Publications
Northeast
Midwest
Western
Lechero
Latino
Holstein
World
Dairyline
Radio
Ag Expos
Farm
Market iD
Internet
Services
College
Directory
EFD
Virtual Farm Show
| |
Facilities -- The Long and Short of Greenhouse Barns
by JoDee Sattler
|
Whether you're looking for a short-term or long-term cattle housing solution, take a
look at greenhouse barns. Considered a user-friendly cattle housing alternative, calves,
heifers and cows perform well in these facilities.
Greenhouse barns use a lightweight, galvanized steel tube frame to support one or
two layers of a commercial-grade plastic film covering. Used for more than 10 years in the
United States and Europe, greenhouse barns offer flexibility. They can be designed with
future growth in mind. And, they can incorporate specialized features, such as office, feed
storage and milk replacer preparation areas.
Producer experiences with greenhouse barns
When Kevin and Dale Heiser of Plain, Wisconsin, explored livestock housing
options for their new jointly-owned dairy, Kevin toured a greenhouse barn near Ladysmith,
Wisconsin. "What really impressed me when I walked in was the brightness," Kevin
remarked. "I liked the light and felt that this would be good for our cows and us."
Lou Kuhn, a building sales representative with United Cooperative in Beaver Dam,
Wisconsin, concurred. "It's a nice place to work in. Greenhouse barns provide a healthy
environment for calves, heifers and cows."
When compared to calf hutches, Kuhn said a greenhouse calf facility fosters a very
pleasant work environment. "Calf feeders are generally willing to feed some calves in
hutches," he noted. "But when herds start growing, most calf feeders demand a comfortable
work environment which greenhouse barns provide."
Kuhn continued, "From my experience, people love to work in them (greenhouse
barns). They provide a bright, dry atmosphere." The United Cooperative representative
said one of his clients in Ohio described his greenhouse barn as having a "super
environment."
Cooler in the summer
On many Upper Midwest days, light and heat is good. But what about those
unbearable sultry days of summer?
Frank and Kathy Dwyer of Hill Point, Wisconsin, recalled their first step into a
greenhouse dairy barn. "It was 90 degrees outside," Frank commented. "You could really
feel the pleasant difference inside the greenhouse. It was at least 10 degrees cooler inside
the greenhouse."
Having raised calves in a pole barn, the Dwyers concurred that the light advantage
sold them on constructing a greenhouse calf facility for their calves and those they custom
raise for the Heisers.
Even though greenhouse structures are cooler than traditional dairy barns, the
Heisers' cows experienced heat stress when the mercury approached 100 degrees
Fahrenheit for several days in July. "We lost 20 pounds of milk per cow during that hot
spell," Kevin explained.
Given the flexibility of their greenhouse barn, the Heisers installed misters. "We
actually went up in milk when the second heat wave struck."
Shade fabric is a must
Greenhouse owners agree that inserting a black mesh shade fabric over the two
sheets of roof plastic is a must. "Without it, it'd be a 'real cooker' in there," Kevin stated.
Shade material is made of polypropylene and comes in many different percent
opening ranges. For greenhouse barns, a minimum 80% blocking shade is recommended.
Usually, the material is fitted with grommets in the edge. Nylon rope or bungee cords are
typically threaded from the grommets to anchoring points on the sidewall to hold the
fabric in place.
"You have to ventilate greenhouse dairy barns properly," stated Roger Epley, a
nutrition consultant from Neenah, Wisconsin. Management of ventilation openings is
critical in a greenhouse barn.
For baby calves, Epley strongly recommended variable openings on both ends of
greenhouse facilities, such as roll-up garage doors. "It's very important to have flexibility
with end doors," he commented. "Without this flexibility, you may end up with too much
of a draft (if the door is completely open) or a 'stuffy' environment (if the door is
completely closed)."
Adjusting the ridge opening, eave vents and curtain sidewalls can also enhance
ventilation. Inadequate ventilation subjects animals to a poor environment, which could
adversely affect animal health.
In addition, Epley noted that shade fabric should cover the gable ends throughout
the year. The shade fabric blocks out 80% of the sun's rays.
Monitor temperature, air flow
To enhance calf/heifer/cow comfort, managers must pay close attention to the
greenhouse barn's temperature and air flow. Raise or lower curtains and/or doors to ensure a
healthy environment.
In the summer, the greenhouse should provide shade and allow cross ventilation by
wind pressure. During winter, a greenhouse should allow for moisture removal and draft
control.
The Dwyer's calf greenhouse has 8-foot sidewalls with 4-foot curtains on top. "This
way the air blows across the top of the calves and not on them," Frank stated. "Fresh air is
pulled in from the sides and stale air goes out the top curtain."
Both the Dwyers and Heisers manually raise and lower curtain side walls that are
located on the north and south sides of their greenhouse facilities. The Heisers have garage
doors on the east and west ends, while the Dwyers only have a garage door on the east end.
A steep drop off on the west end curtailed the Dwyers' desire for a garage door on both ends.
According to Epley, a long and narrow barn is generally better than a short and fat
greenhouse barn. This design helps improve ventilation.
Cleaner and dryer
"The main health benefit a greenhouse provides is a relatively dry environment,"
Epley stated. "You have to pay attention to ventilation. Greenhouses work fine; but if it
smells like a calf barn, you need to open it up someplace."
According to Kathy Dwyer, their greenhouse calf barn is much dryer than hutches.
"We have few weather concerns with the greenhouse," she commented.
Greenhouses are easy to clean and maintain. With this type of structure, feed and
water stay fresh longer, compared to hutches. Calves eat better when feed is fresh and dry.
For calf greenhouse barns, no concrete is needed, according to Epley. "It's relatively
dry in greenhouses, so you don't have to move them (pens)," he said. "In between calves, if
you leave the pen open for a week or so, it dries out and bakes anything out that is in
there."
Kuhn added that the sun helps dry out bedding. This, along with moisture soaking
into the ground, contributes to reduced bedding requirements.
Kevin Heiser said they have experienced some condensation. However, it has never
been a major problem. "Once in a while we'll have a drip of water," he noted.
No freezing experienced
The Heisers' 200 milk cows have spent two winters in the 188-stall, hoop
greenhouse. "We've always been able to scrape the alley," Kevin said. "And, the waterers
have never froze."
Despite concerns over the plastic's durability, Kevin said their roof has been nearly
trouble free. When roofs blew off traditional barns from winds exceeding 80 miles per hour
in November 1998 and May 1999, the Heisers' and Dwyers' greenhouse plastic roofs stayed
intact.
"If there's been a problem, ice caused some minor damage last January (1999),"
Kevin explained. Ice formed on the roof and it rolled down the plastic and tore some of the
roof. The Heisers simply taped the minor tears they found in the 6-mil polyethylene
plastic.
To prolong the plastic's longevity, Kevin recommended keeping the plastic rigid.
This improves the plastic's strength and enhances its insulation qualities.
A small blower inflates the space between the two sheets of plastic. By keeping
each plastic layer tight, flapping from the wind is reduced. This helps minimize potential
tearing.
Greenhouses offer flexibility
For those wanting to expand quickly, greenhouse barns are a good option. Even if
the facility is not used to house milking cows long term, it can later be used to house
heifers, dry cows or calves.
The Heisers designed their greenhouse so they can easily add on to it, should they
decide to continue expanding the dairy herd. "We're far more efficient than we were when
farming on our own," Kevin stated. "You've got to look to the future when expanding your
dairy."
For the Dwyers, flexibility in their greenhouse calf barn allows them to vary the
number of individual and group pens. Calves stay in individual pens until they are weaned
at about 4 weeks old. Then, they go to a group pen until they reach 4 months of age.
Based on the number of heifer calves from their 90-cow herd and the heifer calves born at
Heisers, numbers in individual and group pens varies. The Dwyers can house up to 55 calves
in their calf barn.
Like an Erector set
"It's a simple building," Kevin explained. "I look at it as a big 'Erector set.' If you
have the time, you can put it up yourself."
However, the Heisers and Dwyers hired others to put up their greenhouse dairy
barns. And, both plan to use their barns long term.
Dwyers purchased a basic greenhouse barn kit. "We bought the lumber and designed
it so we could have a feed pad and space for the calf scale," Kathy stated. In addition, they
incorporated an office and milk room. The milk room includes a viewing window for
watching the calves, along with a sink, water supply and milk pail rack.
'Pleased as punch' with their greenhouse barn, Kevin stated, "The building itself has
done everything we've expected it to do if not more."
|
Additional Greenhouse Barn Resources
|
|
|
