressure meter 1 [pcs] 60 60 602.10 Fitting material & sundry 1 [set price] 300 300 3002.11 Repair & maintenace set 1 [set price] 180 180 180
3 Labour
3.1 Unskilled labour 20 [persondays] 4 PM PM -3.2 Skilled labour 10 [persondays] 8 PM PM -3.3 Artiasan 2 [persondays] 10 PM PM -
Total costs per category
Buidling material 15,912 40,050 55,962 Biogas materials - 1,560 1,560 Company fees 40% of comp share in bldg materials 16,644 16,644
Grand total 58,254 74,166
9m3
757520
170
Modified Camartec domestic biogas installation
Bill of Quantities and pricing
qty unit rate household company Programme
1 General bulk materials
1.1 Sand 4.00 [m3] 900 3,600 3,6001.2 Gravel 3.00 [m3] 54 162 1621.3 Stones 2.00 [m3] 900 1,800 1,8001.4 Cement 20 [bags 50 kg] 390 7,800 7,8001.5 Bricks 1,150 [piece] 9 10,350 10,3501.6 Lime 4 [bags 50 kg] 420 1,680 1,6801.7 Acrylic emulsion paint 2 [ltr] 210 420 4201.8 Chicken wire (1 mtr wide) 55 [mtr] 90 4,950 4,9501.9 Welded / square mesh 1 [pcs] - -1.10 Round bar 2 [length] 390 780 7801.11 PVC pipe 4" 1 [length] 420 420 4201.12 HDPE 3.4"class 6 100 [mtr] 240 24,000 24,000
2 Biogas materials
2.1 Dome pipe 1 [pcs] 600 600 6002.2 Single biogas stove [pcs] 900 - -2.3 Double biogas stove 1 [pcs] - -2.4 Biogas lamp 1 [pcs] - - -2.5 Main gas valve 1 [pcs] 360 360 3602.6 Stove tap [pcs] 270 - -2.7 Lamp tap 1 [pcs] - - -2.8 Water trap 1 [pcs] 60 60 602.9 Pressure meter 1 [pcs] 60 60 602.10 Fitting material & sundry 1 [set price] 300 300 3002.11 Repair & maintenace set 1 [set price] 180 180 180
3 Labour
3.1 Unskilled labour 20 [persondays] 4 PM PM -3.2 Skilled labour 10 [persondays] 8 PM PM -3.3 Artiasan 2 [persondays] 10 PM PM -
Total costs per category
Buidling material 15,912 40,050 55,962 Biogas materials - 1,560 1,560 Company fees 40% of comp share in bldg materials 16,644 16,644
Grand total 58,254 74,166
9m3
757520
170
page | 92
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
Page 1
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08 2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09 2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16 3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17 3.2.2. Manure Storage/Waste Water Storage ................................................................................... 18 3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19 3.2.4. Treatment/Handling of Cows ................................................................................................. 19 3.2.5. Milk Storage ........................................................................................................................... 19 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20 3.2.7. Special Needs Cows ................................................................................................................ 21 3.2.8. Grouping of Young Stock ....................................................................................................... 21 3.2.9. Water Supply .......................................................................................................................... 21 3.2.10. Essential Points to Consider for each Module ........................................................................ 22 3.2.11. Management to Increase Number of Cows ............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27 3.4.3. Week-planning ........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34 4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34 4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37 4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39 4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
dens
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20,0
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60,0
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[pcs
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2.5
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[pcs
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000
35,0
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2.6
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[pcs
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30,0
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2.7
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50
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mai
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[set
pric
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3.1
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[ls/d
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1000
016
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3.2
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/day
]25
000
30,0
00
15
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3.3
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isan
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[ls/d
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5000
080
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ervi
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& fe
esU
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Uni
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4.1
Con
stru
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600
700
800
4.2
Ann
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ee[l
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