Calf Shed and Calving Barn – Toora
CASE STUDY
Bairnsdale Engineering:
Transforms a South Gippsland Dairy Operation
Operating in the high-rainfall district of Toora, South Gippsland Farmer, Wendy, needed infrastructure that could improve calving conditions, reduce staff workload, and protect pasture year-round. Her farm experiences periods of heavy rain and flooding, especially during peak calving times, often resulting in boggy paddocks, disrupted livestock movement, pasture damage, increased labour demands, and challenging conditions for calving and animal welfare.
In 2022, Wendy was referred to Bairnsdale Engineering by a local friend who had recently built a custom calf shed and spoke highly of both the build quality and the service. Already familiar with Bairnsdale Engineering’s reputation for durable, farm-ready infrastructure, Wendy set out to compare options. After visiting several local farms, it was the ‘Bairnsdale Shed’ that stood out. What impressed her immediately were the heavy-duty
UB rafters. A practical, low-maintenance design that reduced bird nesting and debris build-up creating a safer, low-maintenance environment for livestock and staff.
That visit led to her first project: a custom-designed calf-rearing shed with a focus on ventilation, hygiene, and young livestock welfare.
The First Build: A Calf Shed Designed for Health and Efficiency
Purpose-built for the demands of early stock management, Wendy’s calf shed was designed to promote animal health, improve hygiene, and support staff safety. The layout and construction reflect Bairnsdale Engineering’s proven approach to young livestock care.
Key benefits of Bairnsdale Engineering’s custom-designed calf shed include:
- Wall vent gaps to offer improved airflow without draughts for healthier calves and to minimise respiratory issues.
- Eave overhangs that keep the wet weather out while allowing for air ventilation to prevent any build-up of stale air.
- Translucent wall lights which provide ample natural light while offering protection from the wind.
- Marine ply lower walls by Wendy to create easy-to-clean surfaces streamlining hygiene routines and supporting biosecurity.
- Layout to suit flexible pen divisions for safer handling and calf separation to adapt as herd size and workflow needs change.
- Hot-dip galvanised UB columns and rafters that are a durable, low-maintenance design built to last
The Second Build: A Multi-Purpose Shed Designed for Growth
Like many of Bairnsdale Engineering’s clients, Wendy returned with a new project in mind. In 2023, she faced a major decision: invest in more land or improve her infrastructure. After careful consideration, she chose to invest in a multi-purpose shed, specifically designed for calving, and provide reliable shelter for cattle during both summer heat and prolonged wet spells but double up as hay and machinery storage in the off seasons.
Positioned on a high-exposure site along the South Gippsland Highway, the build came with its own set of challenges, including a tight turnaround ahead of calving and the need for a thoughtful site-specific design for flexibility, durability, and year-round performance.
A Smarter Shed, Built With Purpose
Unlike a standard off-the-shelf shed, this purpose-built shed had to tick multiple boxes and without compromise. The design had to meet the farm’s vision for the future. The Bairnsdale Engineering team handled every detail from layout to permits with ease.
“They just got it. From the shed builder to the team who managed the permits, the service was excellent. I decided in January, and they had the whole thing built by May—just in time for calving.” Wendy
Key elements of the build were similar to those included in Wendy’s original calf shed – tried, tested and proven design features that work.
Key Features
Ventilation Gaps
Keeping in mind the fact that the body temperature of a ruminant cow runs higher than that of a young calf, the locations of the vent gaps were altered to better suit the grown cattle. Wall vent gaps above the 1.5m high concrete panels and a ridge ventilation gap work together to draw any warm, stale air up and out of the building.
Hot-dip Galvanised UB Columns and Rafters
The rust-resistant main frame made it especially ideal in the highly corrosive environment of a coastal dairy farm. The uncomplicated cut, drill and weld manufacturing method of the universal beam column and rafter combination made customisation of roof pitch and vent gaps straightforward and easy to install. The finished result was a clean, high-clearance, practical structure for everyday farming use.
Performaflow ® Gutter
A custom calculated performance solution gutter enabled Wendy to have all the rainwater to one end of the 80.59m long shed.
The Results: Labour Savings, Welfare Improvements, and Long-Term Value
The second shed delivered immediate and measurable value. By late August, Wendy and her team were able to move cattle off waterlogged paddocks, preventing pasture damage and preserving silage quality. Calving became less labour-intensive, with fewer hours spent retrieving cattle from boggy ground, saving both time and effort during one of the busiest periods of the year.
The multi-purpose design continues to add value across seasons, providing flexibility without the cost and complexity of a full free-stall barn.
It’s the best of both worlds. I didn’t want to build a big free-stall barn and overcapitalise, but I still needed something functional and future-proof. This gave me the flexibility I was looking for - it’s worked in the wet, helped during heatwaves, and saved time and labour during calving. I’ve already seen the savings in reduced pasture damage and better silage quality.”
Why Bairnsdale Engineering?
Wendy’s experience reflects what sets Bairnsdale Engineering apart: quality structures, long-term thinking, and practical, personal service. From the initial consultation to final installation, the team worked to Wendy’s timeline, managed permit requirements, and delivered a product that’s already returned its value in reduced labour, lower pasture damage, and better livestock outcomes.
“I wouldn’t hesitate to use them again. They’re great to deal with, and everything just works.” – Wendy
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