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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…
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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
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Disease ResistanceDisease Challenge
Time
Disease Resistance vs. Disease Challenge:Poor Calving Area Sanitation
Source: Large Dairy Herd Mgmt.
Disease ResistanceDisease Challenge
Time
Disease Resistance vs. Disease Challenge:Poor Colostrum Management
Source: Large Dairy Herd Mgmt.
Disease ResistanceDisease Challenge
Time
Source: Large Dairy Herd Mgmt.
Disease Resistance vs. Disease Challenge:Inadequate Housing
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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
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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.
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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
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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
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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’
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
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
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
-
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
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
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
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
-
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
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
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
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
-
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
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
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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
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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
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Translucent/Transparent Cladding–increased evaporation of moisture–increased production of manure gases–increased air moisture from respiration–heat stress–fluctuating temperatures–pathogen buildup
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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
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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
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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 Stone Base
Truss Webs Omitted for Clarity
Compacted StoneBase (typ.)
Footer BelowFrost (typ.)
Slope toDrain
-
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 Stone Base
Truss Webs Omitted for Clarity
Compacted StoneBase (typ.)
Footer BelowFrost (typ.)
Slope toDrain
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 Stone Base
Truss Webs Omitted for Clarity
Compacted StoneBase (typ.)
Footer BelowFrost (typ.)
Slope toDrain
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 Stone Base
Truss Webs Omitted for Clarity
Compacted StoneBase (typ.)
Footer BelowFrost (typ.)
Slope toDrain
-
ExhaustFan
CeilingInlet
ExhaustFan
CeilingInlet
-
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 Stone Base
Truss Webs Omitted for Clarity
Compacted StoneBase (typ.)
Footer BelowFrost (typ.)
Slope toDrain
11’ 20’60’
8’
Review – Mechanical Ventilation System Options
Positive Pressure
Negative Pressure
Neutral Pressure
-
Air Inlets
Air Inlets
-
Review – Mechanical Ventilation System Options
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.)
Tempered Air Supply Plenum
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
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
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
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
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
Tempered Air Supply Plenum
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
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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
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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
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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