Rob and Darlene HowlandHowland Acres

Candor, NY

Why Renovate the Old Tie-Barn?

The Why, What, How and Results from Our 3 Year Experience

Howland Acres – Rob & Darlene Howland, Candor

*100 Cows and their Replacements, ~200 total

*85 Lbs. Milk/Milk Cow in tank, year ‘round (after renovation)

*Pasture system for all heifers over 350 lbs. & dry cows

*380 Acres Total - 100 Acres Woodland - 150 Acres Pasture - 100 Acres Hay Crop - 30 Acres Corn Silage

*Cows are currently sending 5th Daughter through college

Heifer and Dry Cow Facility

Brief History

*1974 Dairy at rented facility

*1976 began Dairy at current site

- a bit of a struggle

- 74 stalls

- 39” – 48” stall widths, 54” – 64” stall lengths

- Swing stanchions, no dividers

*1981 fairly major renovation in use through mid-2006

- “Conventional wisdom” at time – 48” W x 72” L

- Went 48” W x 69” L as compromise

- 12 stalls 54” W for largest cows (not divisible)

- Ended up with 70 stalls

- 1988 Barn cleaner improved/moved out 80 stalls

- Teat injuries decreased from 20 per year to 4

- Expected production improvement materialized

1981 - 2006All but 12 stalls:48” x 69”

Side View:

Neck rail 4” forward from curb.

Neck rail 36” above cow bed.

The somewhat illegal bedded alley

May 25, 2005

How does your farm rate on cow comfort?by Kathy Zurbrigg, OMAF(someone cares about us tie-barns!)

What got us thinking?

…as well as:

*Stalls rusting off

*Production ceiling hit

*Possibility of getting all of the benefits without full concrete bust-out and re-pour.

Further Reflection in 2005/2006…

(-) At 57 years old, why do something like this?

(-) Next generation?

4 remaining years of college commitment (2009)

Want to be 100% debt free at that time (2009)

…So, must cash flow and be paid off in 4 years or less

Other Influences…

1996 heifer barn fire and consequential rebuilding as free-stall facility (comfort/labor savings) got us to question utility of tie-barn

Other Influences cont. …

But the installation of tunnel ventilation in 2000 changed that view.

The potential for a more forgiving resting and standing surface (mattress) and all hardware surrounding the cow (loop divider, height of tie-bar) and possibly a little more elbow room is too great to ignore!

A Major Consideration – to bust concrete or leave it

Does current 48” W x 69” L (12 of 80 are 54” W) fit the cow size pattern in herd?

What percent of the improvement in cow comfort and reduction in injuries is attributable to the mattress, loop stall divider and appropriate tie bar height vs. the width and length of the stall? (couldn’t wait to hear Dr. Anderson’s talk!)

…to answer that we used the “cow imprint” measuring technique

Rump Height

Hip (Hook) Width

Rump Imprint Hook - Imprint Rump Imprint Hook - ImprintHeight Length Bone Width Height Length Bone Width

Cow / Age Weight Resting Width Cow / Age Weight Resting Width(Taped) 1.2 x rump 2x hook w 1.2 x rump 2x hook w

682 10-11 1538 937 04-10 1534 59 70.8 24.5 49748 09-07 1290 57 68.4 23.25 46.5 938 04-10 1375 58 69.6 23.25 46.5785 08-08 1630 55.75 69.3 25.5 51 939 04-09 1415 60.5 72.6 23 46808 08-01 1561 56.5 67.8 24 48 945 04-08 1260 57 69 23.75 47.5854 06-08 1515 59.75 71.7 24 48 947 04-08 1375 59.25 71.1 25.25 50.5863 06-07 1695 949 04-07 1540 59.25 71.1 23.25 46.5866 06-07 1415 58.5 70.2 24.5 49 950 04-07 1450 60 72 23 46889 06-00 1570 61 73.2 23.5 47 953 04-06 1660 59 70.8 23.75 47.5891 05-11 1800 59 70.8 24 48 954 04-06 1308 59.5 71.4 24 48892 05-10 1650 62 74.4 22.5 45 956 04-06 1300 59.75 71.7 23.25 46.5893 05-10 1640 57.5 69 23.75 47.5 957 04-05 1837897 05-09 1640 960 04-05 1538 59.75 71.7 22 44901 05-08 1525 60.5 72.6 23.75 47.5 968 04-03 1650 60.75 73 25.25 50.5902 05-07 1561 61.25 73.5 24.25 48.5 969 04-03 1400 57 68.4 22 44907 58.25 69.9 25.25 50.5 975 04-01 1375 58.25 69.9 23.25 46.5908 05-07 1540910 05-07 1265 58.25 69.9 23 46911 05-07 1350 57 68.4 22.25 44.5912 05-06 1653 58.75 70.5 25.25 50.5916 05-06 1230 56.5 67.8 22.25 44.5918 05-06 1620 59 70.8 23 46926 05-01 1420 59.5 72 24.75 49.5928 05-01 1607 59.75 71.4 26.75 53.5929 05-01 1580 60.5 72.6 23.75 47.5

Aged C

ows

Bold = Cows needing more than current 69” L or 48” W

Bold Italic = Cows beyond 72” length needs

Rump Imprint Hook - Imprint Rump Imprint Hook - ImprintHeight Length Bone Width Height Length Bone Width

Cow / Age Weight Resting Width Cow / Age Weight Resting Width1.2 x rump 2x hook w 1.2 x rump 2x hook w

983 03-09 1270 59.25 71.1 22.75 45.5984 03-09 1375 58 69.6 23 46 1029 02-11 1332 58.75 70.5 21 42

987 03-08 1306 57.5 69 22.5 45 1030 02-11 1308 60.25 72.3 21 42

991 03-07 1651 59.5 71.4 23 46 1033 02-10 1263 59.5 71.4 22 44

992 03-06 1300 61 73.2 25.75 51.5 1036 02-09 1315 60.75 72.9 23.75 47.5

996 03-05 1130 57.25 68.7 23.25 46.5 1038 02-09 1230 57 68.4 23.75 47.5998 03-04 1584 61 73.2 23.75 47.5 1039 02-09 1275 59.75 71.7 22.5 451000 03-04 1470 58 69.6 20.75 41.5 1040 02-08 1425 59.5 71.4 23 461001 03-03 1390 57 68.4 21.5 43 1042 02-08 1370 57.5 69 22.25 44.51006 03-02 1495 59 70.8 22.75 45.5 1045 02-07 1355 58.75 70.5 22.25 44.51013 03-02 1480 61 73.2 23.75 47.5 1046 02-07 1140 56.5 67.8 21 421014 03-02 1354 60.25 72.3 21.5 43 1048 02-06 1400 59.75 71.4 23.75 47.51016 03-01 1490 59.5 71.4 23.25 46.5 1057 02-03 1219 59.75 71.4 22.75 45.51017 03-01 1446 1069 58.25 69.9 22.25 44.51018 03-01 1670 57.75 69.3 22.5 45 1007 57.5 69 23.75 47.51019 03-01 1380 61.75 74.1 23 46 1037 58.25 69.9 24.25 48.5

1020 03-01 1380 58.75 70.5 21.5 43 1061 58.25 69.9 22 441021 03-01 1580 59.5 71.4 24.25 48.5 1062 59 70.8 20.5 411022 03-01 1306 57.5 69 22 44 1059 58 69.6 20 401023 03-00 1435 57.25 68.7 23.75 47.5 1053 56 67.2 22.25 44.5

1024 03-00 1655 61.5 73.8 24.5 49

1026 03-00 1263 57.25 68.7 23.5 47

1027 03-00 1260 56.5 67.8 23.75 47.5

1028 03-00 1330 58.75 70.5 23.75 47.5

951 58.5 70.2 22.75 45.5

1032 60.5 72.6 25.5 51

2 Yr.

old C

ows

Bold = Cows needing more than current 69” L or 48” W

Bold Italic = Cows beyond 72” length needs

Why – II

Why This Particular Stall “Package”?

Dr. Neil Anderson (DVM)Ontario Ministry of Agriculture Food and Rural Affairs (OMAFRA)

Dr. Anderson and others in the Animal Behavior/Cow Comfort arena did the industry a big favor by applying video and other technologies to determine what cow comfort truly is. Dr. Anderson applied this knowledge to the tiestall as well as the freestall.

You will see 3 short videos a few slides on showing the “natural cow” in a pasture setting telling us just how much space she really needs to be comfortable in her stall and to be free of hardware obstructions when getting up and down.

Cows are pretty much all the same size, right?!

Fig. 2. Several cow measurements taken on standing cows are useful for building stalls. Other essential measurements are imprint length and imprint width of resting cows.

Measurements of mature Canadian Holsteins at a local dairy herd and some calculated proportions. For example, mature cows had a rump height of 60 inches, a nose-to-tail length of 8.5 feet and a hook bone width of 25 inches. Their weight exceeded 1550 pounds.

Table 1. Body dimensions, example measurements for mature Holsteins, and estimated ratios to rump height and hook-bone width

Figure 3. Imprint length extends from the folded foreknee to the tail. This length defines the bed length of a stall.

Nose-to-tail length describes the measurement from the tail to the nose of a cow standing with her head forward. A cow has a normal crook in her neck when lying and her nose-to-tail length is less than while standing.

Imprint length describes the length from folded foreknee to tail while lying in the narrow position. It defines the bed length needed for resting with all body parts on the stall. Imprint length is greater when the cow extends her front legs forward in normal resting positions.

Figure 4. For the rear view of the cow in the photo, imprint width extends from the left hock to the right abdomen - a distance of about 52 inches for this cow. It increases when the rear legs extend outwards or the cow reclines in wide resting positions.

Figure 5. While rising freely on pasture, a cow uses the forward, downward and vertical space outlined by the white lines in the photograph. While rising, this cow lunged forward about 22% of her resting nose-to-tail length.

The space needed for lying and rising motions (lunging) extends forward, downward and upward forehead lunge and bob, vertically and forward for standing and laterally for hindquarter movements. Knowledge of this space is essential for properly sizing the opening at the front of tie stalls, positioning tie rails, choosing the shape and dimensions of stall dividers and avoiding hazards when turning out of stalls.

Side

Front

Rear

Table 2. Stall dimensions, estimated relationships to body dimensions and example calculations for mature Holsteins in a study herd.

Figure 6. A tie rail placed 48 inches above the mattress and 86 inches forward of the gutter curb allows medium size cows (about 58 inch rump height) to stand straight in the stall. While standing idly chewing their cuds, their poll will be at tie rail height and behind it and most of their head will extend below and forward of the tie rail. Larger cows will stand diagonally in stalls with those measurements.

Figure 7. In most barns, the divider provides support for milk lines and separation of cows in adjacent stalls. This divider leaves about 30 inches of space for cows to back into an adjacent stall when exiting. The top pipe drops down at the back so a cow can easily swing her head over it. This style is suitable for herds feeding TMR.

Figure 8. A cow friendly manger curb has beveled corners. The curb acts as an obstruction to forward extension of the legs. To get room for this normal behaviour, cows lie diagonally in their stalls with their front legs stretched into the neighboring bed.

A common curb height is 10 inches and this decreases to 8 or less inches on the cow side with the addition of a rubber filled mattress or ample bedding. Despite the 8-inch height, many cows will extend their legs forward into the manger. Therefore, the curb should have rounded, beveled or smoothed edges.

Figure 9. Stalls with ample width and length allow freedom to rest in normal positions. Because of longer chains, cows are cleaner from self-grooming and they show more visible signs of estrous.

Figure 10. The distance from the top of the water bowl to the vertical obstruction is greater than the nose to poll length of the cows. This assures easy access to water. There is also adequate space below the bowl for sweeping the mangers.

If a manger divide is installed, and the bowl mounted within it, it must have about a 30-inch opening for easy access to the water.

Figure 11. For Holsteins in stalls with 70 - 72-inch platforms, the trainer should be 48 inches (range 47 - 49) forward of the gutter curb. For Jerseys in stalls with 62 - 66-inch platforms, the forward location is 42 inches (range 41 - 43). Remember that they are trainers and should be located about 2 inches above the chine for a 24 - 48-hour training period. After training, raise them to 4 inches. They can be lowered for 24-hours of remedial training but must be raised again afterwards. The trainer must have a height adjustment for each cow.

Figure 12. The trainer is located at the chine and slightly ahead of the point where the back begins to arch when a cow defecates or urinates. The trainers should be located at least 2 inches (five-cm) above the chime.

Figure 13. The diagram shows a tie stall with a head rail. The table shows variations in stall dimensions for Holstein cows - First Lactation, Milking and Dry Cows. Nonetheless, it's good advice to measure your cows before deciding on stall sizes.

Now for the “What? Goals

Clean Beds

Dry Beds

No Struggle Getting Up

Why?

Reduce Mastitis

Reduce Foot Problems

Reduce Performance Impairing Injuries

Did Decide to go to 72” L – Jackhammer curb and manger to find 3” more stall length

Cleaning and Leveling Curb and Manager Area

Prepping Forms

Bracing Technique – Holding Divider Post in Place

Welding re-bar to bottom of divider post

Still Day 1 – Section of barn ready for pour

End of Day 1 pour – Too late in day for concrete trucks

Start of Day 2 – Strip forms, hook up waterers, then pour manger and section of bed behind curb

Junction of new and old

“Anti-theft” pipe and clamps from old stalls added to new loop.

Junction of old and new – front view. Note height and forward position of neck rail

Ouch! Neck Compression

Front of new divider still had to accommodate computer feeder.

World of difference – steel relative to bone, cartilage and soft tissue!

Some 54” Stalls Called for 2 Trainers with “Comedian” Cows

Lessons Learned – Adaptations Made

Definitely got the “clean and dry”!

Adopted Bungee Cord Tail Ties SeenWhile Visiting Barns in Ontario

Stayed with the Plastic Manger Liner

Painted steel “flapper” over water bowl. Hinged at top and chain as stopper on bottom. Greatly reduces head skirmishes between bowl-mates!

Not sure why – water bowls very rarely need forage or grain removed

Meets Dr. Anderson’s 22”+ opening specification (greater than length of nose to poll). Normal , easy head positioning to get a drink

Should have taken a stone to round off rough edges of curb while concrete was still green!

Missed the opportunity to lower the manger in southwest end of barn where the old concrete was highest relative to cow beds.

Created a real head knocker!

Results83 – 84 lbs. milk/cow/day routinely, as much as 90 lbs.

SCC – 57,000 (Jan. ’09)

Quality premium $0.60/cwt.

21 Springing Cows and Heifers Sold for Dairy in ‘08

Cows and Springing

Heifers

Costs after all the dust settled:

Stalls/Hardware - $12,327

Labor (Histand’s) - 11,540

Concrete/Sand/Gravel - 2,870

Steel/I -Beams - 684

Nuts/Bolts - 405

Mattresses - 10,080

Total $37,929

Barn Renovation Payback Estimator

Barn Renovation Payback Estimator

(or 41% annual rate of return on investment!)

*Used 5 Hp Vacuum Pump*2” Stainless Milk Line *2” Receiver Group*New Wash System