Gooch.Dairy Calf Group Housing - Calf Congress 2015Calf & Heifer Congress 2015 “Calf Housing Systems That Work: Options & Management” Curt Gooch, P.E. Dairy Environmental Systems

Calf & Heifer Congress 2015“Calf Housing Systems

That Work:Options & Management”

Curt Gooch, P.E.Dairy Environmental Systems Engineer

Cornell Universitywww.prodairyfacilities.cornell.edu

Basic Calf Needs…

Basic Calf Needs…Optimal nutrition (quality and quality)

Free access to clean water

A clean, dry, and comfortable resting area

Pathogen control

Observation by caretaker

Adequate, draft-free ventilation (air exchange)

For Calf Housing Systems to work…

Basic Calf Needs Must be Met!“Optimal nutrition (quality and quality)”

• Formulation and deliver of appropriate feeds/ cleanliness

“Free access to clean water”• Access to & delivery of free choice clean

water/cleanliness

“A clean, dry, & comfortable resting area”• Properly designed & managed calf resting surface

For Calf Housing Systems to work…

Basic Calf Needs Must be Met!“Pathogen control”

• Facility design, stocking density, chemicals, protocols/management

“Observation by caretaker”• Facility design, protocols/management

“Adequate, draft-free ventilation”• Facility design, protocols/management,

maintenance

Disease Resistance

Disease Challenge

Time

Source: Large Dairy Herd Mgmt.

Disease Resistance vs. Disease Challenge:Good Management

Disease ResistanceDisease Challenge

Time

Disease Resistance vs. Disease Challenge:Poor Calving Area Sanitation



Time

Disease Resistance vs. Disease Challenge:Poor Colostrum Management



Time


Disease Resistance vs. Disease Challenge:Inadequate Housing

Spatial Requirements for Pre-Weaned Calves (for a month)

(No. Milking Cows + Dry Cows) x U x CPY x I x XS12

where:U = uniformity of calving (1.1 to 1.2)CPY = total calvings per hd annually (1.05)I = incidence of live birth (0.95)XS = extra space for fallow period (1.25)

Note: CPY based on a preg rate of 15%

The Calf Hutch

Reasons for Moving Away from the Calf Hutch…

“The environment a calf is exposed to depends on barn design & mgmt.”

Group housed calf barns…

should be designedwith the basic calfneeds in mind first.

These needs arenon-negotiablewith the builder.

MIXINGFRESH

AIR IN

SLIGHTLYSTALEAIR OUT

MOISTURE

DUSTPATHOGENS HEAT

GASES

BASICS OF VENTILATION

Draft occurs when:1) Air speed is greater than 50 fpm when temperature < 50F (Mitchell, 1975)

2) Air speed is greater than 98 fpm with calves < 12 weeks (Webster, 1981)

Four Basic Ventilation “Seasons”

Winter (Cold)

Late Fall/Early Spring (Transition)

Early-Mid Fall/Early-Mid Spring (Warm)

Late Spring/Summer/Early Fall (Hot)

VENTILATION:How Much for Replacements?

Air Exchange Rate

cfm per head (No. room volumes/hr.)

Animal Group Weight(lbs.) Cold Mild Warm Summer

Newborn 90 -180 15 (6) 30 (12) 65 (30) 100 (60)

Transition 180 - 400 20 (6) 40 (12) 85 (30) 130 (60)

Adolescent (A & B) 400 - 800 25 (6) 50 (12) 100 (30) 150 (60)

Adolescent (C & D) 800 - 1,200 30 (6) 60 (12) 120 (30) 180 (60)

Manure Gases in Dairy Barns

Area of Ventilation Focus:Calf Nose Zone

Ventilation System Options

Natural

Natural Assisted/Mechanical Assist

Mechanical • Positive Pressure• Negative Pressure• Neutral Pressure

Natural Ventilation

Naturally VentilatedBarns…

Are Cold Barns

Important Natural Ventilation Performance Factors...Site SelectionBuilding OrientationAdjustable SidewallsAdjustable EndwallsEavesRidge Opening

OPEN RIDGEW/ UPSTANDS

CURB

4' x 8' CALF PEN

Compacted Stone Base

BEDDINGCONCRETEWALKWAY SLOPE TO

DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof

Truss Webs Omitted for Clarity

Top CurtainRolls Down To Open

Bottom CurtainRolls Up To Open

OpenEave

Plastic Coated MetalBird Screen

Compacted Stone Base (typ.)

Footer BelowFrost (typ.)

Slope 2% Slope 2%

COUNTER SLOPETO DRAIN

10’

30”

10’ 11’32’


CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%



CURB

4' x 8' CALF PEN



DRAIN

124

10'32'

1'

10'

2'-6"

12-16"

Slope 2% Slope 2%

11' 11'

6" CURB1'

Aluminum Roof




OpenEave




Slope 2% Slope 2%


x

y

Flashing

Trim (typ.)

Top Cord of Truss

Flashing (typ.)

BirdScreen

Roof Cladding

12”

12-16”

x

y

Flashing

Trim (typ.)

Top Cord of Truss

Flashing (typ.)

BirdScreen

Roof Cladding

x

y

Flashing

Trim (typ.)

Top Cord of Truss

Flashing (typ.)

BirdScreen

Roof Cladding

MimimumOpening*

Aluminum RoofFastened w/ SS Screws

Flashing

Purlin (typ.)

Flashing w/ ComfomingFoam Sealer

Truss Top ChordOr Rafter Board

Difficulties with Natural Ventilation

1. Management2. Cool/cold conditions with closed

curtains3. Drafts4. Conditions with little natural airflow5. Barn widths ≥ 35’6. Use of solid pen partitions

Natural Assisted -Mechanical Assist Ventilation

• Use fans to augment natural ventilation

• Two methods:1. Negative pressure system (exhaust fans)2. Positive pressure system (forced air plenums)

Split CurtainSidewall System (typ.)

Truss BottomChord (typ.)

Large Diameter FanSpaced ~20' o.c.

Ceiling (typ.)

InsulatedExhaust Duct

Top CurtainOpenedBottom CurtainOpened

LouveredCupola

Natural Assisted VentilationNegative Pressure - Peak Fans

Up to 1,000 cfm/cow

Natural Assisted VentilationPositive Pressure (forced air plenums)

Forced Air Plenum Systems1. Fans at one or both ends force air into

plenum and discharge through holes

2. Fans, plenum, and hole sizes based on ventilation season

3. Generally one air plenum per ventilation season

4. Bottom of air plenum ~ 7 - 8’ above floor with some flexibility based on limitations

Translucent/Transparent Cladding–increased evaporation of moisture–increased production of manure gases–increased air moisture from respiration–heat stress–fluctuating temperatures–pathogen buildup

Mechanical Ventilation

Mechanical Ventilation Systems are Appropriate when…

1. The barn is poorly exposed to wind2. Summer winds are not sustained3. Barns are wider than ~> 35’4. Desired to operate as a warm barn5. If the owner prefers this approach

VENTILATION:How Much for Replacements?

Air Exchange Rate

cfm per head (No. room volumes/hr.)

Animal Group Weight(lbs.) Cold Mild Warm Summer

Newborn 90 -180 15 (6) 30 (12) 65 (30) 100 (60)

Transition 180 - 400 20 (6) 40 (12) 85 (30) 130 (60)

Adolescent (A & B) 400 - 800 25 (6) 50 (12) 100 (30) 150 (60)

Adolescent (C & D) 800 - 1,200 30 (6) 60 (12) 120 (30) 180 (60)

Design of Mechanically Ventilated Barns is…

a combination of artand science.

Review – Mechanical Ventilation System Options

Positive Pressure

Negative Pressure

Neutral Pressure

OPTIONAL 12" OPENING

USE AWNINGWITH 12" OPENING

EXISTING HAYMOW

NEW SCRAPEALLEY

CONCRETEAPRON

NECK RAIL

FEED TABLE

W/ 10 ' 12' CLEARANCEOPEN FRONT

EXISTING COLUMN

BEDDING

WATERER

6" STEP

124

6' 10'

SLOPED 2%

ACCESSALLEY

EXISTING BANK BARN

30"X48"DUCT

2" CONT.OPENING

NORTH

< 75’ from inletto exhaust

412

Slot Inlet (typ.)ContinuouslyOpen Eave (typ.)

Negative PressureVentilation Fan Bank (typ.)

Ridge Cap

Fluorescent LightFixture (typ.)8'

60'

11'20' 20' 20'

CurtainSidewall (typ.)

4' x 8' Calf Pen (typ.)

Aluminum Roof

Truss

Feed & WaterPails (typ.)

Inlet Air (typ.)Inlet Air (typ.)

Exhaust Air

18" Flat CeilingAdjacent to Inlet (typ.)

2% Slope 2% Slope

11'

2% Slope2% Slope

Counter SlopeTo Drain (typ.)

1'

Foam BoardInsulation (typ.)

6" Curb (typ.)

Slope Slope Slope Slope



Compacted StoneBase (typ.)


Slope toDrain

412



Ridge Cap


60'

11'20' 20' 20'



Aluminum Roof

Truss



Exhaust Air


2% Slope 2% Slope

11'

2% Slope2% Slope


1'


6" Curb (typ.)






Slope toDrain

412



Ridge Cap


60'

11'20' 20' 20'



Aluminum Roof

Truss



Exhaust Air


2% Slope 2% Slope

11'

2% Slope2% Slope


1'


6" Curb (typ.)






Slope toDrain

412



Ridge Cap


60'

11'20' 20' 20'



Aluminum Roof

Truss



Exhaust Air


2% Slope 2% Slope

11'

2% Slope2% Slope


1'


6" Curb (typ.)






Slope toDrain

ExhaustFan

CeilingInlet

ExhaustFan

CeilingInlet

412



Ridge Cap


60'

11'20' 20' 20'



Aluminum Roof

Truss



Exhaust Air


2% Slope 2% Slope

11'

2% Slope2% Slope


1'


6" Curb (typ.)






Slope toDrain

11’ 20’60’

8’


Positive Pressure

Negative Pressure

Neutral Pressure

Air Inlets

Air Inlets


Positive Pressure

Negative Pressure

Neutral Pressure

Novel Approach toCalf Barn Ventilation

Mechanical ventilation to control ventilation air streams for cold and transition ventilation seasons using neutral ventilation to ensure predictable, low-velocity air exchange at calf nose level

Provide a means to temper ventilation air for very cold conditions

Use natural, natural-assist, or positive pressure ventilation for warm and hot conditions

10'

412

InsulationStop (typ.) Painted Aluminum Ceiling

w/6 mil Poly Continuous VB

Closed Eave& Soffit (typ.)

Vented Ridge Cap

50'

Air Plenum for min vent only(tempered air) (typ.)

Negative pressure exhause plenumwith fans at each end, continuous operation

16'

5'-5"4'-11"

8'

Insulated CurtainSidewall (typ.)

Insulation

3' x 5' PPAir Duct

3' x 5' PPAir Duct

3' x 5' PPAir Duct

3' x 5' PPAir Duct

Novel Approach to Pre-weaned Calf Barn Ventilation

(cross sectional drawing)

10'

412

InsulationStop (typ.) Painted Aluminum Ceiling

w/6 mil Poly Continuous VB

Closed Eave& Soffit (typ.)

Vented Ridge Cap

50'

Air Plenum for min vent only(tempered air) (typ.)

Negative pressure exhause plenumwith fans at each end, continuous operation

16'

5'-5"4'-11"

8'

Insulated CurtainSidewall (typ.)

Insulation

3' x 5' PPAir Duct

3' x 5' PPAir Duct

3' x 5' PPAir Duct

3' x 5' PPAir Duct

Novel Approach to Pre-weaned Calf Barn Ventilation

(cross sectional drawing)

50'

150'

Calf Needs

Support Room

Rolled steel platew/ plenum inlet holes

Slo

pe 2

%

16'

8 Pens at 8Calves Per Pen

Tempered Air Supply Plenum

Vent Supply Fan 15'

Slop

e 2%

8'

14'

8'

25'

4'-10"

20' 130'

2'

10'

4'-9"

5'

2' Deep x3' Wide Exhaust Air Plenum(Below Grade) 2' Deep x 3' Wide Exhaust Air Plenum

(Below Grade)

10,000 cfm fan

10,000 cfm fan

10,000 cfm fan

10,000 cfm fan

10,000 cfm fan

10,000 cfm fan

10,000 cfm fan

10,000 cfm fan

3'x5' Air Duct (typ.):In Attic CeilingMounted

VerticalTransition (typ.)


Novel Approach to Pre-weaned Calf Barn Ventilation(plan view drawing)15’ x 15’ pens

8 calves/pen28 sq. ft./calf

8 Pens

8 Pens

Ventilation Air Inters Attic Through

Engineered Endwall Louvers

Ventilation Air Supply Plenum

Engineered Discharge Holes (size and Spacing

Engineered Ventilation Fan (Not Visible)

Water to Air Heat Exchanger

Engineered Ventilation Exhaust Air

Plenum/Wash-down Gutter

Engineered Exhaust Fan (Both Ends of Exhaust Air Plenum)

Demko Calf Barn1. Site for barn – not well exposed to wind

2. Farm wanted to full mechanically ventilate barn

3. Four ventilation season approach used

4. Cold air can be tempered

Demko Calf Barn

4. Designed with 8 pens, 25 calves/pen

5. Exhaust air plenum doubles as washdown water collection gutter

6. Automated feeders

7. Constructed 2012

Demko Farm Wet Calf BarnFloor Plan

66'53'

8 Pens at up to 25Calves Per Pen

Air Plenums (Stacked) with Discharge Holes

22'Exhaust Air Plenum/Floor Wash Down Gutter(Below Grade), Bottom Sloped to the East

182'

N

Pos. Pressure VentilationFans (4, Stacked), Both Ends

Air PlenumExhaust Fan,

Both Ends

Plate 1

5' 5'

BeddedArea

Scraped/Washdown Area

Plate 2 Plate 3 Plate 4 Plate 1Plate 3 Plate 2Plate 4

ExhaustFan (typ.)

22’ x 53’ pens25 calves/pen46 sq. ft./calf

8 Pens

Demko Farm Wet Calf BarnFloor Plan

66'53'

8 Pens at up to 25Calves Per Pen

Air Plenums (Stacked) with Discharge Holes

22'Exhaust Air Plenum/Floor Wash Down Gutter(Below Grade), Bottom Sloped to the East

182'

N

Pos. Pressure VentilationFans (4, Stacked), Both Ends

Air PlenumExhaust Fan,

Both Ends

Plate 1

5' 5'

BeddedArea

Scraped/Washdown Area

Plate 2 Plate 3 Plate 4 Plate 1Plate 3 Plate 2Plate 4

ExhaustFan (typ.)

Below-Grade Exhaust Air Plenum/Floor Wash

Down Gutter

New Insulated, Mechanically Ventilated Barn 180’ x 66’, 10’ ceiling height

8 pens, 22’ x 53’, 20 calves per pen – 52.8 ft.2 /calf Mechanical Ventilation System – Positive Pressure Air Plenums and Discharge Holes

Automated Calf Feeder

Designated Wash-down Area

Engineered Ventilation Exhaust Air Plenum/Wash-

down Gutter

Ventilation System – Negative Pressure (North) Side of Barn

One of two Trench DuctFans – East Side

Exhaust Fans in Wall for Warm/HotVentilation Seasons

All‐weather Trench Duct,Engineered Holes

Ventilation System Controls – Stage Control

Starter Grain also at Front of Pen. Intakes at Weaning 4 – 6 lbs. (and up) Improved Efficiency

Average Daily Gain Days on Milk

n=18

n=17n=18

n=17

2013 – Avg. Birth weight = 86 lbs.2012 – Avg. Birth weight = 95 lbs.

Increased Weaning Weights Sheland Calf Barn1. Site for barn – not well exposed to wind

2. Farm wanted to mechanically ventilate barn for cool/cold & naturally for summer

3. Five ventilation season approach used

4. “Cold/cold” season air can be tempered

5. Mech. assist for warm & hot seasons

Sheland Calf Barn

6. Designed with 4 pens, 25 calves/pen

7. Automated feeders

8. Constructed 2014

Moserdale Calf Barn1. Site for barn – not well exposed to wind





Moserdale Calf Barn6. Wanted exhaust air plenum to be

located above grade to save costs

7. Air streams – perpendicular to pens

Whey Street DairyCalf Barn

6. Wanted exhaust air plenum to be located above grade to save costs

Beller Calf Barn1. Site for barn – not well exposed to wind





50'

Calf NeedsSupport Room

Rolled steel 8' platesw/ plenum inlet slots(see table for specs.)

Slop

e 2%

30'8 Pens at 10 - 12Calves Per Pen


Vent Supply Fan 16'

10'

12'

12'

14'-6"3' Wide x 2' DeepCast-in-Place Concete

Air Plenum/Drain Gutter Below Grade

8'4'

8"

24" x 32" Opening to ReceiveAeroTech Pit Transition with

Model AT18F Fan (typ.)

Existing 45' Wide Barn

134'

6'

128'

Section 1 Section 1 Section 1 Section 2 Section 2 Section 3 Sections 3/4 Section 4Plate 1 Plate 2 Plate 3 Plate 4 Plate 5 Plate 6 Plate 7 Plate 8

Section 1Section 1Section 1Section 2Section 2Section 3Sections 3/4Section 4Plate 9 Plate 10 Plate 11 Plate 12 Plate 13 Plate 14 Plate 15 Plate 16

Phase 3 – Dec 2014 New Barn!• 132 x 48 ft• ‘Neutral Pressure’

Ventilation• Curtain on north

wall • Interior Fresh Air

Inlet Ducts on North wall

• Floor Exhaust Ducton south side

3 intake fans for 2 positive air ducts

• New barn ‐ Tees to old milk house which Tees to heifer barn

• South side has auxiliary exhaust wall fans as well as floor duct exhaust fans

Fans for floor exhaust duct

3 intake fans for 2 positive air ducts

Neutral Pressure Ventilation‘Natural’ (curtain) with Mechanical Assist (Ducts)

*Ventilation Design & Engineering ‐ Curt Gooch, PE Cornell

Right wall:Positive Pressure Ducts – air at nose level winter and transition seasons

Left side alley floor:Floor Exhaust Duct and fans – air out

Left wall:Auxiliary exhaust wall fans‐more exchange

Fresh air nose level

Fans and size of openings in intake ducts and exhaust duct are designed for appropriate fresh air inflow flow and exhaust = neutral pressure

Floor exhaust duct (plenum)

Transition duct –intake fan at each end

Winter/year round duct, 1 intake fan

*Ventilation Design & Engineering ‐ Curt Gooch, PE Cornell

All year (lower) and transition season ducts (upper)Not using supplemental heat; insulated ceiling Fan and Curtain Controls

Pathogen Control

1. Trickle in, all out model

2. Fallow period – 25% “extra space”

3. Biosecurity protocols

4. High pressure washing in the barn?

5. Wash feeding systems

Closing Comments

1. Implement the basics

2. Remember the calf hutch model!

3. Caretakers/barn managers need to understand ventilation principles

Closing Comments

4. Ensure air exchange at calf level – get help with ventilation system design.

5. Provide fallow space

6. Pathogen control – very important

Have Fun!

www.prodairyfacilities.cornell.edu

Documents

Gooch.Dairy Calf Group Housing - Calf Congress 2015Calf & Heifer Congress 2015 “Calf Housing Systems That Work: Options & Management” Curt Gooch, P.E. Dairy Environmental Systems