Dairy barn to horse barn resoration

HI all,

We are thinking of restoring a family owned dairy barn. Not quite sure how old it is, but probably well over a century. It is a large bank barn, with a 45 cow tie stall. Plus there is a chicken barn, beef barn and heifer barn. All are in pretty good shape. I was wondering if you had any before and after photos? We realize it will be a big undertaking, but hopefully (maybe wishful thinking) since the structure is still good, we may not have to spend as much as constructing a stable from scratch.

Thanks!!

Our old dairy barn has been converted to a straight stall barn which we use for daily feeding. Ours is much smaller with only 17 stalls. We tore out the stancions and the pipeline and put in dividers between the stalls. Filled the barn cleaner channel with limestone gravel which, over the last 20 years has turned back into solid limestone. Put up butt chains to keep horses in their stalls during meals.

Biggest considerations would be if you have curbs and/or raised walkways or do you have a totally flat floor. Other serious problem is if you have enough height floor to ceiling for horses to be comfortable (at least 7’ for most horses). Some old barns were made with especially low ceilings to keep the cows warmer.

It wasn’t terribly hard or expensive to convert our barn;
just a lot of “grunt” work which we took on with enthusiasm 20+ years ago when we were younger and still full of energy. Don’t have any before/after pictures
but I think there are some pictures of our dairy barn on our farm Facebook page under Dancing Horse Hill.

I converted mine; I knocked out the concrete six by six that the stantions were set in, filled with concrete the three inch deep drop from the walkway in the front of the cows to where the cows stood, and left the gutters…built box stalls, and the horses just step across the gutters to get into their stalls; figured if I ever wanted to put it back to cows, leaving the gutters would be a help. At this point I think I could have just filled them. Ceiling height is lower, so I put the shorter horses in this barn, and in the addition we put on put the taller horses.

We converted our old bank barn, best thing we did was replace and reposition the support posts to where we wanted them for stall walls and doorways. DH basically planned the stall layout based on the the ceiling supports. We knocked out a few low cement feed troughs and filled the gutter with concrete. One side is slightly lower than the other, so we have stalls on the higher side and the tack room, feed room and blanket storage on the other. I love my old barn!

Old Cow Barn redo

I am in the finishing stages of this type of redo.

Wasn’t that bad to be honest. Once all the stantions and pipes and milking equipment was gone, things have gone pretty easy.
The ledges where the cows were, we knocked out. We used this gulley to put in french drains and covered and compacted small rocks in over them.

The trenches that lead down center aisle, we left too. Covered them.

Put in box stalls, using 2" rough cut boards. Those have gone in super fast.

I hope that for your stalls you are not using any sort of pine, spruce or hemlock!!

Use oak or hickory!!!. The extra work dealing with those woods is more than saved by not needing to replace them as a result of equine bevering.

I’ve boarded at two barns that were converted. The first place had very low ceilings. I had a colt and then a (different) gelding throw their heads in the cross ties and destroy the light fixture (it was in a plastic case, like an office would have). I know my horses weren’t the only ones to take out the light.

The other issue was the cement floor, after many decades, was worn completely smooth. It wasn’t a problem until it was (i.e. a horse slipped and went down). The nice thing about that place was at least the stalls were dirt floor, so they were dug down and the horses had better head room in the stalls than in the isle.

The second barn is adorable. They don’t have nearly as low of ceilings. However the stalls and the isle has concrete floors (we just mat them and bed like normal). The walls are block (almost look like huge bricks) and we had a horse kick many holes into his stall–worried about it, he was ultimately moved to a wood-walled stall. They filled in the drainage areas, etc. w/concrete.

I will say, both store hay above in the loft (second in the barn as well). In addition to the fire hazard, it is the dustiest arrangement. Dust comes down through the floor boards overhead and just coats everything.

Glad to hear this has been done successfully many times! We lucked out that the barn ceilings are quite high for a cow barn. We would have to re-do the concrete flooring as the dairy cows have to step up into their individual tie stalls…we are thinking of keeping the barn cleaner for the horses…just throw all the droppings outside the stall and it will be brought outdoors to the manure pile. Although, I don’t like the look of a manure pile right outside the barn, it would be easy and efficient. There is also a shavings chute that we would keep and use…although a bit dusty, but again very convenient. The thing I have noticed about several older style dairy barns is that are very dark, as is the one we would be restoring. I love a bright, airy barn with lots of natural light and windows.

I can’t wait to start the process of restoring the barns! May be years down the road, but what fun it would be :slight_smile:

[QUOTE=merrygoround;5366852]
I hope that for your stalls you are not using any sort of pine, spruce or hemlock!!

Use oak or hickory!!!. The extra work dealing with those woods is more than saved by not needing to replace them as a result of equine bevering.[/QUOTE]

I used Oak. Had a local lumber yard custom mill it for me, which was actually cheaper than if I had bought pre-cut wood boards from like Big Box Lumber Store.

Barn restoration- milk paint removal

We have removed stanchions and piping and cemented in the manure troughs from our large bank barn- does anyone have a non toxic horse friendly suggestion for removal of the layers of milk paint chipping from the wood beams and ceiling? I would prefer not to sand blast- considering compressor air and then pressure washing since alot of the paint cracks right off the beams.

I have heard that simple pressure washing will do it. It is sort of a white wash.

Thanks- I have my fingers crossed for the pressure washing once the weather stays warm. The paint is on as thick as frosting- literally. Chipping it away is taking a lifetime and inhaling the lime dust is not conducive to breathing even with a mask.

I have built and rebuilt/converted nearly a dozen barns over the years, pole barns, horse barns, riding arenas. I have converted our old 1865 cow barn to a 4 stall, with a grain and tack room. Both my nephew in law and I agree that the building and creating new horse space is one of the most fun aspects of these equestrian facility projects, so enjoy the ride and have fun. Lostkiwi makes a very good point: most of the wood needed for barns should come from a local rough cut sawmill and should be a lot cheaper than inappropriate big box store lumber, especially in New Brunswick. Post pictures when you get a chance.

You need to look at the current issue of COTH, abd look at McLain Wards barn that was once a cattle barn…Maybe you to could have a ballroom in your barn…:slight_smile:

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Question for you all regarding flooring.
has anyone left the concrete floor as is and filled in the scraper lanes with something ?
my initial idea was to fill them with manure cover with straw and lay the matting over them . I’ve talked to several folks about it who thought it a great idea. Giving the horses a softer area to stand or lay .
Thoughts from y’all on this is appreciated .

Manure and straw will compact significantly and FAST, you will have to keep pulling up the mats and adding more. Eventually you will get solid dirt but it will rot and smell terrible in the mean time, and you are wasting stuff that could be more profitably used as fertilizer. I would use something non-organic, like the kind of sand that doesn’t compact (I can never remember if it is round or angular).

We salvaged our 1890s barn. One side was dairy, the middle hall was the hay mow, and the other side was for the draft horses. The dairy side has pretty low (11-12ft?) ceilings due to the loft overhead. I’m using that side for tack room and other storage, but I did build a stall in the back just as a spare/overflow stall. If I ever have it occupied, I would prob put some kind of bumper cushion on the overhead joists as poll protection.

Here’s a link to some photos from the renovation. http://s1280.photobucket.com/user/IAWindpower/library/Barn%20Renovation

Both sides were so full of manure-- hadn’t been cleaned out in well over a decade-- that the side walls of the barn were pushed out off their foundations. By shoveling it out, we lowered the “floor” level by 3-4 feet. It was insane. OMG the absolute worst was the dairy side. That cement floor kept the very bottom layers wet. It was literally hard to breathe and eyes were watering as we dug into that decades-old rotting cow manure. Once we did that, the contractor lifted the barn up a bit, set a new foundation under the sides, and it should be good to go for another hundred years.

Anyway, of all the reno we’ve done on this farm, it was by far the most satisfying project. That barn makes me smile all the time. So glad you are going to save yours-- there are fewer and fewer of them around!

HH, it looks like your photobucket gallery is password protected - just FYI.

I was wondering if anyone has ever converted a bank barn utilizing the wooden floor area instead of the top low dairy area. I was considering building stalls after putting down tarpaper or rubber roofing material , then basically putting in prefabbed horse barns with and extra layer of 2x10 rough cut oak that would be anchored for easy removal for replacing when needed from rot from urine. Do you know of anyone who has done this type of conversion and is the original floor protected from rot?

@TomG - this is an 8 year old thread. Best to start a brand new one for your question! :slight_smile: