Calf Housing

Shed structure

Materials used

• Galvanised iron on west wall and roof
• Plastic sheeting on east wall
• Cement flooring

Aspect

• Length of shed on east-west orientation

Dimensions

• 54.0 metres long x 9.0m wide x 4.4m high

Roof design

Pitch

• Difference in height/width: 90 centimetres in 9.0m
• Single pitch from west to east

Roof height

• Lowest point: 4.0m

• Highest point: 4.9m

Air space

Total air space

• 2,138 cubic metres

Air space per calf at peak

• 11.2m³

Ventilation

Type

• Passive

Cooling/airflow

• 6m wide gap in middle of west wall
• 3m wide gap in middle of south wall
• 3m wide gap in middle of north wall
• 2m wide plastic sheeting along the top of 24m of east wall
• Old building restricting air flow along 20m of east wall

Shed capacity

Maximum number of calves housed at peak

• 160 calves

Month of peak use

• September/October

Age of calves entering and leaving shed

• 0 to 24 hours. Calves are collected from the calving down area once each day.

Age/body weight of calves leaving shed (weeks/kilogram of body weight)

• Eight weeks of age, following weaning

Labour requirements (total man hours/day at peak use)

• Four man hours per day

Labour hours/50 calves at peak (total man hours/50 calves/day)

• 1.1 man hours/50 calves/day

Process

Calves are collected once per day after suckling dams for colostrum and an initial feeding of two litres of colostrum per calf.

The autumn configuration is to only use half the shed for rearing calves. This is 16 pens, each 3.0m x 3.5m in size. The rest of the shed is used for storing extra gates, troughs and teat feeders required for spring calf rearing.

The width of the aisle between the two batches of group pens, 2.0m, is only just sufficient for easy access and maneuvering of the bike and trailer carrying the milk from the dairy shed.

Pen structure

Type

• Group pens (3.0m x 3.5m) for five calves

Wall height

• 800 millimetres. These are purpose-built gates.

Wall materials

• Solid/mesh

Front

• Gates with metal slots to join them. Removable for cleaning the shed.

Sides

• Gates with metal slots to join them. Removable for cleaning the shed.

Back

• Solid wall of west wall, gates with metal slots on east wall.

Process

Only half of the shed was fitted out for calf rearing since there were only 70 autumn calves, compared to 160 calves in spring. All pen gates can be easily removed to allow for complete cleaning of the calf shed, floor and walls using a pressure hose. Leaving the shed completely empty for several months between batches of calves also allows solar sterilisation of the shed.

Pen flooring

Type

• Concrete

Drainage

• Concrete slopes (0.5m in 24m) from north to south but there is no slope from east to west

Total floor space per pen

• 10.5 square metres

Floor space per calf at peak capacity

• 2.1m² per calf

Bedding

Type

• Wood shavings

Minimum depth

• 150mm

Maintenance

• New wood shavings added weekly and entire bedding is removed following eight weeks of milk feeding.

Other

Soiled bedding is dumped in the manure pit at the bottom of the milking shed.

Feed and water

Milk feeding system type

• Teats in batches of five per pen

Milk delivery method

• Whole milk is transported from the milking shed in a tank located on a trailer and motorcycle

Hay

• In a hay rack in the middle of each pen

Pellets

• Calf muesli fed in a 2.5m-long trough in each pen

Water

• Water fed from a bucket, located inside a wheelbarrow tire for stability on the edge of each pen

Other

• Each calf is fed 3–4 litres of milk per day (twice daily) for three weeks then 3L/day (once daily) until weaning at 7–8 weeks of age
• Calves are offered ad-lib water and oaten hay from week one onward
• They are also fed calf muesli (20% protein) from week one onward with a gradual change over to calf rearing pellets (18% protein)
• They are weaned off milk once they are eating 1.5 to 2.0 kilograms of pellets per calf per day
• The calf pellets are stored in a silo, while the calf muesli is stored in bags.

Cleaning and disinfection

Type

• Lime is placed on the cement floor prior to covering it with new wood shavings

Other

• The calf shed has been located close to the farm house so the farm family can occasionally wander through it to check on calf health and welfare

Biosecurity

Boot/hand washing facilities

• No strict protocol, rely on common sense

Housing of sale calves

• Kept close to access road for once-weekly pickup by calf truck

Quarantine area for sick calves

• There are several calf igloos in which sick calves can be isolated away from the healthy calves

Colostrum management, record keeping system

• Eartags and date of birth of all calves and sick calves are recorded

Feed preparation and storage

Facilities (if in calf shed)

• Sink, fridge, storage cupboard, records/filing cabinet

Other

• Calves are fed pellets twice daily and pens with high intakes are noted for weaning off milk

Shed structure

Materials used

• Walls: tin and laser light (recycled)
• Roof: tin and plastic-domed greenhouse roof (plastic over three-quarter inch pipe)
• Floor: concrete under feeders and deep wood chips elsewhere
• External yard: pasture with shelter trees

Aspect

• East to west (wind from south-west)

Dimensions

• Structure: 24 metres long x 5.45m wide x 3.2m high (domed section), 24m long x 4.15m wide x 2.15m high (roofed section)
• External yard/calf paddock: 75m x 30m

Roof design

Pitch

• Difference in height/width: domed roof (5.45m wide and 1.05m high) and extension roof (4.15m wide and 0.2m fall) - 5% slope

Roof height

• Lowest point: 1.95m (south wall of extension)
• Highest point: 3.2m (domed roof)

Air space

Total air space

• Under greenhouse: 392 cubic metres
• Under extension: 202m³
• Total: 594m³

Ventilation

Type

• Passive, assisted by two fans under greenhouse roof if required

Cooling/airflow

• Tunnel designed to pick up breeze
• South wall: 800 millimetre x 2m gaps in wall at 760mm height
• North wall - 400mm gap in wall entire length
  
  

Shed capacity

Maximum number of calves housed at peak

• 150

Month of peak use

• March

Age of calves entering and leaving shed

• Zero to 12 hours old

Labour requirements (total man hours per day at peak use)

• 1.5 hours/day once all calves started

Labour hours per 50 calves at peak (total man hours/50 calves/day)

• 30 minutes/50 calves/day

Process

• Calves collected at least twice daily
• Iodine dip navel
• Probiotic paste
• Tagged
• Colostrum tubed if needed,
• Put in small pen to get started on auto feeder. 

Pen structure

Type

• Smaller pens for start-up (up to 15 calves) then into communal pen with access to paddock

Wall height

• 760mm (width of sheet of tin)

Wall materials

• Front: mesh to feeders, tin to paddock
• Sides: removable mesh/gates
• Back: bottom 800mm tin, laserlite to roof

Removable

• Side walls swing back to wall and can be removed for cleaning
• Solid concrete gutter for scraping against south wall

Pen flooring

Type

• Concrete for feeding area, deep wood chips over dirt for the rest

Drainage

• Sloped concrete to central drain (to effluent pond)

Total floor space per pen

• 231 square metres in shed

Floor space per calf at peak capacity

• 1.5m² in shed but calves also have access to 2,250m² in paddock

Other

• Feed and water kept on concrete area

Bedding

Type

• Wood chips 

Minimum depth

• 300mm

Maintenance

• Replaced every 3–4 weeks through season

Other

• Composted then spread on paddocks

Feed and water

Milk feeding system type

• DeLaval automatic feeder

Milk delivery method

• Fourth line in dairy to refrigerated vat
• Pumped underground to calf shed
• Non-refrigerated vat in calf shed filled up every 2–3 days
• Automatic milk feeders draw from this

Hay

• Wire baskets hung from wall, 500mm high

Pellets

• DeLaval auto feeders filled up by bucket

Water

• Small drinking dishes on walls
• Piped water to clean-up/preparation area

Cleaning and disinfection

Type

• Continuous, run as a mob

Other

• Very low mortality rate

Biosecurity

Housing of sale calves

• All bull calves are kept

Quarantine area for sick calves

• Small pen next to calf shed (rarely used)

Other

• Book kept in shed next to feeders
• DeLaval reports and exception list checked daily

Feed preparation and storage

Facilities (if in calf shed)

• Wheel barrow to transport pellet buckets

Layout of calf housing shed at Bagot.

Shed structure

Construction materials

• Walls: colourbond on north and south ends. No walls on west and east sides 
• Roof: colourbond with one-metre wide skylight every five metres
• Floor: concrete and dirt 

Aspect 

• Oriented north-south, providing sun in the morning and afternoon into calf pens
• Prevailing winds from the north-west

Dimensions

• Structure 70m long x 15m wide x 4.8m high

Roof design

Pitch (1:4) 

• Difference in height/width: 15%

Overhang eves

• 1,000 millimetres

Roof height

• Lowest point: 3.4m
• Highest point: 4.5m

Air space

Total air space under roofline

• 4,200 cubic metres

Air space per calf at peak (6-8m³) 

• 6m³

Ventilation

Type 

• Passive

Cooling/airflow 

• No walls along sides of shed
• Solid gates on windward side (west) to 1,200mm in height

Shed capacity

Maximum number of calves housed at peak

• 728 calves total
• Up to 26 calves per pen (mostly 23 to 25 calves per pen)

Month of peak use

• September

Age of calves entering and leaving shed

• 24 hours to 10 weeks of age

Labour requirements (total man hours per day at peak use)

• Two people x 1.5 hours per day
• A single person can feed 700 calves in an hour once all the calves are self-feeding

Other 

• Calves brought in during early afternoon and tubed

Pen structure

Type 

• Group

Wall height

• 1,000mm

Wall materials 

• Front: rails 
• Sides: solid on concrete, two swinging sheep gates (2.15m) on bedding 
• Back: two sheep yard panels, solid to west 
• Removable: crush frame 'bows' concreted in

Pen flooring

Type

• Concrete and deep litter over dirt

Drainage

• Concrete drains to centre walkway (about 2% slope)
• Centre walkway drains to south end of shed (5% slope)

Total floor space per pen

• 35 square metres

Floor space per calf at peak capacity 

• 1.35m²/calf
• Usually 23 calves per pen, so 1.5m²/calf

Bedding

Type

• Sawdust

Minimum depth 

• 300mm

Maintenance

• Scrap out at end of season
• Completely replace between batches

Other

• Used bedding composted and given to gardeners

Feed and water

Milk feeding system type 

• Teat feeders made to order

Milk delivery method

• Pumped from tank on trailer 

Hay

• Wire net on fence

Pellets

• Ad-lib supply from hopper in each pen
• Fed by standard herringbone set-up from a silo into cut away 25-litre drum, 600mm off the floor

Water

• Nipples in each pen

Other

• 4.5L per calf (some over feed)
• Feeders have a mark in to ensure staff give the correct amount

Cleaning and disinfection

Type

• Batch

Other 

• Aim to move batches further apart once CSD is shifted

Biosecurity

Boot/hand washing facilities 

• Hose at northern end of shed

Housing of sale calves

• All calves are reared, including males

Sick calves quarantine pen 

• Moved to bottom pen (very few problems)

Other 

• Colostrum tube fed twice in first 24 hours
• Records kept on whiteboard in shed and in note book
• No tags on calves at this age

Feed preparation and storage

Facilities (if in calf shed)

• Portico to be built at northern end of shed for storage

Shed structure

Construction materials

• Walls: corrugated iron on timber frame
• Roof: corrugated iron on timber frame
• Floor: sawdust over soil
• External yard: pasture

Aspect

• Facing east

Dimensions

• Structure: Each shed is six metres long x 3m wide x 2.5m high (18 square metres)
• External yard/calf paddock: 22m x 200m for each shed (4,400m²)

Roof design

Pitch

• Difference in height/width: 0.5m:3m = 1:6 (single slope to rear)

Roof height

• Lowest point: 2m
• Highest point: 2.5m

Air space

Total air space

• Inside only – 42 cubic metres

Air space per calf at peak 

• Inside only – 1.4m³

Ventilation

Type

• Passive

Cooling/airflow 

• Open on east wall

Shed capacity

Maximum number of calves housed at peak

• 30 per shed
• 240 calves across eight sheds

Month of peak use 

• August/September

Age of calves entering and leaving shed

• Enter at seven to 10 days old
• Leave at 12 weeks old

Labour requirements (total man hours per day at peak use)

• One hour per day to feed 240 calves with one 450-litre Calfateria feeder

A 1,000L tank to be installed at site to avoid towing Calfateria back to main dairy twice a day for each feeding 

Pen flooring

Type 

• 150mm of sawdust

Total floor space per pen

• 18 square metres

Floor space per calf at peak capacity

• 0.5m² (internal)

Other

• 4,400m² per 30 calves

Bedding

Type 

• Straw, shavings, chips, sand

Minimum depth 

• 150mm of sawdust

Maintenance

• Top-up at start of the season

Feed and water

Milk feeding system type

• 450L Calfateria does three batches
• 5L/calf per day

Milk delivery method 

• Calfateria transport to paddock
• Installing a 1,000L tank on ute to transport milk from dairy to calf paddock

Hay

• Wire net on fence

Pellets

• Troughs

Water

• Trough in paddock

Cleaning and disinfection

Type

• Single batch only on the area then rested for eight months until next season

Other 

• Sheep graze the area when calves are not using it

Biosecurity

Access restrictions 

• Try not to drive vehicle into paddocks (except with Calfateria)

Housing of sale calves

• In a shed at the dairy

Quarantine area for sick calves

• Taken back to a shed near the dairy

Shed structure

Construction materials

• Walls: zinc aluminium 
• Roof: zinc aluminium and skylights
• Floor: concrete/gravel 
• External yard: pasture

Aspect 

• Facing west to east
• Wind from north-west

Dimensions

• Structure: 42 metres long x 20m wide x 5m high (4.2m at eaves) 
• External yard/calf paddock: 12 x 0.3-hectare areas

Roof design

Pitch

• 8% (1:12.5)

Roof height

• Lowest point: 4.2m
• Highest point: 5m

Air space

Total air space 

• 3,780 cubic metres

Air space per calf at peak

• 9.45m³

Ventilation

Type

• Passive through open doors

Cooling/airflow 

• Three large roller doors to west
• One large roller door (3m) to east
• Six small roller doors (2m) to sides

Shed capacity

Maximum no calves housed at peak 

• 400

Month of peak use 

• September

Age of calves entering and leaving shed

• 24 hours to 60 days

Labour requirements (total man hours per day at peak use) 

• One person takes six hours at peak (not including fetching milk and new calves)

Labour hours per 50 calves at peak (total man hours/50 calves/day) 

• 0.75 hours/50 calves/day

Other 

• Lighting: Three metal halide globes used 24 hours per day at peak to encourage feed intake

Pen structure

Type 

• Group of 30 to 35

Wall height

• 1,000mm

Wall materials:

• Front: welded mesh on steel frame 
• Sides: welded mesh on steel frame 
• Back: zinc aluminium walls with 2m x 3m roller door
• Removable: Side walls swing back to wall and can be removed for cleaning

Other 

• Gates on either side of calf feeding units
• Can drive ute to pens through central race for unloading

Pen flooring

Type 

• Concrete and gravel covered with deep wood shavings

Drainage

• Drainage of concrete at nib wall, 2-3% slope on concrete to nib wall

Total floor space per pen

• 52 square metres

Floor space per calf at peak capacity

• 1.7m²

Other

• Feed and water kept on concrete area

Bedding

Type

• Pine post peelings (wood)

Minimum depth

• 150mm

Maintenance

• Completely replaced for each batch

Other

• Used bedding composted and used as mulch on neighbouring berry farm

Feed and water

Milk feeding system type

• DeLaval automatic feeding units
• 12 units servicing 12 pens
• One controller per four units (not networked)
• Calves fed up to 6L/day (2L every eight hours)

Milk delivery method

• Transported by 1,000L container to two refrigerated 3,000L vats in calf shed (milk lasts up to 30 days)
• Fed milk only: colostrum, antibiotic milk and sale milk if run out

Hay

• Hay racks in paddocks

Pellets

• Auto feeders feed up to two kilograms per calf
• Manually top-up feeders

Water

• Pig nipples in each pen
• Some paddocks have troughs

Other

• Hot water service, wash drum and chemicals
• Underfloor pipes to supply refrigerated milk to feeder units

Cleaning and disinfection

Type 

• Batch

Other

• Sometimes batches follow each other (pens cleaned in between)
• Lime over gravel, formalin wash over concrete parts

Biosecurity

Access restrictions

• Shed door locked
• Gate locked to stop entry to area from public road

Housing of sale calves

• Housed in another separate shed on another property

Quarantine area for sick calves

• Separate pen made at end of shed

Other

• Closed herd but mixing calves from four different farms

Feed preparation and storage

Facilities

• Sink, fridge, storage cupboard, records/filing cabinet