Case Study: Calf Rearing Shed – Maffra VIC
Serious Scale, Smarter Design: Gippsland’s 120m Calf Shed Built to Last
Darren and Michelle Berryman run a large-scale dairy operation in the Maffra district of Gippsland, milking 700–800 cows. Over the years, they’ve invested in their infrastructure to keep pace with the demands of a growing herd and the day-to-day realities of modern farming.
The Berrymans’ have built three sheds with Bairnsdale Engineering: a tall machinery and hay shed, a freestanding roof over the dairy working yard, and most recently, a 120-metre-long custom calf shed.
The Challenge: Disconnected Facilities and Growing Herd Size
Before their latest project, the Berrymans’ were managing calf rearing across four or five separate areas. The lack of a centralised facility made daily operations harder, affecting efficiency, calf health, and workplace flow. Darren saw firsthand the benefits of consolidating operations under one roof after seeing a similar design built by his father-in-law, and knew it was time to make the investment.
With calves, feed, and handling equipment all spread out, the aim was to bring everything together in one place, purpose-built for better animal care and a more efficient workflow.
The Solution: A 120m Custom Calf Shed, Built for Practicality and Longevity
Working with the Bairnsdale Engineering team, Darren and Michelle commissioned a 120m x 13m skillion shed designed specifically for calf rearing, capable of housing up to 240 calves when full. The design considered every operational detail: ventilation, sunlight, feeding zones, and pen layout were all integrated into one streamlined structure.
Key Design Features for the Ultimate Calf Rearing Shed:
Skillion Roof: The concept of the skillion design offered many health benefits in calf rearing. Open to the north, sunlight reached the back wall during the winter solstice providing light and warmth during the autumn and winter calving season. With the back wall to the prevailing weather, the skillion roof is an excellent design for effective ventilation offering unobstructed airflow up and out of the building.
Universal Beam Frame: Bairnsdale Engineering’s use of hot-dipped galvanised universal beam columns and rafters and heavy-duty connections ensured long-term durability, even in the demanding, high-moisture environment of a calf-rearing operation. Universal beam rafters enabled straightforward overhanging eaves offering weather protection without interfering with the ventilation solutions. The result was a high-clearance, corrosion-resistant structure built to support intensive use, and built to last.
Sloped Floor: The concrete floor sloped 1% to the centre of the shed along its length and a stepped 5% + 2% across its span allowing for effluent to drain to a central location for an easy cleanup process. This required graduated column heights, a custom solution where Bairnsdale Engineering’s uncomplicated manufacturing process shines.
Concrete Panels: The design incorporated concrete panels on the inside of the shed. Not only do the panels enable effective and efficient clean out of the shed, they also provide a second ventilation gap on the back wall above the calves drawing stale air out of the shed.
Performaflow® Gutter: With a roof area of 1667.8m ² a performance solution was calculated and a gutter was designed to take a runoff of 22.57 litres per second into three 150mm downpipes.
“It was a big project, but the team were marvellous. They were easy to deal with, and every part of the shed was well thought through.”
– Darren
Maffra Farmer
The Results: Healthy Calves, Happier Staff, and a Smarter Farm Layout
The impact was immediate. With everything in one place, feed, water, shelter, and equipment, staff efficiency improved, and calf health outcomes were noticeably better. The large, well-ventilated space allows for easier handling and cleaning, reducing stress for both animals and workers.
“It’s made the workplace better, and the animals healthier. You’ve got everything you need for calves right there in one spot. It just works.”
– Darren, Maffra Farmer
For a project of this scale, the return on investment was always top of mind. But with labour efficiencies, healthier livestock, and fewer management headaches, Darren has no doubt the shed is already delivering real value.
Why Bairnsdale Engineering?
The Berrymans’ experience reflects what many Gippsland farmers already know: Bairnsdale Engineering builds more than sheds – they build lasting partnerships. Known for their practical approach, quality workmanship, and clear communication, the team brings decades of rural construction knowledge to every project.
“If I’m going to build a big shed, it’ll be a Bairnsdale shed. They know their stuff, they give good advice, and they’re great to work with from start to finish.”
– Darren, Maffra Farmer
