Document 526 POST IMPLEMENTATION REPORT CHAPTER ...ewb-uaa.org/projects/rhema_grace/Documents/Phase 1/526(PH1)_Post... · For the purpose of this implementation, we have identified

Document 526

POST IMPLEMENTATION REPORT

CHAPTER: University of Alaska Anchorage

COUNTRY: Cameroon

COMMUNITY: Rhema Grace Orphanage

PROJECT: Wood Burning Cook Stove

PREPARED BY

Student(s): Kris Homerding, Wesley Phelps

Mentor(s): Nancy Hibbert

October 20, 2010

ENGINEERS WITHOUT BORDERS-USA

www.ewb-usa.org

Document 526 - Post Implementation Report

University of Alaska Anchorage

Rhema Grace Orphanage, Cameroon

Wood Burning Cook Stove

© 2007 Engineers Without Borders – USA. All Rights Reserved Page 2 of 23

Post Implementation Report Part 1 – Administrative

Information

1.0 Contact Information

Title Name Email Phone Chapter

Project Lead Wesley Phelps [email protected] 907-299-4299 EWB-UAA

President Robert Champion [email protected] 907-841-8434 EWB-UAA

Mentor #1 Nancy Hibbert [email protected] 907-360-3279 EWB-SCA

Mentor #2 Chuck Stilwell PE [email protected] 406-491-1129 EWB-SCA

Mentor #3 John Pepe PE [email protected] 907-830-9231 EWB-SCA

Faculty Advisor Utpal Dutta PhD [email protected] 907-786-1952 EWB-UAA

Health & Safety Officer Nancy Hibbert [email protected] 907-360-3279 EWB-SCA

Assistant Health & Safety

Officer

Carla Buys [email protected] 907-602-3948 EWB-UAA

NGO/Community Contact Peter Njodzeka [email protected] 237-7771-6288 EWB-UAA

Education Lead Nancy Hibbert [email protected] 907-360-3279 EWB-SCA






2.0 Travel History

Dates of Travel Assessment or Implementation Description of Trip

August 2009 Assessment

Collect information sufficient to

develop a plan, based on needs

identified by the orphanage and the

goals of EWB, which can be

developed into an engineered design

that could be implemented in two

weeks one year later.

August 2010 Assessment & Implementation

Constructed an efficient wood

burning cook stove to reduce the

inhalation of smoke, collected

information (pertaining to the daily

water supply and usage) sufficient to

develop a plan that could be

implemented in August 2011,

conducted a health assessment to

later gauge the success of the overall

project, and developed a

maintenance program within the

orphanage.

3.0 Travel Team

Title Name Email Phone Chapter

Project Lead Wesley Phelps [email protected] 907-299-4299 EWB-UAA

Implementation Lead Kris Homerding [email protected] 907-947-2260 EWB-UAA

Assessment Lead Brittany Barkshire [email protected] 907-244-3045 EWB-UAA

Mentor #1 Nancy Hibbert [email protected] 907-360-3279 EWB-SCA

Mentor #2 Chuck Stilwell PE [email protected] 406-491-1129 EWB-SCA






4.0 Safety

4.1 Safety Incident Reports

No health and safety incidents. Each morning of the trip we held a safety meeting to

discuss risks involved in the daily tasks, medication, communication and any concerns.

No one in the travel group or those working with us on the project was hurt in any way

during the time we were there.

5.0 Budget

5.1 Cost

Expense Total Cost (Students) Total Cost (Students + Advisors)

Airfare $8,957 $12,131

On Ground $4,703 $5,242

Stove Materials $947 $947

Maintenance $119 $119

Services $810 $810

Other $180 $200

Total $15,716 $19,449

6.0 Project Location Longitude: 9.3680556; 9° 22' 5" E

Latitude: 4.0786111; 4° 4' 43" N

Mailing address of Rhema Grace Orphanage:

P.O Box 1016 Limbe

Fako Division

South West Region

Cameroon – West Africa






Post Implementation Report Part 2 – Technical Information

1.0 INTRODUCTION

The following report was developed with information from the trip to the Rhema Grace

Orphanage in August 2010. This document covers the implementation aspect from Phase I of

the project. The implementation consisted of building, with assistance from the orphanage and

hired local help, a wood burning cook stove in the existing kitchen to reduce the inhalation of

smoke and burn wood more efficiently.

2.0 PROGRAM BACKGROUND

In August of 2009, a team including two students and one professional engineer conducted an

assessment of the conditions at the Rhema Grace Orphanage. The assessment team found that

there were many projects that could be made to improve the living conditions of the children that

live in the orphanage. Please refer to the Community Assessment Document submitted to EWB-

USA in September of 2009.

An initial project was proposed at that time that included building a refectory (cafeteria) with

hand sinks; however, after beginning to design the project, we found that this proposal wasn't the

orphanage's top priority and that we would have trouble finding a funding agency. In December

of 2009, in cooperation with our professional mentors, we re-evaluated the information gathered

on the assessment trip and developed a new project scope. The goal of this project was to meet

the needs identified by the orphanage while addressing the long term sustainability and

ownership requirements of EWB-USA. This new project was also more realistic in terms of

funding and implementation. The methodology used to arrive at this scope is described in the

523 Alternative Analysis document submitted to EWB-USA in January 2010. The 523 outlined

plans to implement kitchen improvements, including a roof rain catchment system and a wood

burning stove, and upgrades to the potable water system by adding a hand pump to supplement

the orphanage's expensive electric pump run with a diesel generator. However, in the subsequent

months, we have determined that more assessment of the community's water system was

required before implementation. Therefore the scope for implementation on this trip included

only the plans for the stove. Further assessment was conducted this trip to determine the

potential for clean water solutions. See our post-assessment plan submitted in October 2010.

Our NGO partner in Cameroon, Peter Njodzeka of the Life and Water Development Group,

traveled to the orphanage in February 2010 to collect additional information needed for the new

scope of the project. Peter was given an extensive list of required information and questions for

the Orphanage staff regarding existing facilities, cooking practices, fuel consumption, etc. He

conducted video interviews, took photographs, made measurements and researched in the local

market for materials. Direct correspondence with the orphanage has also provided further data

and additional insight to their needs and priorities. This information was incorporated into the






design documents for the project.

In August 2009, fifty-four children and 17 full- and part-time employees and volunteers were at

Rhema Grace Orphanage relying on its infrastructure. The orphanage rents some of the space

they occupy and own another portion. The scope of work in the kitchen includes only work on

property owned by the orphanage.

3.0 TRIP DESCRIPTION

In August of 2010, a team including three students and two mentors traveled to the Rhema Grace

Orphanage and constructed a wood burning cook stove, with assistance from the orphanage and

hired local help. Using the information provided in our design and further information collected

on-site, materials for the stove were located in the surrounding communities and purchased.

Once materials arrived on-site, construction was underway.

Preparation of the kitchen was needed before stove construction could begin. A desired location

was decided by the orphanage in the unused side of the kitchen building. Also after observing

cooking habits for a couple days and talking with the staff and older children who did the actual

cooking we determined that the stove would need to accommodate two pots otherwise a 3-rock

fire would still be used for many meals. This was critical in formulating the stove dimensions.

Through connections from the orphanage, a mason was hired to help construct the stove. With

his help, a concrete slab, 235cm by 145cm by 10cm, to be built beneath the stove was poured

and took one day to cure. A total of seventy-two concrete blocks, 20cm by 20cm by 40cm, were

also poured but took two to three days to cure. After the concrete blocks were set in place,

mortar filled the gaps to create a tight seal. Volcanic rock, found in Limbe, filled the holes in the

blocks and was used as insulation throughout the stove. Two types of burn bricks were used to

construct the channel within the stove: refractory bricks and high heat bricks. The refractory

bricks were set in place wherever fire came in direct contact and directly underneath the pots

because of their strength. The high heat bricks were used to line the rest of the channel and

could withstand the temperatures that the stove produced.

A sheet of metal, 1m by 2m by 10mm, served as the plancha for the top of the stove. Once the

dimensions of the pots were determined, circles were drawn on top of the plancha to be cut out

by a welder in Limbe. A third hole, where the chimney would rest, was also measured and

drawn. Once the holes were cut and the plancha arrived back at the orphanage, it was placed on

top of the stove to know the exact location where the pots would sit. Once determined, the pots

were used for the molding of the channel and bricks and mortar filled in the gaps. A hole was

cut in the roof of the kitchen using tin snips and the custom-built chimney was inserted through

and attached to the stove. Flash band sealed the gaps of the chimney and the roof so water would

not leak through. Once all gaps in the stove were sealed, we began testing.

A fire constructed in the stove was compared to one constructed over a 3-rock fire. Results






showed that water boiled faster over the 3-rock fire; however, it was a noticeable difference in

the reduction of smoke with the stove. Meals were prepared using the stove during the last three

days of our stay.

4.0 COMMUNITY

4.1 Description of Community

For the purpose of this implementation, we have identified the ‘community’ as the Rhema

Grace Orphanage. In August 2010, fifty-four children and 16-18 full- and part-time

employees and volunteers were at Rhema Grace Orphanage relying on its infrastructure.

At any given time, fifty to eighty children are supported by the orphanage (around 15

young adults are supported while at vocational school). The children range in age from

infancy to twenty-one years of age. Mercy Batetataw, the founder and director, is the

only caretaker who lives at the orphanage full time. The other employees and volunteers

live within the surrounding area. These employees include volunteers, teachers, night

guards, cooks, laundry assistants, and babysitters.

The Rhema Grace Orphanage is located in the village Ombe (Quarter 20). Ombe is

located within the town Mutengene, which is in the Tiko subdivision. Ombe is about 3

km west of Mutengene along Route N3, down a dirt road leading south on the east of a

river. About 2.5 km south of Route N3, the Orphanage is located on the east side of the

road. It is the first of a number of buildings after passing through farmland. The name of

the orphanage is painted prominently on the front of the building. The village of Ombe

is composed of 77 homes and around 300 people. According to Mercy, the founder and

director of the orphanage, the recent population is diverse and composed of many tribal

groups from other parts of the country. The land is owned by the Bakwerian people, but

inhabited by Bebe, Meta, Bayange, Keaka, and Keyak (Manfi) Tribes. The main group is

the Bebe people, who compose 75% of the population. She indicated that the

government had recently made inexpensive land available in the area and that is what had

drawn the people from many different areas.

The infrastructure relevant to the orphanage community includes 3 km dirt road access

from Route N3, a 37m deep borehole, two dormitories (main dorm and new boy’s dorm),

a partially-complete reading room, a bathhouse with latrines, and a kitchen structure. Of

those, the orphanage owns all except the road and main dormitory building. All of this is

located on two adjacent properties, one rented and one owned by the Orphanage; the

main dormitory is on the rented land and everything else is on the parcel owned by the

orphanage. The Orphanage owns an additional plot of land up the road towards Route

N3 that they use to raise crops, although this provides very little value because many of

the crops are stolen. The Orphanage grows a portion of the food they need. They would

like to raise meats as well but currently do not have the capacity with the exception of a

few chickens. There is a gravel pit about a quarter mile further down the road that






provides crushed stone of different, sorted sizes. Agriculture is the largest employment in

the area. The orphanage grows plantains, bananas, squash and other crops. Palm

plantations are common in the area. Limbe has a cement works and there is much oil

produced in the area. There is a French refinery about 20 miles away on the coast near

Limbe.

The borehole is part of a larger water system built in partnership between the Limbe

Rotary Chapter and a Spanish Rotary Chapter. It includes the borehole, a submersible

pump, a small generator, an elevated water tank, a tap near the kitchen and a bathhouse

with latrines. Wastewater from the showers and latrines flows to a poured concrete tank

underground next to the bathhouse.

4.2 Community Relations

For the Rhema Grace Orphanage, the primary contact is via e-mail with Mercy, the

director. Mercy was ill this winter, however, we were able to maintain regular contact

through one of the oldest orphans, Gloria. While at the orphanage we were able to hold

discussions with a good cross section of the orphanage from residents to staff and

volunteers. We met with the local clergy, a mason, elders, business people, police, the

American consul, and the Assistant Chief of Regional Control and the Southwest

Regional Minister of Social Affairs for the region. The clergy tend to the people in the

surrounding population; the mason aided with the stove construction and would like to

help us in our future projects; elders are not as in traditional African communities but

their care is partially provided by the orphanage. The business people sell materials or

are a part of Rotary. Rotary may work with us to fund our water project since they

previously drilled a well and constructed a water system at the orphanage. The police

officer who helped us with transport and general information was a high school classmate

of Mercy’s and is now the head instructor at the nearby commando/police academy. The

Southwest Regional Ministry of Social Affairs provides some measure (it is unclear how

much) of support for the orphanage. He mainly expressed distaste for the corruption in

the politics in the region and warned us to be cautious of this. Our primary NGO partner

is The Life and Water Development Group through director Peter Njodzeka. The

orphanage is willing and excited to help with the implementation and maintenance of

future projects. The surrounding community seems less likely to aid in implementation,

costs, or maintenance unless the project specifically impacts them as well, such as

electricity. Refer to the MOU in Appendix A.

5.0 PROJECT SUMMARY

5.1 Summary (Expenses)

The following table lists all of the expenses related to the construction of the stove, which

include materials prices and services. Please keep in mind that without the hired help,






prices for materials would have been substantially higher and the quality of the stove

would have been lower without the help of local professionals.

Material Location

Purchased Quantity Unit

Unit Cost

(CFA)

Total Cost

(CFA)

Total Cost

(USD)

Hammers Bonaberi 2 each 8500 8500 $17.00

Sand RGO 2 loads 55000 55000 $110.00

Rebar Rods Mutengene 2 each 1900 1900 $3.80

Chimney Sheets Mutengene 2 each 7800 15600 $31.20

Cement Mutengene 5 bags 4700 23500 $47.00

Wire Mutengene 2 meters 1000 2000 $4.00

Form Board

(4mx30cm) Mutengene 1 each 3200 3200 $6.40

Nails Mutengene 1 kg 900 900 $1.80

Flash band Mutengene 1 each 1500 1500 $3.00

Refractory Bricks Douala 60 each 600 36000 $72.00

High Heat Bricks Douala 325 each 200 65000 $130.00

Cement Douala 4 bags 4500 18000 $36.00

Chimney

Fabrication Mutengene 1 each 10000 10000 $20.00

Rebar Rod #10 Mutengene 1 each 3700 3700 $7.40

Refractory Bricks Douala 15 each 600 9000 $18.00

Plancha

(1mx2mx10mm) Douala 1 each 130000 130000 $260.00

Wheelbarrow Douala 1 each 19000 19000 $38.00

Welding

Equipment Rental RGO 1 each 10000 10000 $20.00

Welding

Materials/Equip. Limbe 1

lump

sum 26000 26000 $52.00

Plancha

Fabrication Limbe 1 each 34500 34500 $69.00

Total 473300 $946.60

Service Description Total Cost

(CFA)

Total Cost

(USD)

Steve Asah Assisted in acquiring all materials 35000 $70.00

Christopher Boh Mason, construction of stove 60000 $120.00

Total 95000 $190.00

Grand Total 568300 $1,136.60






5.2 Difference Between Planned and Actual Implementation

Coming into this project, we were under the impression that the orphanage used one pot

at a time when cooking. However, we learned that they used at least two pots and to

build a stove for only one pot wouldn't meet their needs. Building a stove for two pots

called for a slightly bigger stove. Since block dimensions in Cameroon are different than

block in the United States, dimensions and material quantities were redesigned on-site

using the Design Principles of Wood-burning Stoves document that was the basis for our

design work all along the way.

The main differences between our prototype built in Anchorage and the stove constructed

in Cameroon were matters of scale. The pots used at the orphanage were substantially

larger than the pot around which the prototype was designed. As a result more building

materials were required and a thicker plate of steel for the plancha. After building the

prototype several design factors were altered to better optimize stove. These were

incorporated in the stove at Rhema Grace. Adjustments included centering the first pot

directly over the fire, adding a collar to the top of the plancha to better support the

chimney and adding a ledge under the combustion chapter entry for a more continuous

fuel feed.

Additionally we were under the assumption that the travel team would be executing much

of the manual labor for stove construction. We felt somewhat confident after building the

prototype that we would be able to successfully implement our project in Cameroon. We

were unsure of the orphanage community's ability to provide able workers. Fortunately

the older boys at the orphanage and professionals from surrounding towns were integral

to the success of our project. Much of our work was project management such as

communicating design principles, verifying dimensions and ensuring that the overall

objectives were met. As a result we had a much better product in the end that

incorporated local knowledge, the recommendations of the orphanage and an indicator of

future project sustainability. Also the older boys were taught skills by a local builder

who lives 20 minutes away and can be an asset to the orphanage in the future.

5.3 Drawings

When we discovered the dimensions of the concrete blocks, the dimensions of the

plancha, and that the orphanage used more than one pot at a time, we knew the proposed

dimensions would be different than the actual dimensions. After determining the

dimensions of concrete blocks that would be created, a drawing of all layers of the stove

was created. This drawing was used for effectively communicating the plan for stove

implementation within the construction team. Since the original document was drawn on

engineering paper and suffered some damage during the construction process, a new

drawing was created on EXCEL so the information could be seen easier. This document

is located in Appendix B.






6.0 PHOTO DOCUMENTATION

6.1 Material Acquisition

Figure 1: Markets in Limbe, Cameroon

Figure 2: Resource for lumber for future projects






Figure 3: Resource for purchasing burn bricks

6.2 Mixing Concrete

Figure 4: Sand arriving to the orphanage

Figure 5: Black Mongo sand for increased strength in blocks






Figure 6: Mixing concrete outside the kitchen

Figure 7: Adding water to the mixture






6.3 Block Construction

Figure 8: Older boys assisting the mason create blocks for the stove

Figure 9: Blocks created and waiting to cure






Figure 10: Blocks waiting to cure under the roof of the kitchen away from the

rain

Figure 11: 1st block!






6.4 Stove Construction

Figure 12: Concrete slab poured before stove construction

Figure 13: Mason lining the blocks within the 2nd layer of the stove






Figure 14: Older boys insulating the stove with volcanic rock

Figure 15: 3rd layer of stove






Figure 16: Effective communication throughout stove construction

Figure 17: Burn bricks used to insulate the stove

Figure 18: Air-channel with same cross-sectional area






Figure 19: Welder cutting holes in plancha

Figure 20: Mason creating a tight seal between the plancha and 3rd layer






Figure 21: Relief on Mercy's face after completion of stove construction

Figure 22: Completion of stove construction






Figure 23: Stove construction team

7.0 MONITORING AND EVALUATION

Maintenance of the stove is highly likely primarily because they are thrilled to be cooking in a

less smokey environment. Many of the older children at the orphanage participated in all aspects

of construction and the construction tools now belong to the orphanage. We expect the stove to

be well cleaned and maintained because they have the tools, the skills, the materials are easy to

obtain and inexpensive, and they have an interest in making this stove work well. We discussed

maintenance throughout our time there.

Replication of the stove is, however, unlikely because of the plancha. We had great difficulty in

getting 3/8” steel plate cut locally. The steel plate was also of significant cost and so large sums

of money would likely be put to other measures locally. A smaller, less expensive stove would

be more appealing to others in the surrounding community and would be more appropriate for

residential needs.

As stated in the Trip Description, a fire constructed in the stove was compared to one

constructed over a 3-rock fire. Results showed that water boiled faster over the 3-rock fire;

however, it was a noticeable difference in the reduction of smoke with the stove. Meals were

prepared using the stove during the last three days of our stay.

Since we have returned from Cameroon, we have received multiple e-mails relaying the

happiness from the members of the orphanage and that they are solely using the stove to prepare

their meals. Although the time to prepare food is slightly greater using the stove compared to the






3-rock fire, the absence of smoke in the kitchen has significantly made an impact. However,

after multiple uses, the time to prepare food has greatly diminished and they have zero intentions

of going back to using the 3-rock fire. Also, since the stove is insulated with Volcanic Rock and

High Heat Bricks, the heat stays within the stove and meals throughout the day are prepared

faster than the initial meal in the morning. Though the 3 rock fire boiled water faster than the

first pot of the stove, it is likely that 2 pots can be boiled with the stove more fuel-efficiently than

two 3 rock fires. This was briefly assessed in testing the stove against the 3-rock fire and will

need further evaluation.

8.0 LESSONS LEARNED

Maintenance is probably the largest need at the orphanage in terms of infrastructure.

Improvements may be made but they have the essentials of what they need, if they can keep it

up. One of the biggest challenges is tools, especially since the orphanage had none when we

arrived. They had to go beg through the village to borrow a wrench if they needed it to work on

the generator. We left a number of tools for them to help with maintenance and established a

locked location for their storage. Even so, the place is full of children and keeping them from

grabbing and running with anything you put down proved challenging.

In addition, beware of low quality plumbing parts! Too many of the valves used for the existing

water system were obviously low-bid and failing after two years. We replaced a number of

valves and trained a number of the older orphans how to do simple repairs and provided the

tools.

Blocks are made and not purchased in Cameroon. This is due to the low quality standards and a

lack of regulation on materials. The risk of buying them prefabricated is that the blocks will most

likely have too little cement in the mixture and will not be structurally reliable. An experienced

block maker can produce about 250 blocks per day provided the materials are on location.

Making block in the rainy season increases the risks of block quality. The builder told us that

not many construction projects are underway in the rainy season since it is harder to guarantee

proper curing of blocks. This may be a concern for future trips if the group continues

implementation travel each August.

The welders in Cameroon can do a lot with a little but do not have the capacity to cut thick

metal. Grinders and hacksaws do most of the cutting.

Quality control can be very challenging. In our case, welders stood on the plancha while

working and bent it. We were able to make it work by tipping it up towards the front of the stove

and sealing the gaps with mortar to prevent smoke from escaping. Working with steel this thick

was one of our greatest challenges. Oxy-acetylene cutting technology is very difficult find in

rural Cameroon. The most experienced welder in Limbe told us that he does a job similar to ours

(cutting through 3/8” steel plate) once every five to six years.






9.0 NEXT PHASE OF THE PROGRAM

Please refer to the 522 Post Assessment Report (Section 7) that was submitted in September

2010 in regards to the next phase of our program. Anticipated future travel dates are August

2011.

10.0 MENTOR ASSESSMENT

This document was prepared by the travel team of the EWB-UAA chapter with oversight by

their professional mentor for the stove, Nancy Hibbert.

Prior to travel to Cameroon, the design and travel teams built a prototype stove in Anchorage to

practice construction and test the founding principles of stove design. This prototype was a

success and the group learned a tremendous amount by working with a mason who instructed

students and mentors on masonry techniques and woodstove design. This prototype was a

smaller scale than the one constructed in Cameroon, but served as a model for all of the work

done at Rhema Grace.

Once in Cameroon, the travel team was divided into a stove implementation team and an

assessment team. Constructing the stove was of primary importance and so assessment team

members contributed to stove material procurement and consulted with the stove team when

crucial decisions had to be made. Kris Homerding was the primary project manager on stove

construction and worked closely with the local builder and older boys at the orphanage to

execute the project. I, Nancy Hibbert, as the mentor over the stove was integrally involved in all

decisions, material selection and construction details. Involvement of community members at

every step of the planning and construction process while in country was an important indication

of the maintenance of the stove and the success of future projects.

In summary, I, Nancy Hibbert, agree that this report meets EWB’s expectations for the 526

report. A 522 report concerning the assessment part of our work in Cameroon has already been

submitted and gives more detail about plans for future work at Rhema Grace.

10.1 Nancy Hibbert