Aquaponics Manual rough draft4

101 Pages·2005·3.1 MB·English

by  Travis Hughey

Barrel-ponics

(a.k.a. Aquaponics in a Barrel)
By Travis W. Hughey
Photos by Travis W. Hughey
Copyright 2005
All Rights Reserved

1
Conditions of Use Statement

This document, in part or in its entirety, may be copied, reproduced or adapted to
meet local needs
without permission from the author or publishers, provided credit is given to
Travis W. Hughey.
These provisions apply only provided the parts reproduced are distributed free or
at cost – not for profit.
Travis W. Hughey would appreciate being sent a copy of any materials in which
text or illustrations have been adapted.
For reproduction on commercial basis, permission must be first
obtained from Travis W. Hughey.
Any commercial or for sale application of the Flood Valve technology is strictly
forbidden without prior approval in writing from Travis W. Hughey.
Travis W. Hughey can be reached at [email protected] .

2
Table of Contents

Cover Page………………………………..................................................... 1.

Conditions of Use Statement………………………………........................ 2.

Table of Contents………………………………........................................... 3.

Introduction………………………………..................................................... 4.
How It All Began………………………………............................................. 5.
Let the Danger Begin!……………………………......................................... 6.

Jumpin’ In………………………………........................................................ 7.
“I Don’t Have the Education!”………………………….................................. 7.
The Nitrogen Cycle……………………………….......................................... 7.
What the Plants Need………………………………....................................... 8.
What the Fish Need……………………………….......................................... 9.

Parts List for Aquaponics System………………………………..................10.

Swimin’ with the Fishes……………………………….................................. 13.

Barrel Growbed Construction………………………………........................ 22.

Building the Stand……………………………….......................................... 28.

Building the Floodvalve………………………………................................. 43.
Assemble the Sub-assemblies………………………………......................... 49.
Let’s Put This Thing Together……………………………….......................... 61.

The Floating Raft Tank………………………………................................... 69.

Movin’ the Water………………………………............................................. 75.
Plumbing It All Together………………………………................................ . 76.

Options………………………………............................................................ 80.

Maintenance……………………………….................................................... 87.

Starting the System………………………………........................................ 89.

Why I do What I Do………………………………......................................... 91.

A Little Bit Of What To Look Forward To………………………….............. 92.

3
Introduction

If you are looking for an introduction to aquaponics that is simple to build, fun
to watch and demonstrate to friends and family the joy of soil less gardening,
then this small unit may be for you. It is capable of growing various vegetables
and herbs and would be a wonderful addition to the home kitchen as a source of
fresh herbs and occasionally (depending on the species used) a fish or two.
What it most likely won't do is provide the vegetables to sustain someone on it's
own. That is for a much larger system. Fish production is also limited because of
the small size of the unit. The actual production possible is mainly dependant on
the operators ability to manage it. I have personally grown tilapia in this system
to about 1/2 Lb. Not a lot of them, just a few. I have grown tomato plants and
papaya trees in this system with nothing more than 4 each of 1/2Lb. tilapia as
the nutrient source. Remember this is not magic. This systems fish tank at the
lowest point in the cycle will only have a little over 20gal. of water in it. In my
opinion it's simply not practical in the real world to grow high densities of fish and
have a system that is forgiving at the same time. This unit is specifically
designed as an introduction to aquaponics and to make one familiar with the
principals involved with minimal expense. It is very adaptable to situations where
conventional electric pumps may not be practical. This is all about learning fun
and not intended to be a commercial unit in itself although I believe the principles
can be enlarged to do so. Please read this material in it's completion before
attempting to build this unit. If you are unfamiliar with something don't worry
about it too much. It will come clear as the project progresses. Before we get

into the system please allow me to give a little information about myself.

4
How it all Began

I first became interested in aquaponics after acquiring a greenhouse in the
spring of 2002 from a local middle school here in coastal South Carolina. The
school system here was converting to a "Technical curriculum" and no longer
needed the mainstay piece of equipment of their horticulture class. A donation
to the PTA and a few weekends of hard work by my family and the green house
was on our property. Now what to do with it? It was a 28 x 45 hoop style
greenhouse with cooler, fans, and all the standard equipment.
I then started researching what to do. The first thing I considered was
hydroponics but decided it wasn't for me after visiting a hydroponic tomato
operation and found out there was a hazardous waste byproduct that had to be
hauled off periodically. I'm not saying hydroponics is a bad thing at all. I'm just
saying it wasn't for me at the time. I wanted to do something unique and during
a web search ran across the term "aquaponics". This intrigued me as I was a
biology major at Oral Roberts University but never got to finish my education
there. This was a natural fit, aquaculture and horticulture in a soiless medium.
The search led me to Tom and Paula Spraneo. They were selling a manual on
aquaponics so I ordered it. To say it opened my eyes was an understatement to
say the least. Their manual is very informative and I highly recommend it if it is
still available. Tom and Paula have done a great service to have helped in the
pioneering of this great technology. I must say I was a little intimidated at first
but became more and more comfortable with the information the more I studied
it. Our quest then led us to an opportunity to attend an aquaculture workshop in
2003 that included aquaponics as one of the topics. The workshop was hosted
by Charlie Johnson of Aquaculture International in Bryson City, NC. It was a
very informative time with a lot of contacts I still have today. There were a lot of
mission minded types there and they as well as I saw the importance of this
technology in feeding the poor.
There was one person there that really grabbed my attention. His name is
Frank NcNeely and he is the owner of Aqua-Terra Gardens in Springfield, MO.
He was doing aquaponics in old recycled fiberglass bathtubs salvaged from a
hotel renovation. That inspired me and got me to thinking. I had been putting
together a mold to make my growbeds out of fiberglass. Why not use an
abundance of plastic barrels I had laying around. By the time my wife (Lori) and
I returned home I had the basic idea on how to use these barrels as growbeds. I
couldn't wait, but had to, as my job did not afford much time to pursue my
newfound passion. I definitely had enough information to be dangerous now.
5
Let the Danger Begin!!

Beginning in September of 2003 I started putting together a S&S based
system in concept but using low cost materials. That's the beauty of aquaponics,
you are only limited by your imagination. The system was started in early
October of 2003 and I made all the mistakes everyone talks about. Most
mistakes are made early on from mere impatience. Trying to push the system
too hard in the beginning is a sure formula for disaster. It is no fun carrying out
buckets full of dead fish and frantically trying to find out why they are dying.
Every person new to aquaculture has the potential to be a serial fish killer. I was
no exception. Once the system stabilizes though it is amazingly resilient. My
experience with this system has taught me many things and I look forward
learning much more in the future.
After working with this system it became apparent to me that this technology
would be a Godsend to areas of the world where there is no soil or it is very
poor. Many cultures in the world suffer from malnutrition and I believe
aquaponics may be one of the solutions to the problem. One of the problems is
that aquaponics is somewhat technical and may not be appropriate in it's current
form. This is what got me to thinking about a small system that could be built in
orphanages and teach the principals of aquaponics in such a way it could be
easily understood and become commonplace. For this to happen the technology
has to be reliable and in-expensive. I started working on the idea for a small
barrel based system. This system had to be simple, visual and reliable. I started
working on a variation of a system that Frank NcNeely used as a training tool. It
involved using a toilet float attached directly to the flapper of a standard flush
valve. The problem I found was under very low flow situations the flapper would
lift just enough to allow the water to flow but wouldn't dump the tank as needed.
It was about 9:00 in the evening in March of 2004 and I was coming up against a
wall. Frustrated and feet soaking wet from playing with water for hours I just
stopped and prayed. I knew the Creator of the universe had the answer to the
problem as simple as this, I just needed to clear my frustration and listen to Him.
By 11:00 that night I had the initial prototype working on even the slightest trickle.
A few refinements to the initial concept and the first system was put together
using the barrel half growbeds. That system is still in operation today. Working
day and night with the slightest maintenance required. The flood valve is fully
adjustable as to flood volume and cycle time parameters and uses no timers or
float switches for it to operate. It is very inexpensive to build and is just plain fun
to watch operate. It is very visual and definitely captures the attention of passers
by. Well, let's get started with the system.

6
Jumpin' In

"I Don't Have the Education !"

First let me explain that you do not have to have a college degree to be
successful with aquaponics on the home level. Just like you do not have to
understand the chemical process that goes on during combustion in the engine
of your car to successfully operate it you do not need to fully understand the
complexities of the biochemistry involved in aquaponics. You do need to know a
few things though just as you do to operate your car. If you get the chance to
attend an aquaponics course or seminar I highly recommend it. If not there is
always the school of hard knocks. Just be sure you start small. That's what this
manual is all about. The first basic of aquaponic is the nitrogen cycle. It is how
toxic ammonia fish waste is ultimately converted to not as toxic nitrates. The
following is information provided from Nelson/Pade Multimedia. Thanks
Rebecca!!

The Nitrogen Cycle
Reprinted with permission from Nelson/Pade Multimedia, publishers of the
Aquaponics Journal, www.aquaponics.com

More than 50% of the waste produced by fish is in the form of ammonia,
secreted through the gills and in the urine. The remainder of the waste is
excreted as fecal matter, undergoes a process called mineralization which
occurs when Heterotrophic bacteria consumes fish waste, decaying plant matter
and uneaten food, converting all three to ammonia and other compounds. In
sufficient quantities ammonia is toxic to plant and fish. Nitrifying bacteria, which
naturally live in the soil, water and air convert ammonia first to nitrite
(Nitrosomonas bacteria) and then to nitrate (Nitrobacter) which the plants
consume. Nitrifying bacteria will thrive in the gravel beds and in the water in the
system. The plants readily take up the nitrites and nitrates in the water and, in
consuming it, help to keep the water clean and safe for the fish.
7
What the Plants Need

Plants need nutrients in the proper amounts, oxygen, CO2, water and light.
They can come from natural or artificial means. Aquaponics takes advantage of
a natural process in a controlled environment and fulfills these requirements.
Plant roots need oxygen which brings us to the need for a flood and drain
requirement for the growbeds. If plant roots would tolerate continual emersion in
water we would not need to drain the grow beds and could simply flow water
through continuously. There are several different schemes to accomplish this
using timers, float switches or even computer control. The flood valve eliminates
the need for such technology. I'm not saying technology is bad. I use it when
available. It is a good thing. It's just not available everywhere.
I have grown a large variety of vegetables in my system and the only one's I
have had trouble with are squash. They seem to be very sensitive to the
moisture level of the system and almost always have powdery mildew problems.
A partial list of successfully grown vegetables, fruits and herbs in my system
include tomatoes, onions, peppers (sweet and hot from bell to habanero), beans,
beets, brocolli, basil, cilantro, papaya, collards, cucumbers, carrots, lettuce,
stevia, moringa, dill, chard, okra, peas and parsley to name a few. The plants
thrive in this environment and the planting densities are much higher than in a
conventional garden.

8
What the Fish Need

Fish need clean oxygen rich water and reliable feed to thrive. The water also
needs to be at the right temperature. Conditions that are tolerable vary from
species to species. One would have to get information elsewhere concerning
the specific species desired. All you need is an aquatic animal with gills to
provide the basic nutrients for the nitrogen cycle to operate and the bacteria to
make the conversion for the plants to take up the nutrients. It is a natural
process that simply has to have the right conditions to occur.
The bacteria and plants in my system keep the water crystal clear and the
water has the sweet smell of healthy creek water. This is one of the basic
indicators I use to check the overall health of the system. If it get's out of
balance you will know it. When things die they smell bad. Whether it's fish or
microbes. The most common cause of problems in a stabilized system is over
feeding. The water gets cloudy and the first reaction is to get nervous about the
change. I just back off the feed for a day or two. The fish will be fine unless
there is a toxin causing the problem. At which point they will probably be lost
anyway. The key to all this is to familiarize oneself with the day to day operation
and nuances. It will become intuitive after a while. Have fun with this and don't
worry too much.
As far as feed goes it all depends on the fish you are using. I have tilapia in my
system. Tilapia are a wonderful choice in tropical climates as they are extremely
forgiving as far as water quality is concerned and they are not picky eaters. They
are vegetarians and will consume leafy scraps from the garden as well as water
hyacinth, water lettuce and duckweed. I have even had them gobble up dried
rabbit pellets just as if it were fish feed. They do very well on standard floating
fish feed and I have even heard of people feeding them dog food when the fish
pellets are not available. Don't forget about the natural feeds available in your
area. There are large amounts of protein flying about in the form of insects and
would be attracted by a light suspended over the fish tank at night. Not to
mention worms, grubs, maggots, etc...

9
Parts List For Aquaponics System

First let me state that this list is for parts commonly found in the United
States. Please don't be put off by the detail of the list. If these things are
common to your area or village fine, if not, be creative, this is a guide to how I
have done it in the states. By all means please don't be discouraged. I am
presently working on ways to accomplish the same thing with different materials
that would be appropriate in different parts of the world. I will make that info
available as the development and testing is done. I don't want to steer you
wrong!! Now here are the parts you need

PVC parts:
a. 1 ft. 1/4" pex pipe
b. 3 each of 1-3/4" long 1/2" pipe
c. 1 each 3" long 1/2" pipe
d. 4 each 4" long 1/2" pipe
e. 1 each 6" long 1/2" pipe
f. 2 each 10" long 1/2" pipe
g. 2 each 12" long 1/2" pipe
h. 1 each 3" long 3/4" pipe
i. 1 each 4" long 3/4" pipe
j. 1 each 6" long sch 40 1" pipe
k. 1 each 19" long 1" thin wall pipe
l. 2 each 8 1/2" long 1" thin wall pipe
m. 8 each 1/2" ell (Lowes #26054, 10 pk.)
n. 6 each 1/2" male adapter (Lowes # 23855)
o. 2 each 3/4" male adapter (Lowes # 23856)
p. 1 flush valve (Lowes # 24452)
q. 1 each 2" female adapter (Lowes # 23906)
r. 1 each 2"x1" sch 40 bushing (Lowes # 22909)
s. 1 each 1 " street ell (Lowes # 1636)
t. 1 each 1" tee (Lowes # 23876)
u. 2 each 1"x3/4" ell (Lowes # 42980)
v. 1 each 1/2" IPT to 1/2" 90deg. barb (Lowes # 54092)
w.2 each 1/2" IPT to 1/2" barb (Lowes # 53802)
x. 1 each 3/4" threaded ball valve (Lowes # 21482)
y. 1 each 3/4" street ell PXM (Lowes # 22699)
z. 34” of 4" corrugated slittted sewer pipe (The type used in septic systems.
Not the type with holes).
aa. AR 1/2" black poly pipe (type used in irrigation)
bb. 3" of 3/8" vinyl tubing
Misc. fittings needed to couple pump to unit dependent on pump used.

10