Considering Dairy Farm Construction in 2023?

Jason Hartschuh, Field Specialist, Dairy Management and Precision Livestock, Ohio State University Extension

Remodeling existing facilities to improve cow comfort can improve the longevity and production of your herd. When remodeling with a few improvements, you may consider free stall size, bedding material, water availability, lighting, floor grooving, and fan placement.

If an expansion is in your future, many of the same decisions will apply along with alley widths, the distance between cross-overs, and the alley cleaning system. All of these building projects will be affected by the availability and price of construction materials.

Inflation and rising interest rates are beginning to influence the construction industry, with fewer new construction projects being planned. In October 2022, the architecture billing rates index dropped below 50 which is considered the required amount for construction to remain fully booked (an index above 50 represents an increase in billed architectural plans and below 50 a decrease compared to the prior month). Construction will remain busy through 2023 with a 9 to 12-month lag between a decrease in architecture billing hours and construction projects. Since the architects complete most of their work prior to construction beginning there is a lag. Over the past year, construction has seen a 3.3% increase in total needed employees, but like other industries, it is struggling to attract enough employees which is causing delays in construction project completion.

Concrete costs have risen 11.6% over the last year and are expected to stay at these levels through most of 2023, with tight supplies of both cement and sand (Figure 1). Lumber prices are remaining strong as of September with soft lumber being up 14.5% and plywood up 19.6%. A few materials have come down, including steel which is 23.8% lower than last quarter but still 200% higher than 2018 prices. Since September, lumber has declined 9% from quarter 3 to quarter 4 of 2022 and is still about 110% higher than in 2018. Construction companies are expected to remain at full capacity through most of 2023 and building costs to not decrease until late into 2023. The location has a great effect on the construction market outlook.

 Figure 1. Construction Connection, Bureau of Labor Statistics https://www.ecmag.com/magazine/articles/article-detail/falling-into-place-2023-construction-outlook

When installing new free stalls, they should be sized to match the largest 25% of the cows in the group. Compromises do occasionally have to be made if your groups have a high percentage of first lactation cows in the group, especially if there is intolerance for manure on the back of stalls. Mature Holstein cows need 3 to 4 feet of open space in front of the stall for cows to lunge or they will lay at diagonally in your stalls, leaving manure in the corners instead of the alley. Stalls that are against a wall should be 10 feet from the back of the stall to the wall while head-to-head stall platforms should be a total of 18 feet. Even in head-to-head stalls when they are too close together, cows lunge to the side, especially cows who are socially intimidated by a dominant cow. 

1000-pound cows should have stalls that are 42 inches on center with 64 inches from the curb to the brisket locator and 58 inches from the curb to the neck rail. A 1600-pound Holstein cow needs a stall that is 50 inches on center with 70 inches from the curb to the brisket locator and 64 inches from the curb to the neck rail. Other cow sizes can be found in Figure 2.

Animal Weight

Total Stall Length

Total Stall Length

Length to Brisket Tube or Board

Length to Neck Rail

Stall Width Center to Center

Height to Top of Partition

Height to Neck Rail

Brisket Board or Tube Height

(lb)

Closed Front

Open Front

(in)

(in)

(in)

(in)

(in)

(in)

 

(inches)

(in)

 

 

 

 

 

 

900-1100

90-96

78-82

64-66

62-64

41-43

42-44

42-44

4-6

1100-1300

96-102

80-86

66-68

64-66

43-45

44-46

44-46

4-6

1300-1500

102-108

90-96

68-70

66-68

45-48

46-48

46-48

4-6

1500-1700

108-114

96-102

70-72

68-70

48-52

48-52

48-52

4-6

 

 

 

 

 

 

 

 

 

 

 

 

 

 


Figure 2. Freestall sizes based on animal weight. Dairy Freestall Housing and Equipment, Midwest Plan Service, Iowa State University, Ames.

Water availability is another critical component. Cows consume 30 to 60% of their water needs shortly after milking so waters need to be located close to the parlor or robot exits and throughout the barn. The stand-by has been 2 inches of assessable water trough perimeter per cow, but recent research has shown this needs to be 3 to 5 inches per cow, especially in the summer during heat stress periods. Each group of cows should have at least two waters so that more timid cows can access water when a dominant cow is controlling them. Barn crossovers and alleys with water or feed should be 14 feet wide so that eating and drinking cows are not disrupted by cows walking by.

Figure 3. Distance for fan air plume to reach cows and dissipate. Comparing the fans, the first black fan has a 20-foot gap before it reaches cow height. With a 24-foot spacing, the black, red, and blue fans can be shown to provide the overlap necessary to eliminate dead zones between fans. (The Dairyland Institute, https://thedairylandinitiative.vetmed.wisc.edu/home/housing-module/adult-cow-housing/ventilation-and-heat-abatement/)

Assessing barn ventilation also is critical during the building process. Stalls should have an air speed of 200 to 400 ft/minute at the cow lying height, about 2.5 ft off the stall surface. Air speeds over 400 ft/minute provide little additional heat abatement benefits. A 48-inch fan previously was used to cover 40 ft, but newer research shows that when these fans are pointed correctly for cooling while cows are lying down, they need to be closer at 24 ft apart or 5 times the blade diameter. It takes about 20 ft for air to reach the cow’s back from the fan, so fans that are 40 ft apart are really covering 60 ft with a 20-ft dead zone (Figure 3). Best wishes with your upcoming construction projects, whether it is a renovation or new construction.