Modular Calf Care

 

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Main Category: Modular Building Design
Company: Art's-Way Scientific, Inc.
Affiliate:
Location: Sturgeon Bay, WI
Building Use: Dairy Calf Nursery
Gross Size of Project: 12040 Square Feet
Days to complete: 158

Award Criteria

  1. Architectural Excellence

    Art’s Way Scientific was challenged to bring our modular calf housing to a Wisconsin county whose code read in part “no trailers allowed”. A plan was developed to incorporate our proven environment for calves into a building that would blend into the existing farmland. Seven, 16’ x 88’ modules were used to create a 10,340-sf calf housing area. Combined with a 1700 sf site built corridor and attached to a 2400 sf milk mixing parlor we could provide the dairy with all its calf raising needs under a single roof. In total this facility can house and care for up to 518 calves. In an environment subject to government regulation and approval, sanitary conditions are of highest priority. Stainless steel calf stalls with antimicrobial flooring and walls provide cleanable surfaces for compliance. Steel siding and roof were matched to existing buildings. The corridor is designed to allow for vehicles to enter the building without compromising the air quality in the animal rooms.

  2. Technical Innovation & Sustainability

    Although comprised of seven modules, the design intent was that this facility could be disassembled. Each individual module could be easily converted to be its own self sufficient unit housing up to 74 calves. This provides the flexibility to expand, relocate or disband. In typical agricultural ventilation, air is moved by fans located at the ends or sides of the unit. With this design, one end and the sides were not options. The solution was to create an air chamber with and accessible fan within the preheat room to provide the necessary CFM and air changes needed to for calf health. Air is exhausted through the roof with an 8” stack topped with a rain cap. Each room is equipped with its own pressure wash and potable water lines. Power is provided from a master distribution panel to each module through a 60A panel. Units are anchored side by side with full walls between the animal rooms. Minimal mating was needed only at the door thresholds.

  3. Cost Effectiveness

    In our agricultural industry market segment regulations limit producers to how large their facilities can grow. Many communities are concerned with the environmental impact of large facilities and have tight controls and restrictions on manure management. This facility allowed taking advantage of building placement and a lagoon. Prior to this facility, the producer experienced up to a 30% death rate in calves acquired from outside source. By taking control of that aspect of the business through the construction of this facility, the producer now has a 1% loss and control over how his calves are medicated, handled, raised and used. The producer also saves cost involved with animal health by eliminating illness and the treatment needed to fight it. Additionally there are no costs incurred for bedding and the associated labor to remove, replace and dispose of it. With calves a commodity, currently at $300-400 per calf, the building can pay for itself in a short amount of time.