Every cattle producer reaches a point when their working facilities need to be upgraded or replaced. The temptation is often to replace a chute, add a few panels or build another pen. But according to two experts who spend their careers evaluating livestock facilities, the best projects don’t begin with steel or concrete. They begin with a plan.

The Most Common Mistake

Jake Schubert, owner of Aurochs Consulting, said many producers construct their facility one piece at a time, over time, without thinking about how it all fits together. “The biggest mistake I see is people not having a plan,” Schubert said. “They build one piece at a time — maybe a new barn or a new chute — without thinking about how it fits into the whole operation.”

Eventually, they discover how difficult it is to move cattle through the facility efficiently and expansion becomes nearly impossible. In many cases, Schubert is called after producers have spent a significant amount of money to correct the issues.

Iowa State University Extension and Outreach field agricultural engineer Tony Mensing has experienced similar scenarios. “I’ve heard a lot of people say they wish they had spent the money on the last thing they cut from the project,” he said. “It’s easy to cut something when you’re writing checks, but afterward that’s often the piece people wish they hadn’t left out.”

Start With the End Goal

Before a single post is set, producers should step back and ask one simple question: What do I need this facility to accomplish?

“Truly think about what the goals are for the handling facility and the overall system,” Mensing said. “Whether it’s a cow-calf operation, a feedlot or something in between, knowing what you’re trying to accomplish helps direct every decision that follows.”

Those goals influence nearly every design decision, from the amount of space required, to the type of equipment needed, to where the facility should be located. They also help producers prioritize investments when budgets become tight.

Schubert recommended clients gather aerial images, building dimensions and create an inventory of existing equipment before beginning the design process. Scaled drawings or accurate aerial imagery provide valuable context around the facility and allow producers to visualize how every component fits together, reducing surprises once construction begins.

“If you’re working with an existing barn, get accurate measurements and know exactly what you already have,” Schubert said. “Figure out what equipment you’ll reuse, what needs replacing and write down exactly what you want the facility to do before you start designing.” Mensing said to avoid forcing facilities into spaces that are too small. Trying to squeeze alleys, holding pens or working areas into inadequate footprints often creates long-term frustrations that are difficult and expensive to fix later.

Finally, Schubert encourages involving everyone who will use the facility, including the processing crew, veterinarians and anyone who will be loading and transporting cattle. . Incorporating their perspectives can help create a facility that is more efficient for everyday use.

Budget for Today, Design for Tomorrow

One challenge producers frequently face is determining how much a project will actually cost. Unfortunately, there is no universal answer. Facility size, cattle numbers, production systems and long-term goals all affect the budget. Schubert recommended designing the entire facility first, then adjusting construction phases to match available finances.

“Make the design in such a way that you can scale it back or build it in phases,” he said. “If estimates come back higher than expected, you can postpone some holding pens or reuse existing equipment while keeping the core design intact.”

Having a complete design before requesting contractor estimates also produces much more accurate bids. Without detailed plans, costs often balloon as overlooked needs surface during construction. When deciding where to invest limited dollars, Schubert recommended prioritizing the components producers use everyday.

“The heart of the system is the chute, the alleyway and whatever you’re using to move cattle into the alley,” he said. “That’s where I’d spend money first. After that, buy good gates because they’re the pieces you’re constantly moving.” If budget cuts become necessary, he suggested postponing additional outside holding pens, which can often be added later without disrupting the entire system.

Mensing approaches budgeting from a slightly different angle. Rather than naming one piece of equipment every producer should purchase, he encouraged everyone to evaluate which investments best support their specific operation. He also emphasized one often-overlooked feature that deserves attention.

“I think everybody gets value from thinking about loading and unloading cattle safely,” Mensing said. “Whether you’re a cow-calf producer or a feedlot, you’re always moving cattle in and out. Having a safe, efficient loading area benefits everyone.”

Choosing the Right Location

Selecting the proper site requires more than finding an empty piece of ground. Producers should evaluate space, drainage, future expansion needs and proximity to existing facilities and utilities before committing to a location.

Mensing encouraged producers to think about how the facility fits into daily chores. “It needs to be convenient to use but not interfere with everyday feeding or other operations,” he said. “You also need to think about utilities like electricity, water and heat if you’re processing cattle during colder weather.”

He also reminded producers to picture the site under less-than-ideal conditions. A location that looks perfect on a dry summer afternoon may become nearly unusable in the fall after rain. Drainage and runoff management should be considered before construction begins, not after the first storm.

Schubert agrees that every site presents unique challenges. But whenever possible, he looks for naturally sloping ground with good drainage and easy truck access. “If you know cattle trucks need to get there, start by designing around that,” he said. “That usually narrows down where the facility needs to be.”

He also encourages producers to envision what the operation could look like 10 years from now. Rather than designing only for today’s herd size, reserve room for future expansion so additional pens or working areas can be added without relocating buildings or utilities.

Creating Cattle Flow

Even the best-built facility won’t perform well if it ignores one important factor: cattle behavior. Both Mensing and Schubert emphasized that understanding how cattle naturally move can often improve handling more than adding another gate or panel.

“There is a lot of information available on cattle handling practices,” Mensing said. “Cattle like to move as a group. They like to go back where they came from. If we can give them a way to go where we want them to go, but make it seem like it’s their idea, it’s less stressful for everybody.”

Rather than forcing cattle through a facility, Mensing encouraged producers to design systems that work with those instincts. Cattle naturally move toward light and are often reluctant to enter dark spaces. Positioning exits toward brighter areas or eliminating dark corners can improve cattle flow while reducing stress for both livestock and handlers.

Just as important, Mensing noted, is recognizing that facilities are rarely operated by one person forever. Family members, hired employees and veterinarians may all use the system throughout the year.

“We can have two facilities that are basically the same, and the way people operate them could make one work really well and one work not so well,” he said. “Think about the people who are going to use it and how you can maximize safety while using cattle behavior to your advantage.”

A well-designed handling facility doesn’t just make processing day easier. It protects the people working cattle, reduces stress on livestock and creates an operation that can continue adapting as the business grows.

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