SUSTAINABLE FISHERIES

MANAGEMENT PROJECT (SFMP)

AHOTOR OVEN CONSTRUCTION MANUAL

NOVEMBER, 2015
This publication is available electronically in the following locations:
The Coastal Resources Center
http://www.crc.uri.edu/projects_page/ghanasfmp/
Ghanalinks.org
https://ghanalinks.org/elibrary search term: SFMP
USAID Development Clearing House
https://dec.usaid.gov/dec/content/search.aspx search term: Ghana SFMP
For more information on the Ghana Sustainable Fisheries Management Project, contact:
USAID/Ghana Sustainable Fisheries Management Project
Coastal Resources Center
Graduate School of Oceanography
University of Rhode Island
220 South Ferry Rd.
Narragansett, RI 02882 USA
Tel: 401-874-6224 Fax: 401-874-6920 Email: [email protected]

Citation: Avega, B. (2015). Ahotor Oven Constuction Manual. The USAID/Ghana

Sustainable Fisheries Management Project (SFMP). Narragansett, RI: Coastal
Resources Center, Graduate School of Oceanography, University of Rhode
Island GH2014_ACT263_CRC 29 pp.
Authority/Disclaimer:
Prepared for USAID/Ghana under Cooperative Agreement (AID-641-A-15-00001), awarded
on October 22, 2014 to the University of Rhode Island, and entitled the USAID/Ghana
Sustainable Fisheries Management Project (SFMP).
This document is made possible by the support of the American People through the United
States Agency for International Development (USAID). The views expressed and opinions
contained in this report are those of the SFMP team and are not intended as statements of
policy of either USAID or the cooperating organizations. As such, the contents of this report
are the sole responsibility of the SFMP team and do not necessarily reflect the views of
USAID or the United States Government.

Cover photo: SNV

i
 Detailed Partner Contact Information:
USAID/Ghana Sustainable Fisheries Management Project (SFMP)
10 Obodai St., Mempeasem, East Legon, Accra, Ghana
Telephone: +233 0302 542497 Fax: +233 0302 542498
Maurice Knight Chief of Party Email: [email protected]
Kofi Agbogah Senior Fisheries Advisor Email: [email protected]
Nii Odenkey Abbey Communications Specialist Email: [email protected]
Bakari Nyari M&E Specialist Email: [email protected]
Brian Crawford Project Manager, CRC Email: [email protected]
Ellis Ekekpi USAID AOR Email: [email protected]

Kofi.Agbogah
[email protected] Resonance Global
Stephen Kankam (formerly SSG Advisors)
[email protected] 182 Main Street
Hen Mpoano Burlington, VT 05401
38 J. Cross Cole St. Windy Ridge +1 (802) 735-1162
Takoradi, Ghana Thomas Buck
233 312 020 701 [email protected]

Andre de Jager Victoria C. Koomson

[email protected] [email protected]
SNV Netherlands Development Organisation CEWEFIA
#161, 10 Maseru Road, B342 Bronyibima Estate
E. Legon, Accra, Ghana Elmina, Ghana
233 30 701 2440 233 024 427 8377

Donkris Mevuta Lydia Sasu

Kyei Yamoah [email protected]
[email protected] DAA
Friends of the Nation Darkuman Junction, Kaneshie Odokor
Parks and Gardens Highway
Adiembra-Sekondi, Ghana Accra, Ghana
233 312 046 180 233 302 315894

For additional information on partner activities:

CEWEFIA: http://cewefia.weebly.com/
CRC/URI: http://www.crc.uri.edu
DAA: http://womenthrive.org/development-action-association-daa
Friends of the Nation: http://www.fonghana.org
Hen Mpoano: http://www.henmpoano.org
Resonance Global: https://resonanceglobal.com/
SNV: http://www.snvworld.org/en/countries/ghana

ii
Acronyms
CCM Centre for Coastal Management
CEWEFIA Central and Western Region Fishmongers Improvement Association
CRC Coastal Resource Center
CSLP Coastal Sustainable Landscape Project
DAA Development Action Association
DFAS Department of Fisheries and Aquatic Science
DMFS Department of Marine Fisheries Sciences
DQF Daasgift Quality Foundation
FtF Feed the Future
GIFA Ghana Inshore Fishermen's Association
GIS Geographic Information System
GNCFC Ghana National Canoe Fishermen’s Council
HM Hen Mpoano
ICFG Integrated Coastal and Fisheries Governance
MESTI Ministry of Environment Science and Technology
MOFAD Ministry of Fisheries and Aquaculture Development
NDPC National Development Planning Commission
NGOs Non-Governmental Organizations
SFMP Sustainable Fisheries Management Project
SMEs Small and Medium Enterprises
SNV Netherlands Development Organization
SSG SSG Advisors
STWG Scientific and Technical Working Group
UCC University of Cape Coast
URI University of Rhode Island
USAID United States Agency for International Development
WARFP West Africa Regional Fisheries Development Program

iii
TABLE OF CONTENTS

CONTENTS
..................................................................................................................................................................... i
Acronyms...........................................................................................................................................................iii
SECTION 1: ABOUT THE MANUAL ............................................................................................................. 1
1.1 The design of the manual.......................................................................................................................... 1
1.2 Sustainable Fisheries Management Project .............................................................................................. 1
1.3 AHOTOR OVEN ..................................................................................................................................... 1
1.3.1Construction Materials ....................................................................................................................... 7

iv
SECTION 1: ABOUT THE MANUAL
1.1 The design of the manual
This manual is designed to give first-hand information on the steps, procedures, tools and materials
that stove builders require to construct an Ahotor oven. It outlines the basic steps involved in the
construction of the oven based on field testing and experience. This interactive manual is developed
in simple language with sketches that can easily be understood.
The design of the manual is intended to provide practical information and teaching aid for stove
builders and technical knowledge in constructing the Ahotor oven to specification.

1.2 Sustainable Fisheries Management Project

Sustainable Fisheries Management Project (SFMP) is a five year USAID funded project with the
objective of rebuilding marine fisheries stocks and catches through adoption of responsible fishing
practices. The project is a Feed the future initiative and contributes to the Government of Ghana's
fisheries development objectives and USAID's Feed the Future Initiative. Coastal Resources Center
(CRC) leads the implementation of SFMP with a consortium of local and international partners and
MoFAD.FC (Ministry of Fisheries and Aquaculture Development and the Fisheries Commission).
1.3 AHOTOR OVEN

The Ahotor oven was developed by SNV Ghana under Sustainable Fisheries Management Project
(SFMP) to improve on the quality and competitiveness of smoked fish through the use of a clean
smoking technology.
The Ahotor oven is designed as an improvement over the existing Chorkor smoker. The oven
comprises of a combustion chamber fitted centrally to a Chorkor-like outer shell, with fish
processing trays above as in a normal traditional oven. Above the combustion chamber, a fat
collecting tray is fitted that allows the hot gases to flow up through to the fish while preventing any
fat from dropping down onto the fire. A primary air inlet allows for oxygen into the combustion
chamber to enhance efficient combustion of the fuelwood. The secondary air inlet located on top of
the fuelwood entrance introduces cool air into the smoking chamber to meet with heat from
combustion chamber, to enable even circulation of air and heat in the smoking chamber. The grate
located underneath the combustion chamber improves combustion by elevating the fuelwood and
allowing for better heat circulation. The Ahotor oven is energy efficient (reduces fuelwood
consumption by 32%), emits less smoke compared to the Chorkor and produces smoked fish with
low PAH levels of 10.93μ/kg which is less than the EU standard of 12 μ/kg.

1
COMPONENTS OF THE AHOTOR OVEN AND THEIR FUNCTIONS

Table 1: COMPONENTS OF THE AHOTOR OVEN AND THEIR FUNCTIONS

Component Picture Function

It ensures efficient combustionof

Combustion Chamber fuelwood
It reduces smoke emissions It
ensures heat retention

It supplies oxygen into the

Primary Air Inlet combustion chamber

It is the channel for fanning the oven

It elevates fuelwood for better

Grate circulation of air

It supports efficient and complete

combustion of fuelwood

It supplies cooler air into the

combustion tube to mix with the hot
Secondary Air Inlet gases from the combustion chamber
It ensures fast flow of gases in the
smoking chamber

It receives fuelwood
Fuelwood Entrance
It regulates fuelwood use

2
 It redistributes heat into the
smoking chamber
Fat Collector It receives fat and other drippings
from fish and channel it out of the oven
It serves as the ash receptacle for it to
absorb the fat.

Fat Exit It is the exit for fats and other

drippings from the fish

3
 Table 2: Basic measurements

Oven Parts Breath Length Height

Millimetr Inche Millimetr Inche Millimetr Inche
e (mm) s e (mm) s e (mm) s
(inch) (inch) (inch)
Stove Wall (Outer) 1092 43 1120 44 840 33

Primary Air Inlet (Inner) 100 4 356 14 127 5

Firewood Entrance (Inner) 254 10 630 24 ¾ 285 11

Combustion Tube (Inner) 150 6 150 6 356 14

Secondary Air Inlet (Inner) 229 9 350 13 ¾ 220 8¾

Combustion
Chamber(Inne 254 10 629 24¾ 660 26
r)
Oil Collector 851 33 ½ 800 31 ½ 89 3.5
Grate 241 9.5 400 16 75 3

4
 Oven Plan

Figure 1: Oven Plan

Instructions

5
 450m
60mm m
210mm

200mm

100mm

Figure 2: Brick

(Brick) (Block)

Figure 3: Block Dimensions

✓ Masonry Wood patern

ü

✓ Wheel barrow
✓ Shovel/Spade
✓ Plastic bowls/buckets
✓ Hammer
✓ Saw
✓ Spirit level
✓ Trowel
✓ Try Square
✓ Head pan
✓ Measuring Tape
✓ Gloves
✓ Nylon rope/Line

6
1.3.1Construction Materials
The combustion chamber
of the Ahotor oven is built
with burnt bricks with
mortar from clay and
wood ash. Cement mortar
is only used for the
construction of the oven
wall (outer Chamber)
where there is limited
exposure to heat. The
quantity of materials and
the given ratios are very
important for both the
physical and thermal
strength.
Note: Mixing clay with
grog (sand) or mica gives
physical strength whereas
mixing clay with wood
ash gives thermal strength
(can withstand heat)

Table 3: Clay Mortar Ratio and Cement Mortar Ratio

Bag Bag

Headpan
Headpan

7
Table 4: Quantity of materials for constructing single unit Ahotor oven with sandcrete blocks
as the wall

Quantity of materials for constructing single unit

Ahotor oven with sandcrete blocks as the wall

Table 5: Quantities of materials for constructing single unit

Ahotor oven with burnt bricks for outer wall/shell

Quantities of materials for constructing single unit

Ahotor oven with burnt bricks for outer wall/shell

8
Table 6: Retrofit (Single Unit)

9
 OVEN CONSTRUCTION PROCESS

1. Using a measuring tape and a line, measure and mark

out the area where the stove will be constructed.

1090mm

1120mm

Figure 4: OVEN CONSTRUCTION PROCESS

2. Dig out the marked area about 50mm deep into the ground and
pour cement concrete mixture into the dug area. Using the spirit
level, check to correct slopping and dress the surface.

Figure 5: OVEN CONSTRUCTION PROCESS

10
 3. Mark the mid-point to identify the center. From
the center measure and mark out the firewood
entrance and the primary air inlet which are the
inner chambers according to the given
measurements.

630m
m

406mm
Figure 6: OVEN CONSTRUCTION PROCESS

4. Put clay mortar along the mark out and set

bricks on them for the first course of the fire
entrance and the air inlet.

Figure 7: OVEN CONSTRUCTION PROCESS

5. Insert clay mortar to join all the

bricks and lay bricks to bridge the
air inlet.

Figure 8: OVEN CONSTRUCTION PROCESS

11
Intersect the second course in order to avoid continuous joints and insert with clay mortar. Repeat
this until you
th quarter rods to hold bridge. Course and put across
attain 280mm usually at the 4

th
4
Course

6. Set and lay the 5th course to bridge the 4th

course and leave an
th
opening at the end measuring 180mm by 180mm. At the 5 course
(bridge) shift the bricks in slightly, to attain the 150 mm x 150mm
combustion chamber.
5 Course

280mm

4 Course

12
 th
7. Set and lay the 6 course along the
th
edge of the 5 left course and project the
opening.

th
8. Repeat step 7 until the 7 course is complete leaving the last wall between
th
the combustion tube and the secondary air inlet opened. At the 9 course,
put quarter rods across the air inlet and bridge 320mm towards the
combustion tube.

The fuelwood chamber opens into the primary air inlet whereas the
secondary air inlet opens into the combustion tube with one brick opening.

[Type here] [Type here] [Type here]

 220mm

280mm

[Type here] [Type here] [Type here]

9. Put cement mortar along the marked outer line and
set cement blocks on it touching the end of the brick
where they meet the outer lines.

nd
10. Intersect the 2 layer in order to
avoid continuous joints and insert with cement
rd
mortar. Repeat this for the 3 layer.

840mm
11. Drill/create two 100mm diameter holes on the wall opposite the entrances
about 180mm long from each side of the last layer of the blocks and set
the drain oil collector into them.
Set the fat collector first to be sure of the exact location
before drilling the holes.

12. Set the oil collector at an angle of about 25°-30° inthe chamber with the
higher end resting on the 10th course of the bricks.

Check the slope by pouring water on the collector to see the drains flow
gently down through the fat exit holes.
Oil Collector

1- - - - 8 00
¢210 MUSHROO M
HEAD

I
420
840 l
¢66

255 160
t L 180 _]

-400 255

bm ™
=--1.1....:1=:c:::.:1i::i=1u11:=fiiiHiiFilf:==1=111==11== .,-----.. .1. . J ..1_ FAT m d 75
I I 6050 QTY: 1COLLECTOR (FINAL
NOTE: THE TRAY HEIGHT MUST BE MATL: GALV.
MODEL)
FOLDED
-I f- go TO A FINAL HEIGHT OF DESIGNED: SNV
40 m m OFFICIALS DRAWN:
HOLE ENDS MUST BE FOLDED IN G.BOATENG
DATE: - AP
JUNE, P
2017
AT 10mm HEIGHT. IAH

SNV/ FRI COLLABORATION

ON FISHSMOKIN

(210mm 8)

Heat escape hole (20mm) high

Raised mouth of heat escape hole

(180mm 8) to a height of
5mm, which prevents oil
from dropping into the fire
12
 1,107mm

1. Cut a (2 by 1) Wawa wood

beam in pairs of two, one-
1,107mm long and the other-
890mm long.

865mm

1,107mm

13
3. Turn it over and nail to the base of the tray wire mesh, usually
1cm².Then nail buttons to cover the mesh ends and hold them
firm to the tray. Repeat the previous steps until the required
number of trays is achieved.

14
 1,107mm

15
 355mm

16
SUSTAINABLE FISHERIES MANAGEMENT PROJECT (SFMP)

Figure 9: SUSTAINABLE FISHERIES MANAGEMENT PROJECT (SFMP)

17
18