18. Construction (Part one)

 

The original idea when the Lancos were first brought together featured a low-cost housing model that could be developed or replaced as funds accrued.  The housing plan was simple.  The original building designed for ten finishing pigs could be extended or modified as required.  With minor adjustments the design could suit sows in gestation, weaned pigs, or farrowing sows.

 The business model was based on a plan of producing about 3400 pigs per year, slaughtering them through a wholly owned abattoir and selling fresh pork through local outlets including at the abattoir door.  This required a sow herd of about 200 sows farrowing about 8 sows each week and weaning about 64.  The herd would start with about 25 foundation high health status sows and grow from there.  Funding would determine how quickly the herd would grow and how we would shape the construction program.

 As it turned out the WAL board was far more successful at raising money that anyone had thought possible.  Exxon Mobil and Kumul Foundation were generous benefactors.  This together with the advantages that came with being close to both Transwonderland and Hides Gas Development Company (HGDC) allowed contracts with HGDC to support a building program to house, in the first stage, 100 sows, farrow 4-5 sows every week and produce batches of about 120 weaned pigs every month for distribution to village households for raising to about 24 weeks of age when they would be slaughtered.

 The level of scale necessitated construction of proper buildings that would withstand the tropical climate, last the distance, and be integrated with the feeding system based on silage.  Because of the high rainfall the effluent management system was based on sawdust bedding, manual removal and composting.  This meant buildings made from steel and cement rather than wood and thatch.

Site specification for HGDC:

Build the all-weather internal farm roads, building pads, pads and shelter for silage bunkers,turning circle (crushed rock), car park and wheeel wash. Ensure drainage to guarantee access and protect the river from effluent run-off. Provide for rainfall run off water (wetlands or pond), a separate effluent pond for urine and cleaning water from sheds, run off from compost area and run off from the vehicle wash down area. Connect effluent or any runoff dams or ponds with pumps so that the water can be used for irrigating crops on the site. Make sure drinking water for people and animals is separated from the runoff and effluent system.

  

B&M Slots Pty Ltd, a Melbourne based business, specialising in design of buildings for intensive animal production was engaged to develop a two-stage concept.  They developed building designs for group housing sows on solid floors using bedding (sawdust) and generous space allowances.  The buildings were naturally ventilated.  They had a wide internal aisle to enable a tractor and feed trailer to drive through and dispense the kau kau[1] silage-based diet.  Manure was removed daily through a gap to an outside concrete gutter where it was collected for composting.  Liquid was removed, with cleaning water and rainfall runoff via a drain to a pond that provided for irrigation of the kau kau gardens.

Figure 1.  Laying the slab for the sow house

Figure 2. Sow house showing internal walls

Figure 3. Sow house showing external walls, gaps for manure removal and external concrete 

channel for manure and bedding pick up

 

Figure 4. Completed sow house showing security mesh with concrete drive way access for feed tractor

Figure 5. Construction of drain to liquid effluent storage pond

Figure 6.  Farrowing house pens under construction.  The pens allowed the sows to turn around.

Figure 7.  Staff amenities: office, lunch/seminar room, toilets, showers and laundry.

Approved visitors pass through the showers and change into farm clothing and boots.

Figure 8. Machinery shed

 

Figure 9.  Biosecurity fence surrounding the pig farm compound

Figure 10.  Staff accommodation under construction.  The central area will be roofed and work as an out door recreation area and mess. It will have a concrete floor.  The compound will be fenced for security.  It is outside the pig farm compound so that outside farm workers can stay without entering the pig farm space.

WAL approached HGDC, also a shareholder in WAL, to quote on the first stage; a sow house, a farrowing house, a machinery shed and silage bunkers, together with farm roads, plumbing, and drainage and effluent management systems.

Building started in July 2022 about three months later than expected due to last minute funding complexities, but it was still expected that the sow house would be completed and that the whole site could be secured in advance of the arrival of the foundation breeding stock in late September.

This is Papua New Guinea and there were regular stoppages for weather (rain) and further negotiation on personnel, wages, security, skills, and equipment availability.  Black plastic was tied to the fence to keep prying eyes out and prevent anybody electing to take a pot shot at staff.

As the building gathered pace and shape, the drainage lines to the liquid effluent pond (5 cubic metres) were completed.

The machinery shed was completed and by mid-September the sow house was completed ready for the first foundation sows.  We had 3 tonnes of the protein mineral premix in bags in storage and about 30 tonnes stored in bunkers on the model farms at Teni, Obai and Juni.  We moved the silage in bags by the trailer load and kept it in the silage bunker on site.

There were multiple interruptions to the build.  Barely a week went by without one security alert or another.  By and large the site was ready for the 24 gilts and 3 boars when they arrived.  We had sufficient space. Water was in storage and available. The silage and premixes were on hand and our staff could mix the feed in the sow house or the machinery shed.

The gate was not completed to the standard of a gate that might keep serious people out.  There was only one outside fence and the shower in facility was not finished by the time the pigs arrived.  There were also gaps in supply of materials.  However, we had enough accommodation, feed and water for the sows and dedicated people to care for them.  Then life as we knew it ended.  There was a riot just down the road.  People were killed.  Facilities were trashed.  The farm and staff were indirectly implicated, so fearing risk to their lives we pulled our staff out.  HGDC wrapped up their work and everybody left the site save for the local staff who continued to care for the pigs.  They didn’t miss a beat. They were untroubled by the local mayhem.  They ate the silage based diet, grew well, cycled and were bred.  But the local violence and the biosecurity gap had a profound impact on the business and cash flow.

END.

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[1] Sweet potato see chapter 16