Slurry tanks

slurry tanks

Slurry tank is a prefabricated reinforced concrete structure for safe storage of liquid animal manure in accordance with environmental requirements. They are manufactured from C35/45 class concrete with increased chemical resistance, using technology that ensures full tightness and resistance to aggressive effects of ammonia and organic acids. They are used on livestock farms as a mandatory component of the infrastructure for proper manure management.

For each farm manure tanks price is calculated individually based on the required capacity, ground conditions and additional equipment. We guarantee comprehensive advice in selecting the capacity in accordance with the density of DJP, professional installation and documentation necessary to obtain permits. We invite you for a free quote tailored to the size of your farm.

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Prefabricated slurry tank – a complete solution for farms

The manure tank is a key component of the infrastructure of any modern livestock farm, providing safe storage of manure for a minimum period of 6 months, as required by law. Prefabricated reinforced concrete structures manufactured under controlled factory conditions guarantee the highest quality of workmanship and full tightness eliminating the risk of environmental contamination. The modular system allows the capacity to be adapted to any size of farm.

The production of slurry tanks is based on the use of concrete of minimum class C35/45 with a compressive strength of 45 MPa and watertightness of W8. Increased cement content and sealing additives ensure the structural integrity of the concrete. A-IIIN steel reinforcement at 80-120 kg/m³ protects against scratching from hydrostatic loads.

Construction of prefabricated slurry tanks

The slurry tank is made as a monolithic cylindrical or rectangular structure from prefabricated elements joined on site. The system of concrete circles with a diameter of 3-8 m and a height of 1-2 m allows for quick installation. The bottom of the tank is a 20-30 cm thick reinforced concrete slab with a profiled slope to the collection sump.

An alternative is slurry tanks made of large-scale wall segments mounted on a prepared foundation slab. The height of the walls of 3-5 m allows the construction of tanks with a capacity of 500-3000 m³. A system of expansion joints sealed with bentonite tapes ensures tightness of connections.

Legal requirements for slurry tank regulations

According to the current standards, the slurry tank regulations define the minimum capacity as the product of 6 months of production and the number of LU on the farm. For cattle it is assumed 20 m³/DJP/year, for pigs 8 m³/DJP/year, for poultry 3.5 m³/DJP/year. The reservoir must have a capacity reserve of 20% for rainwater and process water.

The slurry tank system must meet the requirements of the Nitrate Directive limiting nitrogen application to 170 kg N/ha/year. Watertight construction with no possibility of infiltration into the ground. Mandatory manure slab for manure leachate. Design documentation in accordance with the Construction Law.

Types and capacities of tanks

Standard 20m3 slurry tanks are a solution for small farms up to 10 LU. Popular capacities are: 100 m³ (up to 30 LU of cattle), 200 m³ (60 LU), 500 m³ (150 LU), 1000 m³ (300 LU), 2000 m³ (600 LU). Modular tanks allow expansion when livestock numbers increase.

Special concrete slurry tanks with cover eliminate ammonia and odor emissions. Floating membrane system or reinforced concrete floors. Agitator systems prevent sedimentation and drossing. Two-chamber tanks allow methane fermentation.

Advantages of a prefabricated slurry tank

The tightness of the slurry tank

The prefabricated slurry tank guarantees 100% watertightness thanks to W8 concrete and additional sealing coatings. Elimination of leaks protects groundwater from nitrate contamination. The system meets the strictest environmental requirements and permits.

Durability of slurry tanks

Slurry tanks made of C35/45 concrete have a service life of more than 50 years. Resistance to chemical corrosion from ammonia and organic acids. No need for maintenance or repairs over the lifetime.

Economics of the slurry tank

A prefabricated slurry tank costs 30-40% less than a monolithic one for the same capacity. Quick installation of 2-5 days reduces labor costs. Possibility of obtaining RDP subsidies up to 60% of eligible costs.

Capacity of slurry tanks

Modular slurry tanks allow flexible capacity adjustment of 50-5000 m³. Expansion system by adding more coils or segments. Optimization of capacity to actual farm needs.

Slurry tank compliance regulations

Slurry tank regulations met by prefabricated units with full technical documentation and certificates. The design includes capacity calculations in accordance with the DJP. Documentation simplifies administrative procedures and inspections.

Functionality of the slurry tank

Slurry tank equipped with piping system, pumping stations and agitators. Integrated inspection and intake sumps. Possibility of automation of filling and emptying.

Installation of a 20m3 slurry tank

Small slurry tanks 20m3 assembled in one day without heavy equipment. Finished elements require no concrete setting time. Immediately ready for operation after installation.

Resistance of concrete slurry tank

Frost-resistant concrete slurry tank thanks to exposure class XA3. Resistance to loads from freezing slurry. No degradation in extreme weather conditions.

Application of manure tank on farms

The manure tank is used in all types of livestock farms as a mandatory component of the manure management system. Prefabricated structures adapt to the specifics of different types of farming – dairy cattle, pigs, poultry or mixed production. The modular system allows optimal adaptation to the size of the herd and the system of keeping animals.

Dairy farms

On dairy cattle farms, manure tanks with a capacity of 500-2000 m³ store manure from free-stall barns. A system of slotted grates and slurry channels transports manure directly to the tank. With a stocking rate of 100 cows, a minimum capacity of 400 m³ is required, plus a reserve for rainwater.

The manure tank on organic farms must allow separation of manure from different groups of animals. Multi-chamber tanks allow separate storage of manure from the grazing and barn periods. The system meets the requirements for organic certification.

Pig farms

Industrial piggeries require slurry tanks with increased resistance to high ammonia concentrations. Capacity of 1000-5000 m³ for farms over 1000 head. Covered tanks reduce nuisance odor emissions. A biofilter system in the ventilation reduces the spread of odors.

Small farms use a slurry tank regulations specifying a minimum of 50 m³ for 50 fattening pigs. Tanks sunk into the ground minimize the occupied area. Location away from residential buildings in accordance with sanitary regulations.

Poultry farms

Poultry houses and laying hen farms use a slurry tank for liquid manure from the cage system. High nitrogen content requires airtight XA3 concrete tanks. Capacity of 200-1000 m³ for farms of 10-50 thousand poultry.

Broiler farms use 20m3 slurry tanks mainly for water from washing poultry houses between cycles. Manure from litter farming stored on the manure slab. Leachate discharge system to the main tank.

Mixed holdings

Multi-directional production requires a concrete slurry tank universal for different types of manure. Capacity calculations add up the requirements for all animal groups. Tanks of 300-800 m³ are typical for family farms of 50-150 LU.

Agricultural biogas plants

Biogas plants use septic tank for slurry as digestion and digestion tanks. Capacity adjusted for retention time of 30-60 days. Tanks insulated and equipped with agitators for the fermentation process. Underfloor heating system maintains mesophilic temperature.

Digestate tanks require the same capacity as input slurry septic tanks. Increased ammonium nitrogen content requires a cover. Dosage facilities for field spillage.

Agri-food processing plants

Slaughterhouses and meat plants use slurry tanks for process wastewater from the washing of livestock transport vehicles. Fat separators before the main tank. Capacity adapted to daily wastewater production.

Agritourism farms

Small demonstration farms require aesthetically pleasing slurry tanks covered with greenery. Location out of sight of tourists. Odor neutralization system with biopreparations. Capacity of 20-50 m³ for several animals.

Horse stables

Sport stables use the manure tank mainly for leachate from horse manure piles. Low manure production with bedding maintenance. Capacity of 50-200 m³ for stud farms of 20-50 horses.

Fur farms

Mink and fox farms require manure tanks with extreme chemical resistance. Very aggressive manure with high ammonia content. Tanks with additional chemical-resistant insulation. A forced ventilation system for the halls.

Technical parameters of the slurry tank

The slurry tank is designed and manufactured in accordance with the PN-B-03264:2002 standard for concrete, reinforced concrete and prestressed tank structures. Calculations according to PN-EN 1992-3 (Eurocode 2 part 3) for concrete structures for liquid storage. All elements have a declaration of performance and meet the requirements of the Water Law.

Material parameters of the structure

Prefabricated slurry tanks are made of concrete of minimum class C35/45 with the following parameters: compressive strength fck = 35 MPa, watertightness W8 (pressure 0.8 MPa), frost resistance F150, absorbability < 5% by weight. Exposure class XA3 for strong chemical aggression.

Slurry tank reinforced with class A-IIIN (B500B) steel in the following amounts: walls 80-100 kg/m³, bottom 100-120 kg/m³, ceiling (if any) 90-110 kg/m³. Reinforcement cover 40 mm on the slurry side, 30 mm on the outside. Contraction reinforcement φ8 every 20 cm.

Typical dimensions and capacities

Standard dimensions of cylindrical slurry tanks: diameter 6-30 m, height 3-6 m, usable capacity 85-4200 m³. Wall thickness 15-25 cm depending on the diameter. Thickness of the bottom 20-30 cm with a layer of lean concrete 10 cm.

Rectangular slurry tanks regulations dimensions: length 10-50 m, width 8-20 m, depth 3-5 m. Capacity 240-5000 m³. Walls 20-30 cm thick with reinforcement at the corners. System of buttresses every 4-6 m in length.

Chemical resistance

Slurry tank design resistant to: pH 5.5-9.0, ammonia up to 4000 mg/l, hydrogen sulfide up to 200 mg/l, organic acids (acetic, propionic, butyric), soluble salts up to 5000 mg/l. Diffusion coefficient of chlorides < 8×10-¹² m²/s.

Additional protection of slurry tank 20m3 and larger: epoxy coatings 300-500 μm thick, PE/PP welded membranes, heavy type bitumen insulation, silicate hydrophobic impregnations. Durability of coatings minimum 25 years.

Hydraulic parameters

Capacity of the supply system to the concrete slurry tank: pipelines DN 200-400 mm for gravity slurry, DN 100-200 for pumping slurry. Pump capacity of 50-500 m³/h with a head of 5-15 m. Agitators of 5-30 kW.

Soil requirements

The foundation of the septic tank for slurry requires the bearing capacity of the soil min. 150 kPa. Groundwater level at least 1 m below the bottom of the tank. Soil filtration coefficient k < 10-⁸ m/s or additional sealing layer. Slope of the land max 2%.

Tank cover system

Slurry septic tank covers: 15-20 cm thick reinforced concrete ceilings with 80×80 cm manholes, PEHD floating membranes with ballast, double-layer pneumatic tents, 10-20 cm thick natural biofilms. Reduction of ammonia emissions by 80-95%.

Technological equipment

Standard equipment of the slurry tank: sump φ1000 mm deep 0.5 m below the bottom, stainless steel descending ladder, process platform 1.2 m wide, guard rails 1.1 m high, overflow alarm system.

Operating parameters

Filling of slurry tanks: up to a maximum of 90% of the total capacity, 0.2 m rainfall reserve, retention time of at least 6 months. Slurry temperature 5-25°C. Increase in bottom sludge 2-5 cm/year. Frequency of mixing 1-2 times/week.

Dimensional tolerances

Accuracy of slurry tank manufacturing: dimensions ±20 mm, verticality of walls ±15 mm/3m, crown level ±10 mm, straightness of edges ±10 mm/5m. Gaps between elements max 10 mm. Surface irregularities max 5 mm/2m.

Certifications and standards

Required documents for slurry tanks: ITB Technical Approval, PZH Hygienic Attestation, CE Declaration of Conformity, Certificate of Factory Production Control. Compliance with the Nitrate Directive 91/676/EEC and the regulation on the action program.

Installation of a slurry tank – instructions for implementation

Proper installation of a prefabricated slurry tank requires proper preparation of the ground, precise positioning of the elements and ensuring full tightness of the connections. The process is carried out in stages with technology that guarantees the durability and safety of the structure. Prefabricated system allows installation regardless of weather conditions in 3-7 days.

Preparation of the excavation and subsoil

Excavation for slurry tanks made with slopes of 1:1 to 1:0.5, depending on the soil. Dimensions of the excavation larger by 1.0 m from the outer contour of the tank. The depth takes into account the leveling layer of 10 cm and the bottom plate. Drainage of the excavation with needle-filters at high groundwater levels.

The foundation for the slurry tank leveled and compacted to Is>0.98. A layer of lean concrete C8/10 10 cm thick is the base. In weak-bearing soils, replace the soil with a bedrock or use piles. Checking the bearing capacity with a static plate E₂>80 MPa.

Installation of the bottom plate

Bottom slab of slurry tanks laid on prepared ground as a prefabricated element or poured on site. Thickness 20-30 cm with a 1% slope to the collection sump. Bottom and top reinforcement with φ12 mesh every 15 cm. Edge expansion joints 2 cm filled with elastic putty.

As an alternative for a slurry tank, the regulations allow a bottom of bottom coils joined with waterproof mortar. Seal joints with intumescent bentonite tapes. Water tightness test before wall installation.

Positioning of wall elements

Concrete circles of the slurry tank set with a crane with a capacity adapted to the weight of the elements 5-15 tons. The first coil leveled on levelling mortar. Subsequent circles joined on adhesive mortar 10-20 mm thick. Verticality control ±10 mm/3m height.

Segments of rectangular slurry tank 20m3 and larger assembled in order from the corners. Stabilization with stays during mortar setting. Connecting reinforcement φ16 in sockets filled with concrete. Wall assembly time 1-2 days for a 500 m³ tank.

Sealing of joints

All joints in a concrete slurry tank sealed with multi-stage sealing: waterproof mortar in the joint, 20×5 mm bentonite tapes, polyurethane putty on the inside. For tanks >1000 m³ additional welded PEHD membranes.

Pipeline passages through the walls of the septic tank for slurry in protective sleeves with sealing flanges. Sealing chains or segmented culverts for pipes DN>200. All passages above the minimum level of the slurry.

Installation of equipment

Installed in slurry septic tanks: submersible or surface mixers on booms, submersible pumps in sumps, supply pipelines with valves, ladders and service platforms, level sensors with overflow alarm.

Aeration system for slurry tank for odor reduction – bottom diffusers or surface aerators. Ex explosion-proof electrical system. Control cabinet outside the danger zone.

Performing backfilling and landscaping

Backfill slurry tanks with sandy soil in layers of 30 cm with compaction. Without stones and lumps that can damage the insulation. Slope of the ground from the tank a minimum of 2%. Earthen embankment 0.5 m high at a distance of 2 m from the walls.

Around the slurry tank make a maneuvering area of concrete blocks or road plates. Width of 6 m for slurry tankers. Slope towards the tank with drainage into the sewer system.

Leakage test

Leakage test of slurry tanks with water to full working height. Test time 7 days with level measurement every 24h. Allowable drop < 10 mm taking into account evaporation. Visual inspection of leaks and dampness.

Alternative slurry tank test regulations allow a vacuum test for covered tanks. Vacuum of 20 mbar maintained 1 hour. Location of leaks by acoustic or smoke method.

Technological commissioning

First filling of the slurry tank gradual – 1/3 of the capacity in the first month. Control of settlements and deformations. Starting the agitators when the minimum level is reached. Inoculation with biopreparations for odor reduction.

Training of operators in the operation of a slurry tank of 20m3 and larger: principles of filling and emptying, operation of mixers and pumps, monitoring of levels and alarms, record keeping, emergency procedures. Handover of DTR and health and safety instructions.

Slurry tank price – cost calculation for farms

Slurry tank price is shaped by the capacity of the structure, the type of technical solution, accessories and soil and water conditions at the site of foundation. The valuation includes the cost of prefabricated elements, transportation, installation and necessary ground works. Slurry tanks price significantly depends on the possibility of obtaining funding from agricultural support programs.

Cost structure of slurry tanks

The main component affecting the price of slurry tanks is the cost of prefabricated components, which accounts for 50-60% of the investment value. The price per 1 m³ of capacity is 250-400 PLN for uncovered tanks, 350-500 PLN for covered tanks. Slurry tank price of 500 m³ is the cost of 125000-200000 PLN net.

Earthworks and site preparation account for 20-25% of the total outlay. Slurry tanks price increases with high groundwater levels requiring drainage. Installation accounts for 15-20% of the cost, transportation 5-10% within a radius of up to 100 km.

Price list 2024 for slurry tanks

In 2024, prices are seen to stabilize after previous material increases. Slurry tank regulations price in 2024 for typical capacities: 100 m³ – PLN 35000-45000, 300 m³ – PLN 90000-120000, 500 m³ – PLN 140000-180000, 1000 m³ – PLN 250000-350000.

Current rates in 2024 show that the slurry tank the price of covering with a reinforced concrete floor is an additional 400-600 zł/m² of area. Floating membrane 150-250 PLN/m². In 2024, there will be an increase in interest in solutions to reduce ammonia emissions due to tightening standards.

Price forecast for 2025

Predictions for 2025 indicate a possible price increase of 5-7% due to rising cement and steel costs. A 20m3 slurry tank price in 2025 may exceed PLN 10000 for a complete solution. The introduction of stricter environmental standards will force the use of more expensive technologies.

In 2025, subsidies for tank construction are expected to increase under the new RDP. The price of a concrete slurry tank after subsidies can be 50-60% lower. The development of agricultural biogas plants will increase the demand for digester tanks.

Cost comparison of different technologies

Analysis shows that the price of prefabricated slurry septic tanks is 30% lower than monolithic ones. Steel tanks 20% cheaper for small capacities up to 200 m³, but more expensive for larger ones. Earthen lagoons with geomembrane cheapest, but allowed only in some cases.

Flexible silo bag tanks cost 50% of the price of concrete ones, but have a lifespan of only 5-10 years. Slurry septic tanks price with plastic competitive up to 100 m³, above that concrete more cost-effective.

Optimization of investment costs

Reducing the outlay for a slurry tank price possible by: choosing the optimal location close to the barn, using existing pits, group purchase with neighbors, implementation outside the construction season.

Savings on slurry tanks price by forgoing cover where regulations allow. Use of simpler mixing solutions. Staging of the investment with the possibility of expansion. Use of own transportation and equipment.

Tank operating costs

Annual maintenance costs of slurry tank price: energy for mixers 2000-5000 PLN, technical inspections 500-1000 PLN, minor repairs 1000-2000 PLN. Emptying and removal of slurry 50-100 PLN/m³ when ordering the service.

Depreciation of slurry tanks price with a useful life of 40 years is 2.5% per year. Finance costs with a preferential loan 3-4% of the value. Liability and property insurance 0.5-1% of the replacement value.

Subsidized construction of tanks

The RDP program offers support for slurry tank regulations price up to 60% of eligible costs. A limit of 200000 PLN for farms up to 300 DJP. Young farmer additional 20000 zloty bonus. Condition – improvement of animal welfare.

Farm modernization allows subsidizing the slurry tank price as part of comprehensive investments. Cross compliance requires a tank for farms >10 DJP. Inspections by the WIOŚ and ARMA verify the capacity.

Forms of investment financing

Preferential loans for slurry tank 20m3 price and larger with ARiMR subsidy for interest. Repayment period up to 8 years, grace period 2 years. Interest rate 2-3% per year. Security on agricultural property.

Leasing for concrete slurry tank price – own payment 10-20%, monthly installments for 5-7 years. Tax benefits from depreciation. Possibility to buy back for 1% at the end of the contract.

Sample calculations for farms

A farm of 50 dairy cows (65 DJP) requires a 260 m³ tank. Manure septic tanks complete price: tank 75000 PLN, excavation 15000 PLN, installation 12000 PLN, equipment 8000 PLN. Total PLN 110000, after subsidy PLN 44000.

Pig farm of 500 fattening pigs (65 DJP) needs 260 m³. Slurry septic tank price with cover: tank 90000 PLN, membrane 25000 PLN, works 20000 PLN. Total PLN 135000, subsidy PLN 81000, own cost PLN 54000.

Comprehensive slurry tank offer price including design, permits, construction and commissioning often favorable by 10-15%. Warranty 10 years for the structure, 2 years for the equipment included in the price.

The final slurry tank price of each project requires an individual analysis of local conditions, the size of the farm and the possibility of financing. We encourage you to contact us to prepare a detailed tank offer tailored to the needs of your farm.

Here are just some of our realizations regarding our prefabricated products. This list includes only major investments on which our prefabs have appeared.

What are ?

Precast concrete units are prefabricated building components produced off-site that can be assembled into larger structures at the project site. These are standard, repetitive modules produced in series at industrial plants, which greatly speed up and facilitate construction work in various construction sectors.

What are the types of ?

Reinforced concrete. prestressed concrete, post-tensioned concrete – 20+ types

What is the use of ?

Rapid modular construction of various structures

What are the properties of the ?

Repeatability, precision, speed of installation, durability

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