Proper Dairy Flooring and Mats Improve Cow Comfort and Health
Dairy cows are fine-tuned highly specialized animals that are healthiest and most profitable if they are comfortable. The flooring in dairy barns and stalls is very important so that cows can lie down comfortably, and also have adequate (but not abrasive) traction when walking to and from the milking parlor. You don’t want them slipping or scrambling, at risk of falling down, and if they have to stand for very long, you don’t want too much stress on their feet. Lameness is a major cause of pain and drop in milk production.
Cows typically eat for a while and then lie down to chew the cud. They lie down approximately 12 times in a 24-hour day, and you want them to lie down for as long as possible during those periods. A relaxed, comfortable cow produces more milk as long as she has adequate nutrition. Studies have shown that if you can get a cow to lie down for even one more hour per day, there will be an increase in her milk production. Also, she will want to eat a little more. If she lies down for a longer time, she is resting her feet, reducing the incidence of lameness.
Various studies have measured lying times for up to 14.33 hours per cow per day. This means cows are on their feet for the balance of the day. Some cows stand or walk on concrete alleys for an entire lactation – or possibly all of their adult lives. It is important to pay attention to flooring and how it affects cows. The finish on barn floors and alleyways is often the biggest oversight when constructing a new barn and may result in lameness issues.
CONCRETE – Research looking at flooring surfaces has shown that poorly finished concrete surfaces can cause a high incidence of sole ulcer and white-line disease; cows confined on new abrasive concrete wore down their feet 35% more than cows housed on dirt, and hooves of all cows confined on a new concrete surface that had no surface preparation wore down more than they grew for the first two months. Improperly finished concrete floors can speed foot wear enough to cause culling of cows due to lameness in the first three weeks of new barn occupancy.
A concrete floor is easiest to keep clean but can be hard on the cow’s feet if she has to stand a lot, and is sometimes slippery—making it harder for her to get up and down, and more likely to slip when she’s traveling.
The most common flooring surface in both new and older barns is concrete. This is often the first choice of material just because it is readily available, durable, fairly economical, and relatively easy to put into place because it conforms well to irregular areas and can be finished in various ways to provide some degree of traction.
When installing concrete, however, the floor must always provide a flat surface that uniformly supports the cow’s weight, so that even pressure is exerted over the entire bearing surface of the hoof. Floors must also provide confident footing for the cow, so she can move around without worrying about slipping and possibly falling down.
Regarding the finish on the concrete, there are two schools of thought. One is to provide a textured surface that provides enough traction that the cow’s foot has some grip before slipping occurs. The other idea is to provide a way of catching a hoof claw before slipping becomes excessive and the cow goes down. This method is sometimes referred to as a “slip and grip” type of surface.
Floors that are textured too much to try to eliminate slippage can wear hooves excessively, and smooth floors do not offer sufficient traction. There is a fine line between a concrete surface that is too rough and causes injury from abrasion and one that is too smooth and causes injury from inadequate footing and falling. One way to tell if the textured flooring the cows are on is satisfactory; the concrete should be comfortable enough for you to walk on it barefoot. If it hurts your feet or is uncomfortable to you, don’t expect your cows to walk on it.
One solution that many dairies are using now are cattle mats that can be placed over a concrete floor. Dairy cow mats (often made from recycled rubber) are designed to keep the barn floor and stall areas cleaner, warmer, safer, and more comfortable for the cattle. Good mats provide traction that helps prevent slipping, and create a solid surface that helps keep the cows from sliding and falling. If cows are kept in a free stall for resting and lying down, dairy mats provide insulation and cushioning. They can also be used in a milking parlor to keep cows more comfortable if they stand for long periods.
MATS AND MANUFACTURED FLOORING TO COVER CONCRETE– There are several manufacturers of various types of mats and synthetic or recycled rubber flooring for dairy barns, alleys and other areas where cattle spend a lot of time. Here is a sampling of what’s available.
Animat is a company that services cattle producers and dairies worldwide. They have a number of options for dairy flooring and mats. One of these is DairyGrip–an industrial-grade, steel cable-reinforced, rolled rubber flooring system designed to increase cow comfort and mobility while withstanding the demands of sand-bedded flush barns and dairy farms using heavy equipment. This rubber flooring comes in 100’ lengths to reduce the number of seams in an installation. DairyGrip is ideal for use in holding pens, travel lanes, and free-stall alleys.
This product is made from heavy-duty, recycled rubber mine belting for maximum durability. The zigzag surface grooving provides improved cushioning and good bi-lateral traction for cows to reduce slips and falls. The integral steel cable system ensures a longer-lasting product by stabilizing the rubber to prevent stretching caused by skid loader scraping and heavy equipment traffic. This flooring is available in varying thicknesses averaging from 3/4” to 1” to suit specific needs. The easy-to-handle 100’ rolls is available in widths from 48” to 78” in 1” increments in between. This material is durable and long lasting, which makes it ideal for high-traffic areas and heavy equipment usage, and is backed by a 10-year warranty. Animat is the Exclusive Distributor of DairyGrip Rolled Rubber in North America.
Another Animat product is their Interlock Rubber Flooring System, for use on concrete floors. The unique pebble-top design, manufactured using the highest quality 100% recycled rubber, provides excellent traction for all types of livestock, whether the flooring is wet or dry or covered with manure or snow. The Interlock rubber mat adapts to any configuration or surface and can be installed anywhere. It can be cleaned with alley scrapers, flush systems, manual hosing, scraping with a rubber tire scraper on a skid steer or a tractor. The non-slip surface prevents lameness and fall injuries, saving the dairy money from loss of production due to lameness-related problems. The non-slip surface provides exceptional traction, wet or dry, and this flooring provides adequate resiliency for cushioning of feet and legs. It is durable for long and useful service.
Animat Diamond Traction Rubber Rolls are made from 3/4” thick vulcanized SBR (styrene butadine rubber) with nylon inserts. This product can provide good traction for cows in areas where slipping is a concern such as alleys, holding pens, crossovers or sloped areas. Rolled rubber reduces the number of seams in your barn flooring which lowers incidence of cleaning equipment snags. This rubber flooring minimizes lifting and curling.
The diamond surface is specifically designed to increase traction and prevent injuries due to slipping, allowing cows to walk more confidently and safely. The ribbed bottom adds comfort and enhances drainage. This product is available in 48”, 60”, 72” widths in 100-foot rolls. It is ideal for holding pens, feeding areas, crossovers, free stall alleys and sloped areas and is reinforced with nylon inserts for added durability and to minimize stretching.
Animat’s cow mattresses are also a great innovation to increase cow comfort. The Animattress I Mattress System offers a stall bed for most applications associated with a dairy operations including stall bed for cows and heifers. These can be used in either free stalls or tie-stall barns.
Animattress I Mattress System dimensions are 2” x 39” X 69” with an open cell foam pad covered with a heavy-duty poly plastic. This pad is covered with a rubber top cover that completely encases the pad the length of the run of stalls. This stall bed can be used in all free stall applications.
There are two main types of foam used in stalls mattresses for dairy cows–open cell foam and closed cell foam. These foams can be made from different materials. The closed cell foam is like a series of tiny bubbles and rarely absorbs moisture when new. Over time with heavy use, however, these tiny bubbles eventually rupture and begin to compress, and cow comfort is compromised.
Open cell foam can absorb moisture unless it is completely protected by a heavy poly “plastic” which keeps it dry. Over time with heavy use, open cell foam does not rupture and lose its resiliency like closed cell foam. It retains its elasticity and ability to rebound much longer than other types of foam. Since cow comfort is the ultimate goal, Animat uses open cell foam. It provides a soft but firm cushion that molds to the shape of the cow when she is resting and returns to its original shape when she stands up. This foam is never displaced from beneath the cow when she is on her knees getting up or down, or when she rests in the stall.
The top cover for Animattress I Mattress Systems is strong, elastic, comfortable to the cow, waterproof, and non-abrasive. It is made for comfort, strength, elasticity, durability, and long life. In one independent research trial in the Northeast, the study centered around the resting times of cows on different dairy farms. One of the farms in the trial showed an average daily resting time of over 11 hours in the stalls. Considering this herd had a RHA in excess of 30,000 lbs. and was milked 3 times daily, this was a major achievement. The study was not on different types of stall mattresses, but results showed there was a correlation between resting times and mattress choices.
The Animattress III stall bed is a revolutionary new mattress for stalls. It was designed for tie stall barns but can be used in free stall barns as well. The pebble-top surface is bordered by a sturdy rim and alternately-sized rubber cones on the underside for strength, support and comfort. This durable mattress supports the cow comfortably, is durable enough for the rigors a tie stall barn presents, provides superior traction, and is unaffected by moisture.
The Animat Big Momma mat is designed for optimal comfort and performance. Styrene butadine rubber is engineered to provide excellent traction, and the unique texture of the mat’s surface helps prevent buildup of moisture and bacteria, for a healthier barn environment. The Big Momma is also easy to install and maintain.
The durable 1-5/16” thick styrene butadine rubber is built to last and can withstand consistent, high traffic use. The diamond-top surface texture is slip-resistant providing enhanced traction. Deep grooves on the bottom of the mat enhance cow comfort and welfare. This mat is designed specifically for the needs of tie stall barns and requires little to no maintenance once installed
Agromatic Inc. is a family-operated business that has been providing dairies with high-quality agricultural equipment since 1898. It began as Klinzing Manufacturing in St. Cloud, Wisconsin. August F. Klinzing was an innovator and inventor of early barn equipment, with more than 15 patents for various inventions such as manure carriers, stanchions, cow drinking cups and barn cleaners.
In more recent times the company changed its name to Agromatic and has been run as a division of the A.F Klinzing Company, owned and managed by Dave Hoppman for more than 38 years. Then in 2010, Agromatic was purchased by a long-time employee, Dean Birschbach, who started out as Shipping Manager and then as a Territory Sales Manager in Eastern Wisconsin.
The company is now known as Agromatic, Inc. with headquarters in Fond du Lac, Wisconsin, with dealers throughout the U.S. and Canada. They still sell many kinds of dairy equipment but also offer a variety of mats and flooring. The KRAIBURG Cow Stall Mats are designed for different needs within dairy farming, enhancing cow comfort and stall management.
The WINGFLEX mat is renowned for its softness, adapting and shaping to the cow’s body, and is ideal for free stall systems. These thick rubber stall mats offer superior comfort and support for cows when they are lying down. The profile element (wing and supporting stud) creates an extremely stable, wear-resistant and flexible mat. WINGFLEX adjusts easily to the body shape of the lying cow and also provides the firmness she needs when getting up and down. Sealing lips around the outside edge completely surround the mat and prevent dirt and bedding from getting underneath.
This is KRAIBURG’s softest mat, with a comfortable and skin-friendly surface. A slope to the rear edge helps facilitate drainage, keeping mats clean and dry. Connector bars lie flush with the mat’s edges and surface allowing for easy installation. These mats are only recommended for free stalls and are comparable to waterbeds.
KEW Plus stall mats have a three-layer design, provide excellent support and are suitable for both free and tie stalls. The three functional layers create approximately 2.5” of lying comfort. Sealing lips around the outside edge completely surround the foam and lower mat, to keep dirt and bedding from making their way underneath. KEW Plus adjusts to every load condition while supporting the correct resting position of the cow.
Each of the three components adds additional layers of functional softness. The soft lying area within mat’s edges promotes proper lying position as well as improves slip resistance while getting up and down.
There are three variations of this mat: KEW Plus – the KEW Plus three-layer system which has proven its durability since 2004, the KEW Plus Solo with reinforced edges so the mats can to placed side by side instead of using a connector bar between them like with traditional KEW Plus, and the KEW Plus LongLine – the same multi-layer technology of the traditional KEW Plus, but extended into an 82′ roll that covers approximately 21 stalls.
CALMA mats are designed for heifers, with a stable, air-cushioned surface. These interlocking mats are designed for heifer stalls. CALMA has an air-cushion-like lower side to create a stable, durable and slip-resistant mat, and interlock on three sides to fit into stalls. The rear edge is chamfered so there is no stumbling edge. Interlocking stall mats make for easy and flexible installation. They are also easy to clean and disinfect, to keep stalls fresh and odor-free. Sealing lips reduce soiling underneath the mat, for hassle-free maintenance.
KIM dairy barn stall mats have an air cushion profile. KIM mats, available in various styles, provide a comfortable, pebbled surface. This profile supports the weight of cows, allowing them to be comfortable while lying or getting up. These mats are available in three mat styles: 1. Individual interlocking stall mats with puzzled edges that quickly interlock together. 2. Individual rubber stall mats with straight edges that are simply laid side by side or joined with a connector bar—which is recommended if you use fine bedding. 3. Continuous stall mat roll – 86′ 1″
The resilient, pebbled surface optimizes slip resistance. These are great for quick installation. Sealing lips on the underside of the rear edge minimizes soiling under the mat and the integrated slope to rear edge helps facilitate drainage keeping the stall mats clean and dry. KIM mats are recommended for free stalls and tie stalls.
KKM mats feature a unique honeycomb underside for softness and come in three styles: Individual interlocking stall mats with puzzled edges that quickly interlock together, individual stall mats with straight edges that are simply laid side by side or joined with a connector bar, and a continuous stall mat roll – 65′ 6″
All 3 styles are designed with the same unique honeycomb underside to ensure excellent lying softness, with sealing strips underneath the mat to minimize soiling, a comfortable and skin-friendly elastic surface, and soft slope to rear edge for a dry surface. These are recommended for use in free stalls and tie stalls.
POLSTA mats are designed for deep-bedded stalls, to reduce bedding needs while maintaining comfort. Each product is tailored to ensure optimum comfort and welfare for dairy cattle.
The SIESTA and VITA mats by KRAIBURG are specialized for calving pens and other areas with special needs. SIESTA mats feature an air-cushioned underside for stability and slip resistance, with interlocking edges for complete coverage. They are easy to clean and reduce soiling underneath.
The VITA system, with its three-layer design (rubber-foam-rubber), offers 2.5 inches of comfort, a seamless top for hygiene, and a pebbled surface for slip resistance. VITA is also heat insulating and reduces bedding needs. These mats are designed for optimal comfort and hygiene in sensitive areas like calving pens.
KRAIBURG’s pediKURA Anti Slip Mats focus on hoof health, the Cirrus Mats combine traction and softness for dairy barns, and profiDRAIN mats excel in hygiene with their efficient drainage. The pediKURA and pediCIRRUS interlocking cow mats enhance soft rubber flooring with selective “abrasion zones”, similar to conditions in nature, where sandy constituents in the elastic soil ensure that hoof horn growth and abrasive wear are kept balanced.
The MONTA Cattle Traction Mat provides safety on inclined surfaces, while the LOMAX is known for versatility and ease of installation. KARERA mats offer an economical solution for cow comfort, while the PASEO Parlor Pit Mats improve working conditions for farm staff. The LOSPA Slat Rubber Mats and KURA Milking Parlor Mats are designed for specific areas, ensuring comfort and safety for cattle and workers alike. These can be combined with all KURA & CIRRUS products and the selective abrasion zones supports the natural balance between hoof horn formation and abrasion, which contributes to correct claw form. These mats provide ideal softness and slip resistance in all parts of the cow barn
EASYFIX – Established in 1996, EASYFIX is a family-owned and run company that has seen tremendous growth over the last 25 years. The unique patented design of EASYFIX Slat mats enhances comfort, welfare and performance of livestock housed on concrete slats. The award-winning slat rubber systems encompass a reinforced design, which offers durability and comfort for beef and dairy cattle enterprises. The slat mats can be easily applied to new or existing slats and all types and sizes of slats.
The first product launched was the award-winning EASYFIX SR Slat Rubber and it remains EASYFIX’s number one selling product, sold to beef, dairy and veal farmers in over 50 countries. The company relaunched their SR Slat Rubber solution in 2017 with a reinforced design, high-grip profile and a 5-year warranty.
The benefits of EASYFIX Slat Mats include reduction in lameness, better heat detection, cleaner and dryer floor, increased milk yield in cows, increased calf comfort, and durability.
Over the past 25 years EASYFIX has developed an extensive range of dairy housing solutions which greatly enhance cow comfort and productivity. At EASYFIX everything revolves around making cows more comfortable within their environment.
Increased lying times equates to higher milk yields. Research shows that cows can lie for up to 14 hours a day. The more comfortable you make the cows’ environment, the longer they will lie. Studies have also shown that the cows that fail to rest are much more likely to suffer lameness.
DOUBLE D CATTLE MATS – Dale Goetz, a third generation feedlot owner- operator found that he, like many other farmers, was losing time, profits, and cattle to the ineffective traditional anti-slip solutions. He set out to create a product that would provide stability and comfort for cattle in the feedlot processing area while also reducing the number of losses due to cattle slipping. With some old tires, Dale was able to create a weaving method from the topmost section of the tires that is not only durable, but very flexible and able to stay functional in any weather condition.
Today, his company provides much more than their original product yet the goal remains the same: to better the conditions of the cattle and the farm, to provide comfort, increase productivity, and create a less stressful environment for beef and dairy animals.
Double D Cattle Mats are made of tire treads that are woven together and then fastened with stainless steel bolts, washers, and nuts. These cattle mats can be used inside or outside to provide sure footing and a quiet, firm, but resilient surface for livestock. Each tire tread woven into the mat is secured on both ends and fastened with stainless steel bolts in two places. All of these mats can be custom built to fit any area.
By Heather Smith Thomas
