Freestall barns are becoming increasingly popular – and valuable – infrastructure for Australian dairies.
Industry-leading dairy farmers are capitalising on easier pasture management, improved labour efficiency and increased milk production (among many benefits) to strengthen the profitability and sustainability of their dairy operations.
Many forward-thinking milk producers are beginning this journey by using a loafing barn as a stepping stone to a freestall set-up.
This can be a smart move: you gain immediate value from the loafing barn while keeping your options open for the future. This approach also helps expanding operations to manage cash flow and spread financial risk – a valuable strategy given rising input prices.
In this article, we discuss the reasoning behind a loafing barn to freestall barn journey, and whether it is the right fit for your dairy. We also cover the key steps you need to take in the initial planning phase to set your project up for long-term success.
Why Build A Loafing Barn & Convert It To A Freestall Barn? – Is It The Right Choice For You?
A dedicated loafing barn can provide significant value to both small and large-scale dairies alike – regardless of whether it has been designed to be converted to a freestall barn or not.
A loafing barn can:
- Improve pasture management by reducing pressure on paddocks and preserving soil structure
- Maximise production from limited land and eliminate the need (and cost) to expand your property footprint
- Protect your business from staffing issues by improving working conditions and reducing labour requirements
- Increase animal comfort and maximise and maintain consistent milk production, including during weather events.
- Make management easier and reduce stress by giving you peace of mind, confidence and tools to make smart decisions
- Be repurposed throughout the year for fodder storage or used as a calving barn
These benefits make a strong case for investing in and implementing a loafing barn system!
So, Why Convert Your Loafing Barn To A Freestall Set Up?
In many cases, preparing your loafing barn for a freestall setup is a relatively low-cost exercise – it is more about taking the extra time to plan ahead.
With a few strategic decisions now, you can future proof your barn infrastructure and unlock additional longer-term value.
Compared to a full freestall barn, a loafing barn offers a lower initial capital cost, making it an attractive option for dairies looking to scale gradually – and without the immediate commitment to a freestall set up.
Freestall barns typically have higher upfront cost because of the additional steelwork required for the stalls and the concrete through the barn
This is the main reason while dairy farmers are opting for a staged project – building a loafing barn and then converting to a freestall setup later.
However, it is worth noting that a freestall barn offers a lower cost per head than a loafing barn.
This is because the recommended stocking rate for a loafing barn is up to 15m² per cow (depending on the weather conditions and how long cows are housed) so that the other cows can move around them and to and from the feed alley. In contrast, a freestall barn has a dedicated stall per cow – typically around 1.2m x 2.5m.
As a result, a freestall barn can accommodate more cows than a loafing barn of the same size – in some cases as much as 60% more depending on the span size – significantly reducing the cost per head.
We have provided an example below.
Loafing Barn Versus Freestall Example
- A 40m (W) x 120m (L) loafing barn costs approx. $500,000 – $650,000 and can be stocked at 320 cows = $1550 – $2050/head
- A 40m (W) x 120m (L) freestall barn costs approx. $500,000 – $650,000 and can be stocked at 520 cows = $960 – $1250/head
Please note these price guides are approximate only and do not include the cost of the freestall fit out.
Is This the Right Choice for You?
A loafing barn designed to be converted to a freestall barn might be the right choice if you:
- Want to benefit from the immediate advantages of a loafing barn
- Prefer to scale your operation gradually while preserving capital
- Are observing how contained housing evolves in Australia before fully committing
- Want to manage cash flow and spread investment risk
- Want to have the option and flexibility to transition to a freestall system if your operational goals change
However, if you’re confident a freestall system is the best fit for your operation, management style and long-term strategy – and you’re ready to commit – it may be more cost-effective to build a freestall barn from the outset.
Alternatively, a loafing barn may align more closely with your long-term operational goals.
For example, Markus Lang runs a predominantly grazing dairy and uses his loafing barn to complement his system, improving comfort, protecting paddocks, and giving him flexibility without committing to full housing.
4 Steps To Designing A Future-Proof Loafing Barn
If you’re considering building a loafing barn with the potential to convert it into a freestall barn down the track, early planning is essential.
A “future-proof” loafing barn will provide benefits now and sets you up for a smoother transition to a freestall system in the future.
1
Engage Consultants Early
Involving the right professionals from the outset is one of the most effective ways to reduce future risk and cost.
Engage dairy planning consultants, building consultants and freestall suppliers early and in the initial discussions, not after the design is locked in.
Communicate your long-term goals so they can be factored into design, permit, and layout decisions.
2
Smart Site Selection & Planning
Your site choice will influence almost every aspect of your barn’s performance—now and in the future.
- Orientation: The correct orientation is essential for effective airflow and comfortable conditions for both loafing and freestall barns.
- Effluent management: Consider whether your existing or planned flood wash and catchment system is adequate and/or scalable.
- Stormwater management: Barns provide an excellent opportunity to capture stormwater runoff – is there room for water storage?
- Access roads: Allow room for vehicle access and feed delivery
- Existing infrastructure: Consider the location of feed storage and any dwellings that may be impacted
- Planning constraints: Check for any overlays or boundary issues that may trigger permit requirements.
3
Council Permits & EPA Approvals
Designing for freestall conversion may change what permits or environmental approvals you need.
- Anticipate permit requirements for a freestall system now, even if you’re not building it yet. This makes it easier (and faster) to secure approval when you’re ready to expand – and ensures there are no surprises.
- As registered builders, our building consultants can guide you through this process and submit permit applications on your behalf.
4
Best-Practice Bay Spacings & Standard Spans
If you are considering converting your loafing barn to contained housing, such as a freestall barn, you will need to consider what width and bay spacings are required for the internal layout of these types of systems.
For example, a 40 metre span width and 10 metre bay spacings are popular for this reason.
There are a few other points to keep in mind when it comes to loafing barn size:
- As a general rule, longer rather than wider configurations will be more cost-effective
- Industry size recommendations include allowing approx. 300mm bunk space per cow and approx. 10 -15 square metres per cow
- Canopies and eave overhangs can also be used to provide additional weather protection. This often more cost-effective than increasing the span width and can be used to avoid inconvenient column placement.
Our building consultants are available to provide project specific size advice.
So, what else do you need to know?
We’ve rounded up a collation of useful resources on sizes, prices and project planning to help get you started. You will also find several recent project examples for ideas and inspiration!
Useful Resources
Designing your loafing barn so that it can be converted to a freestall barn?
A well-planned loafing barn can provide excellent value now and lay the groundwork for future expansion.
So, start with a clear long-term strategy and involve the right people early.
Our building consultants are available to provide advice and best-practice recommendations – and work with you and your dairy consultants to ensure your barn supports your current operation and future goals.
Book a project consultation on 1800 687 888 or email us at [email protected]
