Skillion Feed Pad Cover & Calving Barn

CASE STUDY

Bairnsdale Engineering Builds:

A Smarter Feed and Calving Shed for Giliam Dairies

Since migrating to Australia in 1990, Jan Giliam and his family have built a progressive dairy operation. Today, Giliam Dairies runs around 800 cows across 1,000 acres, with several outblocks supporting young stock and feed production. It’s a genuine family business; Jan, his wife, and their son and daughter-in-law all work together on the farm.

Their herd, a carefully balanced mix of Holstein, Scandinavian Red, and Montbéliarde, reflects the same focus that drives every investment on the property: practical design, efficiency, and animal welfare that lasts.

If you’re considering a Bairnsdale Engineering shed, it’s a good idea. The shed was easy to put together, it stays straight, and if you have any issues, they’re there to help you.”

Jan Giliam - Giliam Dairies

The Challenge: All Weather Functionality and Smart Site Design

Jan wanted to improve feeding efficiency and animal comfort during Gippsland’s challenging winters. His existing feed pad worked well, but it offered no protection from the weather, and the site presented a unique engineering challenge:

A 3 percent slope: Over 152 metres, the pad dropped more than 4 metres end-to-end.
Support daily use: The structure needed to serve as a feed shed, loafing barn, and calving area, in use every day of the year.
Self-installation: Jan planned to handle the installation himself, so clarity in design and documentation was essential.

The Solution: A 152m × 31m Feed and Calving Shed Built for Daily Use

Working with Bairnsdale Engineering, Jan developed a custom skillion-roofed design built directly over the existing feed pad. The structure was engineered to suit the site’s natural slope and positioned to face north-east, capturing valuable winter-morning sunlight while still providing shade through the heat of a summer day.

Natural airflow was a major design priority. To validate the ventilation performance, a smoke test was carried out, confirming consistent air movement through the central calving and loafing areas, without drafts or dead zones.

Key design features

Functional Layout

Designed to suit the efficient flow of cattle coming directly from the dairy up the dual feed alleys and either into the central loafing and calving area or out to the paddock.

Skillion Roof

The mono-pitched roof offered the ideal solution for Jan. It enabled all the stormwater to run to one side of the shed leaving the second feed alley free of downpipes and underground stormwater.

Universal beam columns and rafters

The straightforward design of the UB column and rafter allowed for easy customisation enabling Jan to install the cover over existing infrastructure. The low-profile frame offered a compact, yet durable, uncluttered interior, essential for withstanding every-day use.

6.3m Cantilevered Eave Overhang

The front eave provided weather protection over the second feed alley without posts impeding on the feed wagon conveyor and avoiding corners for old feed to build up in.

Concrete Panels

Columns were designed to incorporate concrete panels, ideal for a straightforward clean-out process.

Proven Ventilation

A gap under the south facing eave allowed for steady air exchange, verified by smoke testing.

They gave us the plans, and we built it ourselves. It’s good quality, and they make what you want, properly engineered.”

The Results: Healthier Stock and Everyday Efficiency

The shed is now central to Giliam Dairies’ operations, used daily for feeding, calving, and housing younger or recovering cows.

Improved animal welfare: Cows calve indoors, out of the mud and weather, reducing stress and losses.
Cleaner, drier environment: Keeps bedding and feed areas dry, improving hygiene and reducing disease risk.
Year-round productivity: Provides shelter, feeding, and loafing space used 365 days a year.
Proven airflow: Ventilation design tested and proven effective in maintaining air quality and animal comfort.
Practical design: Straightforward to assemble, durable, and low-maintenance.

Why Bairnsdale Engineering?

Jan first met the Bairnsdale Engineering team at a dairy event after seeing their work in local advertising. He was impressed by their practical approach and clear communication from early concept through to delivery.

“It’s engineered properly, easy to build, and it just works. They were good people to deal with.”

For the Giliam family, the result is a hard-working, multi-purpose shed that supports the farm every day of the year, built for efficiency, animal comfort, and future generations.