Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.

com
Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com

CONTENTS
ANNEX 3: 3D PRESENTATIONS AND TECHNICAL DESIGN DRAWINGS

Three dimensional
This Annex includes:presentations of the 20 and 80 cow house modules are available in Google
LIST
SketchupOF TABLES .........................................................................................................................................
format. These are accessible through the drop box and in pdfs that can be downloaded 03
a) the
from 3D
ABBREVIATIONS presentations
SNV of the 20 and 80 cow house modules
Kenya.......................................................................................................................................
website. 04
b) Technical Design Drawings (TDs) of the 4 cow house modules
PREAMBLE
c) the drop
In box................................................................................................................................................
Technical theDesign
FolderDrawings
name is: “Annex (TDs) of 3: biogas installations
3D Presentation”. 05

The
CHAPTERFileBiogas
names Energy
are: calculation example
1: INTRODUCTION diesel to biogas
.............................................................................................................. 07
3.a 3D Biogas Energy
20 Cows module calculation example
CHAPTER

3.b 3D Biogas2: STRUCTURES,
80 Cows BOQmoduleexample steel feed CONSIDERATIONS
fence & stall dividers AND IMPLICATIONS ................................. 08
3.c
2.1 3DA80 Cows
CCESS TOmodule
PUBLIC U wood
TILITIESfeed fence & stall dividers
............................................................................................................... 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.
Screenshot Special
Annex Needs
3.aAnnex
Figure 23. Screenshot 3D 203.a Cows
Cows3D................................................................................................................
20module
Cows module 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
Screenshot
Screenshot
4.5 MANURE Annex
Annex 3.c3D
3.c 3D80
PRODUCTION 80Cows
Cows
ANDmoduleSmodule
TORAGE steelsteel
feedfeedrail. rail.
............................................................................................... 39
4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40
4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41

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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.c 3D 80 Cows module steel feed rail & wooden stall dividers

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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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

Figure 24. Annex 3.e TD Farm layout

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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945 kg dung
CONTENTS

37.8 m3/day
20 MJ/m3

0.04 m3/kg

31.1 m3
82%
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

Specific biogas production cow dung

2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09
2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10

Biogas consumption generator

Biogas Energy Calculation Example Diesel to Biogas

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

Biogas storage volume

Calorific value biogas

Feeding requirement

Biogas storage factor

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
210 kWh/day

0.9 kg/ltrm3

18 ltrs/day
756 MJ/day

2520 MJ/day
6 hrs/day

3.2.8. Grouping of Young Stock ....................................................................................................... 21

41.4 MJ/ltr
46 MJ/kg

3.2.9. Water Supply.......................................................................................................................... 21

35 kW

3.2.10. Essential Points to Consider for each Module ........................................................................ 22

3.6

30%

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
Net electric energy production

4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34

Diesel consumption generator

4.1.2. Biogas Digester ....................................................................................................................... 35

Conversion factor kWh to MJ

Gross energy consumption

Efficiency diesel generator

4.2 HERD DEVELOPMENT ........................................................................................................................... 35

4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36
Calorific value diesel

Calorific value diesel

4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37

4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39
4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40
Density diesel

4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41

Energy
Power

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CONTENTS

Biogas Energy Calculation Example

LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
Power................................................................................................................................................
PREAMBLE installed/required 5 [kW] 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
CHAPTEROn-time 6 [hrs]
2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
Energy produced 108 [MJ]
2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09
2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10
2.4 EXAMPLE LAYOUT
Calorific OF MODULAR DAIRY COW HOUSE ......................................................................
value biogas 23 [MJ/m3] 12
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13
2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
Biogas requirement 4.70 [m3] net
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM
Efficiency DEVELOPMENT ........................................................................................................
conversion 25% 16
3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17
3.2.2.BiogasManure
requirement 18.78 [m3] gross
Storage/Waste Water Storage................................................................................... 18
3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19
3.2.4.Specific
Treatment/Handling
biogas production dung of Cows .................................................................................................
0.04 m3/kg 19
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20
3.2.7.DungSpecial
requirement 470 kg
Needs Cows ................................................................................................................ 21
3.2.8. Grouping of Young Stock ....................................................................................................... 21
3.2.9.HRT Water Supply..........................................................................................................................
40 21
3.2.10. Essential Points to Consider for each Module ........................................................................ 22
3.2.11. Management to Increase Number of Cows............................................................................. 22
3.3 Digester
DESIGN volume 37.57 [m3]
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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CONTENTS
Modified Camartec domestic biogas installation 13m3

Bill of Quantities and pricing

qty unit rate household Company Total

LIST OF TABLES ......................................................................................................................................... 03
1 General bulk materials
ABBREVIATIONS ....................................................................................................................................... 04
1.1 Sand 5.00 [m3] 900 4,500 4,500
1.2 Gravel 4.00 [m3] 54 216 216
PREAMBLE
1.3 Stones
................................................................................................................................................
3.00 [m ] 3
900 2,700 2,700
05
1.4 Cement 28 [bags 50 kg] 390 10,920 10,920
CHAPTER
1.5 Bricks 1: INTRODUCTION 1,550 [piece] ..............................................................................................................
9 13,950 13,950 07
1.6 Lime 5 [bags 50 kg] 420 2,100 2,100
CHAPTER
1.7 2: STRUCTURES,
Acrylic emulsion paint 2 [ltr]CONSIDERATIONS 210AND IMPLICATIONS .................................
420 420 08
1.8 Chicken wire (1 mtr wide) 75 [mtr] 90 6,750 6,750
2.1 Welded
1.9 ACCESS
/ squareTO
mesh PUBLIC UTILITIES 1 [pcs] ...............................................................................................................
- - 08
1.10 Round bar 2 [length] 390 780 780
2.2 D AIRY
1.11 PVC pipe 4" F ARM L AY - OUT P RINCIPLES
1 [length] .....................................................................................................
420 420 420 09
2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10
1.12 HDPE 3.4"class 6 100 [mtr] 240 24,000 24,000

2.4
2 EXAMPLE
Biogas materials LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13
2.1 Dome pipe 1 [pcs] 600 600 600
2.6
2.2 TYPICAL
Single FARM LAYOUT1AND
biogas stove [pcs] FENCING ..............................................................................................
900 900 900 15
2.3 Double biogas stove [pcs] - -
CHAPTER
2.4 Biogas lamp 3: CATTLE BARN MODULAR APPROACH
1 [pcs] - AND OPERATIONS- ............................ - 16
2.5 Main gas valve 1 [pcs] 360 360 360
3.1 Stove
2.6 ODULAR FARM DEVELOPMENT
Mtap [pcs] ........................................................................................................
270 - - 16
2.7 Lamp tap 1 [pcs] - - -
3.2 Water
2.8 Mtrap
ANAGEMENT OF MODULAR 1 [pcs] FARM DEVELOPMENT 60 PLAN ..............................................................
60 60 17
3.2.1.
2.9 Pressure meter Capacity of the Milking Parlour .............................................................................................
1 [pcs] 60 60 60 17
2.10 Fitting material & sundry 1 [set price] 300 300 300
3.2.2.
2.11 Repair Manure
& maintenace set Storage/Waste
1 [set price] Water Storage ...................................................................................
180 180 180 18
3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19
3 Labour
3.2.4. Treatment/Handling of Cows ................................................................................................. 19
3.1 3.2.5.labourMilk Storage ...........................................................................................................................
Unskilled 24 [persondays] 4 - 19
3.2 Skilled labour 12 [persondays] 8 -
3.3 3.2.6.
Artiasan Cows: Milk Production
2 [persondays]and Dimensions ...............................................................................
10 - 20
3.2.7. Special Needs Cows ................................................................................................................ 21
3.2.8. Grouping of Young Stock ....................................................................................................... 21
3.2.9.
Euro = ZWM Water Supply .......................................................................................................................... 21
8.24
Total costs per category Euro
3.2.10. Essential Points to Consider for each Module ........................................................................ 22
3.2.11.
Buidling Management to Increase Number of Cows.............................................................................
material 21,366 45,390 66,756 22 8,101
Biogas materials - 2,460 2,460 299
3.3 DESIGN
Company feesOF FLOORS AND C of comp.....................................................................................................
UBICLES
40% share in bldg materials 19,140 19,140 23 2,323
3.4 FEED FENCE ........................................................................................................................................... 26
Grand total 66,990 88,356 10,723
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27
3.4.3.
Total Week-planning
costs per category ........................................................................................................................ 28
productive biogas
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29
Buidling material 66,756
750 3.6 TREATMENT
Biogas materials AND HANDLING D AIRY CATTLE .................................................................................... 32
8,640
Company fees 40% 30,158
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
Grand total 105,554
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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CONTENTS

Modified Camartec domestic biogas installation

4m3
Bill of Quantities and pricing
LIST OF TABLES ......................................................................................................................................... 03
qty unit rate household company Total
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
1 General bulk materials
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
1.1 Sand CHAPTER 2: STRUCTURES, CONSIDERATIONS
2.2 [m3] AND900 IMPLICATIONS 1,980 ................................. 08 1,980
1.2 Gravel 1.2 [m3] 54 65 65
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
1.3 Stones 1 [m3] 900 900 900
1.4 Cement 2.2 DAIRY FARM LAY-OUT PRINCIPLES12 [bags .....................................................................................................
50 kg] 390 4,680 09
4,680
1.5 Bricks 2.3 DAIRY COW HOUSE DESIGN 700 ................................................................................................................
[piece] 9 6,300 10
6,300
1.6 Lime 2.4 EXAMPLE LAYOUT OF MODULAR DAIRY
2 [bags 50Ckg]OW HOUSE 420......................................................................
840 12840
1.7 Acrylic2.5 SUPPORT
emulsion paint FUNCTIONS AND PHYSICAL
1 [ltr] STRUCTURES ...........................................................................
210 210 13210
1.8 Chicken wire (1 mtr wide) 30 [mtr] 90 2,700
2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15 2,700
1.9 Welded / square mesh 1 [pcs] - -
1.10 RoundCHAPTER
bar 3: CATTLE BARN MODULAR
1 [length] APPROACH 390 AND OPERATIONS ............................ 390 16390
1.11 PVC pipe 4" 1 [length] 420 420 420
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16
1.12 HDPE 3.4"class 6 50 [mtr] 240 12,000 12,000
3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17
2 Biogas materials
3.2.2. Manure Storage/Waste Water Storage................................................................................... 18
3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19
2.1 Dome pipe 1 [pcs] 600 600 600
3.2.4.
2.2 Single biogas stove
Treatment/Handling of1 Cows [pcs]
.................................................................................................
900 900
19900
2.3 Double biogas3.2.5.
stove Milk Storage ...........................................................................................................................
[pcs] - 19 -
2.4 Biogas lamp 3.2.6. Cows: Milk Production and
1 [pcs] Dimensions ...............................................................................
- - 20 -
2.5 Main gas valve3.2.7. Special Needs Cows ................................................................................................................
1 [pcs] 360 360 21360
2.6 Stove tap 3.2.8. Grouping of Young Stock .......................................................................................................
1 [pcs] 270 270 21270
2.7 Lamp tap 3.2.9. 1 [pcs] - -
Water Supply.......................................................................................................................... 21 -
2.8 Water trap 3.2.10. Essential Points to Consider 1 [pcs]for each Module ........................................................................
60 60 22 60
2.9 Pressure meter3.2.11. Management to Increase Number of Cows............................................................................. 22 60
1 [pcs] 60 60
2.10 Fitting material & sundry 1 [set price] 300 300
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23300
2.11 Repair & maintenace set 1 [set price] 180 180 180
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3 Labour
3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
3.1 Unskilled labour 12 [persondays] 4 PM PM -
3.5
3.2 Skilled labour
H YGIENE AND BIOSECURITY ................................................................................................................ 29
6 [persondays] 8 PM PM -
3.6 TREATMENT AND HANDLING D
3.3 Artiasan 2 AIRY CATTLE ....................................................................................
[persondays] 10 PM PM 32 -
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
Total costs per category
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34
4.1.1.
Buidling material Construction Costs Cow House Modules 1-4 ........................................................................
5,645 24,840 34
30,485
4.1.2.
Biogas materials Biogas Digester .......................................................................................................................
- 2,730 35
2,730
4.2 fees
Company HERD DEVELOPMENT ...........................................................................................................................
40% of comp share in bldg materials 11,028 35
11,028
4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36
Grand total 38,598
4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 44,243
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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CONTENTS

Modified Camartec domestic biogas installation

9m3
Bill of Quantities and pricing
LIST OF TABLES ......................................................................................................................................... 03
qty unit rate household company Programme
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
1 General bulk materials
CHAPTER 1: INTRODUCTION .............................................................................................................. 07

1.1 Sand CHAPTER 2: STRUCTURES, 4.00 [m3]CONSIDERATIONS 900 AND3,600 IMPLICATIONS ................................. 08
3,600
1.2 Gravel 3.00 [m3] 54 162 162
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
1.3 Stones 2.00 [m3] 900 1,800 1,800
1.4 Cement
2.2 D AIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09
20 [bags 50 kg] 390 7,800 7,800
1.5 Bricks 2.3 DAIRY COW HOUSE 1,150DESIGN
[piece]................................................................................................................
9 10,350 10
10,350
1.6 Lime 2.4 E XAMPLE L AYOUT OF M ODULAR
4 [bags 50 kg] D AIRY C OW
420 H OUSE ......................................................................
1,680 12
1,680
1.7 Acrylic2.5 SUPPORT
emulsion paint FUNCTIONS [ltr] PHYSICAL STRUCTURES
2 AND 210 ...........................................................................
420 13
420
1.8 Chicken2.6 TYPICAL
wire (1 FARM LAYOUT
mtr wide) AND FENCING ..............................................................................................
55 [mtr] 90 4,950 15
4,950
1.9 Welded / square mesh 1 [pcs] - -
1.10 RoundCHAPTER
bar 3: CATTLE BARN MODULAR APPROACH
2 [length] 390 AND OPERATIONS 780 ............................780 16
1.11 PVC pipe
3.1 4" MODULAR FARM DEVELOPMENT
1 [length] 420 420
........................................................................................................ 420
16
1.12 HDPE 3.4"class 6 100 [mtr] 240 24,000 24,000
3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17
2 Biogas materials3.2.2. Manure Storage/Waste Water Storage................................................................................... 18
3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19
2.1 Dome pipe 1 [pcs] 600 600 600
3.2.4. Treatment/Handling of Cows ................................................................................................. 19
2.2 Single biogas stove [pcs] 900 - -
3.2.5.
2.3 Double biogas stove
Milk Storage ...........................................................................................................................
1 [pcs] -
19 -
2.4 Biogas lamp 3.2.6. Cows: Milk1Production
[pcs] and Dimensions - ...............................................................................
- 20 -
2.5 Main gas valve3.2.7. Special Needs Cows
1 [pcs] ................................................................................................................
360 360 21
360
2.6 Stove tap 3.2.8. Grouping of Young
[pcs] Stock .......................................................................................................
270 - 21 -
2.7 Lamp tap 3.2.9. Water Supply
1 ..........................................................................................................................
[pcs] - - 21 -
2.8 Water trap 3.2.10. Essential Points1 [pcs] to Consider for each 60 Module ........................................................................
60 60
22
2.9 Pressure meter 1 [pcs] 60 60
3.2.11. Management to Increase Number of Cows............................................................................. 22 60
2.10 Fitting3.3
material & sundry 1 [set price] 300 300
DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23 300
2.11 Repair & maintenace set 1 [set price] 180 180 180
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3 Labour 3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
3.1 Unskilled labour 20 [persondays] 4 PM PM
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29 - 75
3.2 Skilled labour 10 [persondays] 8 PM PM - 75
3.3 Artiasan
3.6 TREATMENT AND H2ANDLING DAIRY CATTLE
[persondays] 10
....................................................................................
PM PM
32 -
20
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34 170
Total costs per category
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34
4.1.1.
Buidling material Construction Costs Cow House Modules 1-4 ........................................................................
15,912 40,050 34
55,962
4.1.2.
Biogas materials Biogas Digester .......................................................................................................................
- 1,560 35
1,560
4.2 fees
Company HERD DEVELOPMENT ...........................................................................................................................
40% of comp share in bldg materials 16,644 35
16,644
4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36
4.4 FEED AND FEED STORAGE REQUIREMENTS .........................................................................................
Grand total 58,254 74,166 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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CONTENTS

800
700
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04

600
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
35

40
70

75
60
45
10

50
30

30
60
80
65

15

65
70

90

10
9

1.50
150
150

120

100
150
Used for calcs

-
-
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
7,003

123,500

7,250
31,313
29,293

25,000
61,600

12,875

71,667
55,000

80,500
440

2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09

Average

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
350,000
12,121

120,000

139,000

7,500
75,000
27,000

45,000
35,000

10,000
15,000
24,242.42
24,242

58,000

11,500

70,000

97,000
650

3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16

E

3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17

3.2.1. Capacity of the Milking Parlour ............................................................................................. 17
20,202

25,000
65,000

10,000

65,000
75,000
90,000
85,000

35,000
30,000
36,363.64

750

3.2.2. Manure Storage/Waste Water Storage................................................................................... 18

D

3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19

3.2.4. Treatment/Handling of Cows ................................................................................................. 19
135,000
4,040
32,323

62,000

10,000

80,000

16,000
30,000
28,282.83

250

3.2.5. Milk Storage ........................................................................................................................... 19

3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20
C

3.2.7. Special Needs Cows ................................................................................................................ 21

3.2.8. Grouping of Young Stock ....................................................................................................... 21
130,000
36,364
40,404
4,848
58,000

20,000

30,000

60,000
250

3.2.9. Water Supply.......................................................................................................................... 21

3.2.10. Essential Points to Consider for each Module ........................................................................ 22
B

3.2.11. Management to Increase Number of Cows............................................................................. 22

3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23
75000
45000
45000

35000

10000
25000
50000
150000
100,000
7,500

65,000

20,000

7,000
300

3.4 FEED FENCE ........................................................................................................................................... 26

Unit price

Unit price

Unit price

Unit price
A
1.65 ton/m3

3.4.1. Breeding Bull(s) ...................................................................................................................... 26

7.5 ton
30 ton

3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27

3.4.3. Week-planning........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29
[length 12m]
[bags 50 kg]

[bags 50 kg]

[length 6m]

[set price]
[set price]

3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32

[length]
[length]

[ls/day]
[ls/day]
[ls/day]
[meter]
[piece]
Unit

Unit

Unit

Unit
[pcs]

[pcs]
[pcs]
[pcs]
[pcs]
[pcs]
[pcs]
[pcs]
[mtr]

[ls]
[ls]
[m ]
[m3]
[m3]
3

[ltr]

CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34

4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34
Fitting material & sundry

4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34

Annual maintenance fee
Company services & fees
Double biogas / LPG stove
Single biogas / LPG stove
Chicken wire (1 mtr wide)
Acrylic emulsion paint

Repair & maintenace set

General bulk materials

HDPE pripe 3/4"class 6

Welded / square mesh

4.1.2. Biogas Digester ....................................................................................................................... 35

Aritisan level labour

Construction fee
Unskilled labour
Biogas materials

4.2 HERD DEVELOPMENT ........................................................................................................................... 35

All prices in local currency

Pressure meter
Ball valve 3/4"
Ball valve 1/2"
density bulk

Skilled labour
GS pipe 1/2"
GS pipe 3/4"

Biogas lamp
PVC pipe 4"

4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36

Dome pipe
Round bar

Water trap
Cement
Stones

Labour
Gravel

Bricks

4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37

Truck
Lorry

Sand

Lime

4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39

1.10

1.13

2.10
1.11
1.12

1.14

4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40

1.1
1.2
1.3
1.4

1.6

1.8

2.1
2.2
2.3
2.4

3.1
1.7

2.5
2.6
2.7
2.8

3.2
3.3

4.1
4.2
1.5

1.9

2.9
1

4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41

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