Engineering Feats: What It Took to Build Pipping's Largest Waste Tank Ever

Andrea Galloway
Mar 31
4 min read

If your operation is growing, your manure storage needs to grow with it. Bigger herds, tighter regulations, and longer storage windows all put more pressure on your infrastructure. When storage falls short, it affects everything from daily workflow to long-term planning.

This was the exact challenge at Badger Holsteins in Unity, Wisconsin. To support expansion and plan for the future, they chose Pipping Concrete to build their new waste storage tank. The result is the largest waste storage tank Pipping has built in its 40+ year history. At this scale, you’re not just increasing capacity, you’re redefining what’s possible for agricultural concrete construction in Wisconsin.

A Project Built on Agricultural Concrete Experience

Large manure storage projects require careful planning. Badger Holsteins chose Pipping Concrete based on our reputation and proven experience. For decades, Pipping has focused exclusively on farm infrastructure. This specialization matters when building at this scale, where the margin for error shrinks fast. Every decision, from engineering to crew coordination, has long-term consequences.

Our dedicated focus gives farmers confidence that their builders understand how the tank will be used, the stresses it will endure, and what it needs to withstand for decades.

Expanding Manure Storage to Support Farm Growth

For most dairy operations, manure storage is not just about meeting your current capacity but ensuring your operation can keep moving forward without hitting capacity limits down the road.

The goal of this tank from the start was to increase manure storage capacity, so Badger Holsteins could expand their operation and plan with more flexibility. A tank of this size allows more control over application timing, reduces pressure during busy seasons, and helps the farm stay ahead of environmental requirements.

Increased capacity provides:

More flexibility in when and how manure is applied.
Better alignment with nutrient management plans.
Less stress during peak seasons.
Infrastructure that supports long-term expansion.

For farms that plan ahead, manure storage is not just a box to check but a critical piece of infrastructure that affects efficiency, compliance, and, ultimately, peace of mind every day.

The Scale of the Build and Wisconsin Weather

This tank was the largest waste storage tank Pipping Concrete has ever built. At this scale, everything needs to be considered. Planning is important, and the small details matter. For Badger Holsteins, building big was about future-proofing their operation. A tank of this size gives them the capacity to grow without constantly revisiting storage limitations. For Pipping, it meant applying decades of agricultural concrete experience to a project that we knew we could do better than anyone else.

One of the biggest challenges on this project was the amount of rebar required to support a tank of this size. Tying and supporting that volume of steel is demanding work in its own right. Doing it in windy, cold Wisconsin conditions raises the bar even higher.

Fall and winter concrete work is a reality for many Midwest farms. As the team reflected on the project, one thing stood out:

“On a project of this size, everyone on the team was an integral piece to the success of this project.”

When you’re tying massive amounts of rebar in cold, windy Wisconsin conditions, there’s no room for weak links. Every crew member plays a critical role in keeping the pour on schedule and the quality where it needs to be.

Concrete and Design Choices That Matter Long Term

Most standard concrete applications use 3,000–4,000 PSI mixes. This project required a 7,000 PSI mix to handle sustained hydrostatic pressure from stored manure, freeze-thaw cycles common in Wisconsin, and long-term exposure to aggressive agricultural environments.

Just as important was the engineering behind the structure. This tank was designed by an engineer who specializes in agricultural construction. Agricultural tanks are constantly exposed to waste, pressure, and changing conditions, and they need to remain tight and reliable over the long haul.

Why these choices matter in your operation

Stronger concrete helps extend the life of the tank
Proper curing and acceleration support quality pours in cold weather
Agricultural-focused design supports long-term liquid-tight performance
Fewer issues later mean less downtime and fewer costly repairs

When tanks are designed and built with agriculture in mind from the start, they are better equipped to handle the realities of daily use.

Key Takeaways for Farmers

Every farm is different, but large projects like this highlight a few truths that apply across operations.

Manure storage needs to grow with your operation, not trail behind it
Bigger tanks require careful planning, strong materials, and experienced crews
Cold-weather construction is possible when the right methods are used
Agriculturally focused design and construction help avoid problems later
Investing in the right infrastructure today supports smoother operations tomorrow

When storage is built correctly, it becomes one less thing you have to worry about during the busiest parts of the year.

Planning Your Next Waste Storage Project

Whether you are expanding your herd, updating aging infrastructure, or planning ahead for future growth, your waste storage system plays a major role in how efficiently your operation runs.

Pipping Concrete has spent decades building agricultural concrete solutions for farms across the Midwest and beyond. From waste storage tanks to feed storage and other farm infrastructure, every project is built with durability, performance, and real-world farm use in mind.

If you are considering a new manure storage tank or want to talk through options for your operation, reach out to the Pipping Concrete team. We are ready to help you plan a solution that works today and holds up for years to come!