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Feedyard Construction in a Big Way As Future Beef takes off with the opening of its state-of-the-art processing facility in Arkansas City, Kansas, one of the feedyards supplying a large share of cattle for the program knew their existing facility was not big enough. "When we joined with Future Beef, we knew we needed to expand," says Larry Bilberry, manager of Garden City Feed Yard, just south of Garden City, Kansas. "We had the opportunity to expand, and with the changes in rules and attitudes toward feedyards, we decided we better grow now rather than later," Bilberry says. Before the expansion began, Garden City Feedyard held 30,000 head. By October 15, 2001, when the expansion is scheduled to be complete, the yard will have tripled in size to a capacity of 90,000 head. "One of our biggest challenges was going through the permitting process," says Bilberry. "People are always an issue, and we wanted to have the support of our neighbors." An extensive study was conducted with the EPA, and Bilberry worked with the Kansas Department of Health and Environment (KDHE) to obtain all the necessary permits. Max Jantz Construction was contracted to build the yard. "This was the biggest expansion we have designed and constructed all at one time," says Jerry Starkey, a design technician with Max Jantz. Construction began in October of 2000. "Any feedyard construction or expansion project is a major undertaking," says Starkey. "Most are typically a year-long process, considering the time it takes to obtain permits." Once permits are obtained, Starkey says the dirt work is the next step. "Everything is based on the base and slope of the pens. This is definitely not a place to save money," he says. "If you skimp on the dirt work, you typically have to do extra work in the long run with pen maintenance." Starkey says they try to use whatever dirt is there, instead of hauling in a lot of materials. "We figure in the compaction, etc. to balance the yard. It is done with a civil engineering software system." Next the lagoons are constructed and lined with clay or other material to prevent or reduce leeching. "There are a lot of regulations that must be followed in constructing a lagoon." Once all of the dirt work is completed, the actual construction begins with bunks and fence lines. "There are so many things to consider," says Starkey. "In the entire process engineers are involved in drawing up plans and presenting the plans for permitting. It's a complicated process." Mike Witt, sales manager for Miraco, agrees. Miraco manufactured all of the waterers for the new pens. Even in choosing the waterers, there are many things to consider. "Garden City Feed Yard went with a ball-style waterer because they are energy free, or require no electricity. They also offer clean water quality," Witt explains. The ball acts as a thermos to hold the water at ground temperature. Over 160 of the ball-style waterers were installed at the feedyard. The installation was one of the largest Miraco has worked on. Miraco has a sales staff all over the country, but has one salesman that caters to feedyards. "He works with the yard manager and construction team to determine what watering system will work best," says Witt. "The number of head in a pen, the weather and water quality are all things to consider. In addition to watering cattle, dust control was another important aspect of the construction process. "We chose a golf course-type system that sprinkles in a given pen for 10 or 15 minutes. Then it shuts off and goes to the next one," says Bilberry. He believes a good dust control program is important in public perception. When the expansion is complete, Bilberry estimates he will hire about 40 more people to work at the yard, for a total of 70 to 75. |
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