Verhasselt Farms/U.S. Energy Anaerobic Digester Installation
Built by an Agricultural-Only Concrete Contractor
Verhasselt Farms in Kaukauna, Wisconsin, continues to invest in infrastructure that supports long-term sustainability and operational efficiency. As a progressive dairy operation in the heart of Wisconsin, the farm is focused on managing nutrients responsibly while positioning the business for the future of renewable energy.
To support those goals, Verhasselt Farms partnered with Pipping Concrete to construct two large-scale anaerobic digester tanks designed to convert manure and organic waste into renewable biogas.
This project highlights everything we do best. For more than 40 years, our team has focused exclusively on agricultural concrete infrastructure, from manure storage and feed systems to large-scale anaerobic digesters.
The Challenge
Like many growing dairy operations in Wisconsin, Verhasselt Farms needed a solution that addressed both expanding operational demands and environmental responsibility.
Operational Needs
Manure management at this scale requires dependable storage and processing infrastructure. Verhasselt Farms needed a system capable of handling high volumes efficiently while integrating into daily operations without downtime.
Environmental & Compliance Requirements
Anaerobic digestion systems require strict design and environmental standards. The tanks needed to support nutrient management goals, reduce emissions, and align with regulatory expectations for renewable energy and waste processing.
Wisconsin Climate Considerations
If you know Wisconsin, there are many freeze-thaw cycles, heavy precipitation, and long winters, all of which demand concrete structures engineered for durability.
As you can tell, this wasn’t just any run-of-the-mill retrofit. It was a major infrastructure investment requiring precision planning, experienced crews, and agricultural-specific expertise.
The Solution
Pipping Concrete constructed two massive round anaerobic digester tanks, engineered specifically for agricultural use.
Each tank measures:
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96 feet in diameter
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30-foot vertical walls
These reinforced concrete structures were designed to meet the farm’s capacity and compliance needs while supporting long-term performance under continuous load.
Key Project Features
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Large-diameter, cast-in-place round concrete digesters
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Vertical wall design for maximum volume efficiency
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Reinforced structural system built for long-term durability
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Engineered to integrate with the farm’s biogas and renewable energy system
Project Partners
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Design Engineer: MSA Professional Services
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Concrete Provider: Carew Concrete
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Concrete Pumping: Potratz Concrete Pumping South
With coordinated planning between engineering, materials, and field crews, the installation was executed efficiently and safely.
As an agricultural-only concrete contractor, Pipping understands the demands these systems face every day. That experience shows in every detail, from wall integrity and reinforcement placement to finishes built to perform for decades.
Why Agricultural-Only Matters
Being agricultural-only changes how we plan, build, and manage risk.
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We understand manure chemistry and the corrosive environments in which digesters operate.
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We design and reinforce structures for heavy equipment traffic and long-term hydrostatic pressure.
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We schedule around planting, harvest, and daily farm operations.
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We build with longevity in mind because farms are generational businesses.
That specialization reduces risk. There is no learning curve on-site. Our crews know what these systems demand and how to execute efficiently in active agricultural environments.
Results
With the completion of the digester tanks, Verhasselt Farms can expect long-term operational and environmental success.
Operational Efficiency
The large-capacity system enables the farm to manage manure more efficiently while supporting on-site energy production.
Sustainability & Energy Production
Anaerobic digestion converts manure and organic waste into biogas, helping reduce emissions and recycle nutrients back into the soil. We’re proud to say this project helps support renewable energy production and responsible nutrient management.
Compliance & Risk Reduction
Properly engineered and constructed digesters help farms meet environmental regulations while reducing long-term risk associated with waste storage.
Built for the Future
With two 96-foot tanks in place, Verhasselt Farms has the infrastructure to support continued growth, energy innovation, and long-term agricultural viability.
See the Project in Action:
You’ll want to watch behind-the-scenes footage of this installation, including up-close construction shots and aerial drone views.