Feedlot Layout Design

A well-designed feedlot layout does far more than determine where pens and feed bunks are positioned. It influences how efficiently livestock move, how easily staff perform daily tasks and how effectively the entire operation functions over the long term.

Every movement within a feedlot, whether it’s cattle entering a pen, feed being delivered or machinery carrying out maintenance, follows the pathways established during the planning stage. A practical layout helps reduce unnecessary handling, improve operational efficiency and create safer working conditions for both livestock and people.

Designing the layout around the way your operation works, rather than simply fitting infrastructure into the available space, creates a stronger foundation for long-term performance.

Why Feedlot Layout Matters

The layout of a covered feedlot connects every part of the operation.

Well-planned layouts support efficient livestock movement, consistent feeding routines, safer machinery access and practical day-to-day management. They also provide flexibility for future expansion and help reduce operational bottlenecks that can develop as an operation grows.

Rather than viewing pens, laneways, and feed bunks as individual components, they should be considered as part of an integrated system that supports the entire operation.

A well-planned layout can help:

  • Improve livestock flow.
  • Reduce unnecessary handling.
  • Support efficient feed delivery.
  • Improve machinery access.
  • Simplify maintenance activities.
  • Allow for future expansion.
  • Improve overall operational efficiency.

How Do Cattle Numbers Translate Into Pen Dimensions?

A practical feedlot layout starts with understanding how cattle numbers, stocking density, and feed bunk requirements work together.

According to the MLA Feedlot Covered Housing Systems: Best Practice Design and Management Manual, the dimensions of a production pen depend on cattle numbers, stocking density, whether feed bunks are positioned on one or both sides of the pen, and the amount of bunk space required per animal.

For example, MLA provides a worked example for a pen containing 100 Standard Cattle Units (SCU). At an allowance of 6 m²/SCU, the cattle require approximately 600 m² of pen space. Allowing 250 mm/SCU of feed bunk along one side requires 25 metres of bunk length, resulting in an indicative pen approximately 25 metres wide by 24 metres deep.

Changing any of these inputs changes the layout. For example, increasing bunk space to 300 mm/SCU increases the required bunk length for 100 SCU to 30 metres. Similarly, increasing the space allowance per animal increases the depth or overall area of the pen.

MLA’s guidance demonstrates why pen dimensions should not be selected in isolation. Head count, space allowance, bunk length, building width and ventilation all need to work together when developing the overall layout.

Designing Around Livestock Movement

The movement of cattle should be one of the primary considerations when planning a feedlot layout.

Livestock naturally move more calmly through facilities that minimise sharp turns, dead ends and unnecessary handling points. Creating clear, logical movement pathways can help reduce stress while improving both safety and operational efficiency.

When planning cattle flow, consider:

  • Entry and exit points.
  • Access to feed and water.
  • Separation of livestock movements from machinery where practical.
  • Efficient movement between handling facilities and pens.
  • Future operational changes.

Good layouts make routine livestock movements predictable and practical for both cattle and staff.

Positioning Feed Bunks

Feed bunks form one of the most heavily used areas within a feedlot and should be positioned to support efficient daily feeding operations.

Their location influences vehicle access, livestock behaviour and the overall efficiency of feed delivery.

When planning feed bunk locations, consider:

  • Safe access for feeding equipment.
  • Efficient traffic flow.
  • Consistent access for livestock.
  • Future maintenance requirements.
  • Integration with pen layouts.

Designing these areas early helps improve operational efficiency while reducing unnecessary travel throughout the facility.

How Bunk Position Influences Pen Layout

MLA guidance recommends considering bunk position at the same time as pen dimensions. Feed bunks may be positioned along one or both sides of a pen, and this directly affects the shape and dimensions of the pen.

Where bunks are provided on both sides, MLA notes that the pen can become narrower and deeper compared with a single-sided arrangement. This may provide layout flexibility, but building width also needs to be considered because wider covered structures can restrict natural ventilation.

The MLA covered housing manual indicates that, for most locations, the maximum recommended building width for a naturally ventilated gable-roof structure is generally around 30 metres, while single monoslope spans are generally around 10 metres. Wider structures may be possible in cooler climates or locations with favourable natural breezes, so ventilation and site conditions should be considered as part of the layout.

This means bunk placement is not simply a feeding decision. It can influence pen dimensions, building width, cattle capacity and ultimately the structural layout of the covered feedlot.

Planning Machinery Access

Machinery plays an important role in the day-to-day operation of a covered feedlot.

Feed trucks, loaders, maintenance equipment and livestock handling vehicles all require safe, practical access throughout the facility.

Poor access planning can increase travel distances, create congestion and reduce productivity over time.

When assessing machinery movements, consider:

  • Feed delivery routes.
  • Cleaning and maintenance access.
  • Vehicle turning areas.
  • Separation from livestock movements where practical.
  • Access during different weather conditions.

Providing sufficient space for machinery from the outset helps improve both safety and operational performance.

Designing for Cleaning and Vehicle Movement

Machinery access should also influence pen dimensions and gate positioning. The MLA Feedlot Design Manual notes that smaller-capacity pens can become narrow, which may create problems for pen-cleaning machinery.

Gate position can also support more efficient maintenance. MLA provides examples where gates can swing across the pen to temporarily hold cattle on one side while cleaning takes place on the other, reducing the need to remove cattle from the pen entirely.

Feed delivery roads, cattle lanes, manure movements and vehicle turning areas should therefore be considered together during the initial layout rather than added after pen positions have been determined.

Turning Operational Requirements Into a Building Footprint

A useful starting point for early planning is to work through the layout in this order:

1. Determine the proposed cattle numbers or SCU per pen.
2. Establish an appropriate space allowance per SCU based on the operating system and relevant guidance.
3. Calculate the approximate total pen area required.
4. Determine the required feed bunk space and bunk position.
5. Use these requirements to develop indicative pen dimensions.
6. Consider how those dimensions interact with cattle movement, machinery access, drainage, ventilation and the overall building structure.

These early calculations don’t replace detailed feedlot, engineering or regulatory design, but they provide a much stronger starting point for determining what the covered facility may need to look like.

Planning a new covered feedlot? TechSpan can help test these operational requirements against your proposed building footprint and identify how pen dimensions, building spans, and future expansion may work together before the design progresses.

Supporting Day-to-Day Operations

A feedlot should be designed around the way it operates every day.

Routine activities such as feeding, livestock inspections, maintenance, cleaning and monitoring should all be considered during layout planning.

Well-designed facilities help minimise unnecessary movement while allowing staff to complete tasks efficiently and safely.

Thinking about daily operations during the planning stage often leads to layouts that continue supporting productivity throughout the life of the facility.

Planning for Future Expansion

Many feedlots evolve as operational requirements change.

Planning for future growth during the initial layout design makes it easier to add pens, expand feeding areas or integrate additional infrastructure without disrupting existing operations.

Future expansion may include:

  • Additional livestock pens.
  • Feed storage facilities.
  • Handling infrastructure.
  • Machinery access routes.
  • Supporting operational buildings.

Allowing space for these possibilities during the planning stage provides greater flexibility while helping protect your long-term investment.

Bringing Feedlot Layout Together

Successful feedlot layouts are the result of understanding how every part of the operation works together.

Livestock movement, feed delivery, machinery access, maintenance and future expansion all influence one another. Considering these elements as part of an integrated planning process creates infrastructure that’s easier to operate, safer to manage and better positioned to support long-term operational performance.

Rather than designing around individual components, the most effective feedlot layouts are designed around the way the entire operation functions.

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Ready to Plan Your Feedlot Layout?

An effective feedlot layout is built around the way your operation works, supporting livestock welfare, efficient workflows and long-term flexibility from the very beginning.

At TechSpan, we work with producers to develop covered feedlot solutions that consider livestock movement, feed delivery, machinery access and future expansion to create infrastructure that’s designed for long-term operational success.

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