By Matt Henry and Randy Beckemeyer
Each spring at The Maschhoffs we begin to think about new construction and “digging a hole” as we call it. Spring can be a very busy time for new finisher construction. Unfortunately, the past few years following the pandemic have brought significant price increases to all the components that go into these units.
It began with skyrocketing lumber prices, and it has slowly worked its way into every facet of the barn. Currently lumber has returned to more historically normal levels, but stainless steel, steel components of all types and concrete have risen to take back any gains from the receding lumber costs. All this is in addition to component availability as well. We have seen multiple projects across the Midwest be slowed or halted sometimes for weeks as contractors wait for something that has the dreaded “In Transit” notation in the shipping column.
The newest challenge our industry has to tackle this year is labor costs. Like a majority of jobs in food agriculture, the ag construction industry relies on a migrant labor workforce. After surveying the major industry ag construction companies recently, we discovered most are expecting a 50% to 100% increase in the cost for that labor due to the new Department of Labor H2A wage changes.
In simple terms, this could add roughly $1,000 to $2,000 per day to the cost of new construction crews’ labor rate. That’s not just concrete labor, but each contractor who has workers on the site, including framers, equipment installers, electricians, etc. We could see this add $75,000 to the total cost of a 2,400-head finisher and a few times that amount to projects like a 5,000-head sow unit.
Our Approach to Building Design in 2023
As we begin to review building design and look for ways to incorporate new technology while minimizing cost, our option is the 2,400-head finisher. It is a 101' x 193' barn that incorporates two rooms with nine pens each. It is a small finisher, but it allows us to fill and market it faster than the previous 3,600 unit.
Starting off with the gating package, we utilize a motel-style pen with a sort-off capability that is combined with a fast alley loading system. This enables us to sort off pigs and utilize the same sort area as the loading system just by opening a couple gates. This provides less stress and resistance on the animals and the operator when loading the truck.
The ventilation package is unique as we combine pit and wall fan ventilation to create a comfortable atmosphere in the pens. We utilize a tube heat system that provides zone heating to the wean pig laying area. This heating system, in combination with the ventilation system, provides a low-cost, high impact area for wean pigs to stay warm. To compliment this, we removed the curtains from the side walls which were installed on earlier barn models and closed them in with an insulated sidewall. This allowed us to hold heat in the rooms instead of escaping through the pockets and the curtain itself.
The feeding system consists of two flag systems that provide feed to the wet/dry feeders in the pen. These feeders incorporate water nipples at the feed pan level that enable us to provide a small amount of water to the eating area to help with digestion and increase feed intake.
The Maschhoffs will continue to utilize our world-class research facilities to find ways to implement the newest technologies that not only optimize the barn environment, but offer facility longevity all while keeping construction and operating costs to a minimum.
Matt Henry is the associate director of business development and Randy Beckemeyer is the director of facilities and projects for The Maschhoffs.
Read More from Farm Journal’s PORK:
Don’t Panic, Prepare for Opportunities Before They Materialize
How Illinois Legislators are Removing Obstacles for 4-H and FFA Youth
A Multidimensional Approach to Sustainability in the Swine Industry
