FREE-STAll HOUSING FOR DAIRY CATTl By A. J. Muehling and L. R. Fryman

CIRCULAR 919

UNIVERSITY OF ILLINOIS COLLEGE OF AGRICULTURE

COOPERATIVE EXTENSION SERVICE

THE FIRST FREE-STALL BARN FOR DAIRY CATTLE

in the United States was built near East Stan­wood, Washington in the fall of 1960. Since that time the interest in this type of housing for dairy cattle has been growing, and during the last few years many have been built in Illinois. In free-stall housing, cows are free to enter or leave individual bedded stalls as they please. This is in contrast to the method used in loose-housing operations where there is a resting or bedding area for all the cows. At this time, many loose-housing barns are being converted to the free-stall system, and new barns for free stalls are being built.

The major advantage of free stalls for dairy cattle is reduction in the amount of bedding re­quired. Experience indicates that only about one­fourth as much bedding is used as in conventional loose-housing barns. Since bedding is becoming more expensive and harder to find, this is an im­portant item.

Another advantage of this system is that when stalls are cleaned daily and managed properly, cows stay quite clean. The partitions between stalls also give cows more privacy, better conditions for rest­ing, and require less space per cow than loose hous­

j J

lng. Free-stall housing makes possible the efficient use of mechanical equipment ~o remove manure from alleyways and the storage pit.

There are several problems connected with the management of free-stall housing. A few cows may refuse to use the stalls and become quite dirty from lying in the alleyway or outside. There are also some difficulties in handling the semi-liquid manure. If a liquid manure handling system is used, a high capital investment may be required. Ways of overcoming these difficulties will be dis­cussed in this circular.

The material in this circular is based on a field study of a number of free-stall installations in Illinois, and a review of work conducted in other states.

Stalls

After observing stalls varying in width from 3 feet 9 inches to 4 feet 6 inches, and in varying lengths from 6 feet 9 inches to 8 feet, the follow­ing recommendations are made.

Width of stall. Stalls should be 4 feet wide. Cows seem to shy away from narrower stalls.

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Free-stall barns are becoming increasingly popular in Illinois. Above is a newly-built free-stall barn. A liquid manure storage tank is shown under construction, and is located so that the manure can be scraped directly from the alleyway into the tank. Older barns are also being adapted to this system of housing. (Fig. 1)

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A 2" x 4" neck board located approximately 2 feet from the front of the stall will hold the cows to the rear and result in cleaner stalls. (See also Figs. 4, 5, and 6.) The neck board allows the use of a longer stall with more space for the cow's head after she lies down. The neck board is much less likely to be knocked off by the cows if placed underneath rather than above the top stall partition.

(Fig. 2)

Stalls for heifers or very small cows may be slightly narrower, but not less than 3 Yz feet wide. The important thing is that the animals should not be able to turn around in the stalls.

Length of stall. Stalls should be at least 7 feet 6 inches long for Holsteins, and 7 feet for smaller breeds (see table below). The cows can be held to the rear of the stall with a neck board located approximately 2 feet from the front of the stall, as shown in Fig. 2. The advantage of the neck board is that it allows the use of a longer stall with more space for the cow's head after she lies down. Stalls as long as 8 feet work well when neck boards are used. Use the following table to find the recommended size of stalls:

Average weight Width Length of herd of stall of stall

1,100 pounds or less . . .... 4 feet 7 feet 1,100 to 1,500 pounds . .. .. 4 feet 7Yz feet 1,500 pounds or more .. . .. 4 feet 8 feet

Stall partitions. Stall partitions can be made of lumber or pipe. The partitions must be con­structed of sturdy material and fastened securely or the cows will break or bend them.

It has been found desirable by experienced op­erator to angle the stall partition post away from the alleyway as shown in Fig. 3. This angling of the post gives extra clearance for the hub of the tractor wheel when scraping the alleyway.

A 2/1 X 6/1 brace placed across the top of the partition posts, 5 feet above the curb, provides rigidity to the partitions and also helps to prevent cows in heat from riding the cows in the stalls. Fig. 3 shows such a brace across the top of the partition posts.

Homemade stall partitions constructed with lum­ber seem to work as well as any of the commercial stall partitions. Figs. 4 and 5 and 6 show plans for typical stalls that can be constructed on the farm.

Curbs. Curbs can be made either from con­crete or treated plank. The height of the curb de­pends somewhat on how far the operator must scrape the manure in the alleyway. Where the ma­nure must be scraped long distances, a higher curb should be provided to prevent manure from build­ing up and spilling into the stalls. Curbs should be from 6 to 12 inches high, with 10 inches being a good general recommendation.

Bedding. Many different types of bedding are used including crushed corn cobs, chopped and long straw, sawdust, chopped cornstalks, wood chips, and peanut hulls. Crushed corn cobs work out ex­ceptionally well. Fig. 3 shows the use of 6 to 8 inches of crushed cobs. This seems to make an ideal bed. Sawdust may also be used. Long straw is satisfactory, but works out of the stall more

Angling the partition post away from the alleyway pro­vides extra clearance for the tractor hub when scraping the alley. A 2" x 6" brace placed across the top of the partition posts provides rigidity to the partitions and helps to pre­vent cows in heat from riding cows in the stalls. An ideal bed for the cows can be made with 6 to 8 inches of crushed corn cobs. (Fig. 3)

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---

WALL 2IXS" BRACE

- XS"':::::­n= 2I

0: Il,0 2"XS --­

Detail of a free-stall partition showing angling 2" x 6" par­tition post and concrete curb. It is desirable to use treated lumber for the post when it ]16" BEDDINGextends into the ground. A treated 4" x 4" or 4" x 6" post could also be used. (Fig. 4) ALLEY

7'- 6" ~I

2"X 6" BRACE WALL

5" TREATED POST

2" X 6" ____

Detail of a free-stall partition -0 2"X 4" NECK BOARD

showing a round post and 2­Iinch plank curb. When the 2" X 6" ~------=--=-- -~_

curb is made of wood, treated to , lumber should be used. The ends of the stall partition next to the alleyway should .i~ -=v::::= 2" X 6" -- c::::: -- ----::::ill' I be beveled to eliminate sharp 11 t: edges. (Fig. 5) ALLEY ill

" ' ~'-+IITREATED 2" X 10" III - ~, ~ v ~ -..... ---, --,. =-r- } 11'1i II;

• i i ... • I' 1'1' i i i i . 11'11

illi ~ CONCRETE FLOOR

7'- 6"--·-----­

easily than cobs or sawdust. Chopped cornstalks one converted stanchion barn in central Illinois, can be used as shown in Fig. 7. crushed cob bedding was placed on the existing con­

Materials that can be used for the base under crete base, and this is working quite well. the bedding include dirt, or 6 inches of either sand In general, bedding costs are very low. Some or limestone. Although concrete bases are not rec­ operators add bedding once each week, and others ommended for new free-stall barns, in the stalls of only once a month.

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WALL

Detail of a free-stall partition made with pipe. The neck board could be made with V/4-inch pipe or a 2" x 4" board. Partitions must be constructed rigidly to with­stand rough treatment from the cows. (Fig. 6)

Paved Alleyway

The minimum width of the alleyway should be 8 feet. Alleyways 10 feet wide seem to work best because cows have plenty of room to pass, and boss cows cannot prevent the others from entering the barn. The alleyway should be made of re­inforced concrete 5 inches thick to accommodate tractors for scraping and hauling bedding. Use only a wood-float finish; the use of a steel trowel may result in a surface that is too slick. Cross alleys every 20 to 30 stalls help ease the cow traf­fic, but they may have to be scraped by hand.

Doors at the ends of the alleyways allow for easier "straight line" mechanical operations. A side-unloading wagon is convenient for adding bed­ding to the stalls.

Stall Arrangement

For herds up to 60 cows, it is best to ha,"e two straight rows of stalls with one center alleyway. (Fig. 8 shows a plan of a free-stall barn and one alleyway.) For larger herds, multiple alleyways should be used to shorten the distance that the ma­nure has to be scraped.

Stall arrangement is more complicated when fit­ting stalls to existing buildings than when con­structing new facilities. Using multiple alleyways

1/4" PIPE

which run across the barn is usually the best plan when converting loose-housing barns to free-stall barns (Fig. 9). When multiple alleyways are used, there will be two rows of stalls facing one another. It is not necessary to have a solid partition to keep the cows from seeing one another, although a solid partition in a large barn may cut down drafts dur­ing the winter.

Chopped corn stalk bedding can be used successfully. This is one source of bedding that is usually available in an un­limited supply in Illinois. (Fig. 7)

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I - ---- SO'-O" -I

I ventilation are provided. Openings under both - i - I -- eaves or ridge ventilators, or both, should be pro­I -ro

Iiro : W(\J 0 SLOPE0(1.o -' PAVED ALLEY iD - ...J.... 0 ZO 1/8" PER FT.

<J) (\J - CURB

,­

Arrangement of a free-stall barn with central alleyway. This arrangement is suitable for herds up to 60 cows. Con­sider two or more alleyways for larger herds to shorten the distance alleyways must be scraped. (Fig. 8)

f---- - ------- 70' TO BO '-·------------­

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r--- f--­

-0 r--- t--­v

I r--- PAVED PAVED PAVED t--­U ALLEY ALLEY ALLEY;5 r--- f--­-v

1 (/) r--- ­

0...J ...J -,:,.

r--- ­~ I

~ r--- w'" ­Q.~ r---CURBS _

r--- -.J~ ­fr--- i----­

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Plan of free-stall barn with multiple alleyways across the barn. This arrangement is likely to be useful when con­verting loose-housing barns to the free-stall system.

(Fig. 9)

Barn Construction

Standard clear-span pole construction with cor­rugated metal roof and walls is commonly used for new free-stall barns. Clear-span construction will allow flexibility of interior arrangement. A treated plank skirt board should extend up a mini­mum of 2 feet in order to keep manure from com­ing in contact with the metal walls. The size and shape of a new building for free stalls should be determined by the number of stalls needed, A typ­ical barn with two rows of stalls and a center alley­way is about 26 feet wide (Fig. 10).

It is recommended that the roof or ceiling of the free-stall barn contain some insulation. The insula­

vided. Also, one entrance door should always be left open. Some operators think they are kind to their cows by closing all the doors during bad weather, but may end up with very wet and un­desirable conditions inside the barn.

When the cows are continually confined in a warm (completely insulated) free-stall barn and all feeding is done inside, proper insulation and adequate mechanical ventilation must be provided. Poor ventilation will foster very moist conditions leading to messy stalls and dirty cows. A building with an insulated false ceiling normally requires mechanical ventilation.

Manure Handling

Manure that does fall in the stall must be cleaned into the alleyway at least once a day. Many op­erators clean the stalls every time they milk. Clean­ing the manure from the stalls is a quick operation with a garden rake, and many stalls will not require much cleaning.

The alleyway should be scraped at least once each day. A tractor scoop or blade seems to work best. The manure scraped from the barn will con­tain very little bedding and therefore, is quite thin and hard to handle. Some problems of loading and hauling this manure with standard equipment may be encountered. It is best to have a wall or batter board to push against when loading with a manure scoop. You can use a flail-type manure spreader adapted for liquid manure, or block the

j ­CLEAR-SPAN TRUSS

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-9

BEDDING

tion helps control condensation during cold weather and provides extra comfort from the sun during hot weather. Several operators confirm that during hot weather the cows will remain in an insulated free-stall barn during the day and rest outside dur­ing the cooler night.

A cold uninsulated barn with gravity ventilation will work satisfactorily if adequate openings for

7 '-S" + 10'-0" + 7'- s" ".

26'-0" -:

Cross-section showing typical construction of a free-stall barn with central alleyway. An insulated roof results in a cooler building in summer. It also controls condensation and provides warmth during the winter. If a false ceiling is used, the insulation should be placed above the ceiling.

(Fig. 10)

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rear of a standard spreader with straw to keep the liquids from escaping.

The manure can be scraped directly into a spreader from a loading ramp. Fig. 11 shows a loading ramp built at the end of a free-stall barn. Two passes with a front-end loader cleans the alleyway and load the manure directly into the spreader. The road under the ramp should be paved. A detailed plan of this loading ramp is shown in Fig. 12.

Liquid manure. With proper equipment, dairy manure from the free stalls and paved feeding floors can be stored in a tank and handled as a liquid. The following recommendations should be followed:

A loading ramp built directly off the end of the central alleyway can greatly aid the manure handling problem. Louvers in the gable ends and several ridge ventilators provide winter ventilation and the side doors are opened for summer ventilation. (Fig. 11)

9'--1 6" MIN. 6"

CURB

SECTION A - A 2" PIPE POST

WITH BRACES r------- 12' APPROX . WELDED AT

12"MIN. THE BOTTOM

~.,...--,-,...."..t~~~

RETAINING WALL

In handling manure from the free-stall barn and the paved lots, some additional water must be added to the storage tank so that manure can be handled as a liquid. Usually the wash water from the milk­house and parlor is sufficient.

Install a storage tank of at least 500 gallons per cow to provide for a 3- to 4-week liquid manure storage. The tank should be located as close to the stall area as possible. Things to be considered when determining the total amount of storage needed are the number of cows; the length of time the land is not accessible in bad weather; availability of the land during the growing season; the seasonal labor

This chopper pump can fill the 1,400 gallon tank wagon in less than a minute. By changing a valve, the pump recir­culates the liquid manure in the storage tank and does a good job of agitation prior to hauling. (Fig. 13)

Detailed plan of a loading ramp showing recommended A pressure-discharge tank wagon does a good job of reinforcement. (Midwest Plan Service) (Fig. 12) spreading the liquid manure on the field. (Fig. 14)

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demand due to cropping; and the amount of water that will be added from the milking parlor, surface­runoff, roof gutters, etc.

If a large, paved, uncovered lot is used for feed­ing, provisions should be made for surface water runoff to bypass the liquid manure storage tank. A heavy rain will flood the tank in a short time.

Some agitation is required in the storage tank to keep the solids in solution for handling. This agita­tion can be periodical, or it can be done just prior to the pumping, depending on the type of equipment used. Storage tanks located outside the building have some problems with freezing during the cold weather, but periodical agitation will help prevent serious freezing.

A recirculating chopper-pump does a good job of agitating and pumping the liquid manure, and using a wagon with pressure discharge is a good way of spreading it on the field. Figs. 13 and 14 show this type of equipment in use. The more conventional vacuum-type liquid manure wagons have been found by experienced operators to be inadequate for han­dling dairy manure.

General Management Suggestions

A well-managed, properly designed free-stall barn results in low bedding costs, clean and com­

fortable cows, efficient use of labor, and a reduced number of injuries. The following are some of the more important management practices to be considered:

( 1) Rake manure that is dropped from the stalls into the alleyway twice daily. A garden rake works well.

(2) Scrape the alleyways with a tractor blade or scoop each day. Make it possible for the cows to go outside the barn while the alley is being scraped.

( 3) Cows that refuse to use the stalls should be encouraged to do so by leading them into the stalls several times. If this doesn't work, tie these partic­ular cows in the stalls for a few days.

(4) Do not feed cows in the stall.

(5) Separate cows in heat from the re~t of the herd.

(6) Don't run bred heifers in with the milking herd.

(7) Place cows due to calve shortly in individual box stalls or other areas away from the milking herd.

(8) Allow cows free access to the barn during the hot summer months.

This circular was prepared by A . J. Muehling, Assistant Professor of Agricultural Engineering, and L. R. Fryman, Associate Professor of Dairy Science.

Urbana, Illinois October, 1965

Cooperative Extension Wo rk, University of Illinois, Co llege of Agriculture, and the U.S. Department of Agriculture cooperating. JOHN B. CLAAR,

Director. Acts approved by Congress May 8 a nd June 30, 1914.

l SM- IO-6S-87617