1 THE FIELD GUIDE TO SLAT REPLACEMENT HOW TO IDENTIFY WHEN TO REPLACE SLATS, SPOT DANGEROUS FAILURES EARLY, AND CHOOSE HIGH-QUALITY REPLACEMENT SLATS.
2 FIELD GUIDE TO SLAT REPAIR TOP SIGNS IT’S TIME TO REPLACE SLATS Tip: Beam deterioration—not slats—is the most common cause of catastrophic structural failures. • Hairline top cracks only (no moisture to steel) • Localized wear near feeders/waterers Concrete slat and beam deterioration poses a significant safety and animal‑wellness risk in swine facilities. This guide provides a clear, practical framework for inspecting slats, identifying structural hazards, and determining when replacement is the safest and most cost‑effective option. Use this guide during walk‑throughs, wash‑down inspections, or scheduled maintenance reviews. MONITOR/PLAN FOR SLAT REPLACEMENT IF YOU SEE: Deep cracks or breaks on the underside of slats, typically ~2 inches above the base, caused by swelling rebar. Top‑surface cracks that allow moisture to reach steel, especially if widespread. Uneven or rocking slats, indicating loss of support or beam movement. Beam cracking above columns, missing lower sections, or exposed/swelling steel. Bearing surface < 4 inches on columns or end‑wall pockets. ~40% or more of slats showing moderate/severe wear—full replacement becomes more economical
3 LEVEL 1 - LIGHT WEAR (MONITOR) • Common around feeders and waterers due to high traffic and acidic conditions. • Indicates normal aging, not poor‑quality slats. • Action: Continue monitoring; consider protective coatings. LEVEL 2 — MODERATE WEAR (PLAN) • 1/4”–1/2” wear with rough texture or lightly exposed aggregate. • Counts toward the 40% replacement rule. • Action: Plan replacement timeline; monitor for emerging cracks. LEVEL 3 — SEVERE WEAR (REPLACE NOW) • Deep pitting, exposed steel, or broken edges that widen gaps and create pig‑leg entrapment risks. • Large numbers of Level 3 slats indicate the need for partial or complete slat replacement. • Action: schedule replacement; inspect support beams closely for concurrent failures. DAMAGE LEVELS EXPLAINED Reminder: Damage levels help guide planning, but structural red flags override wear levels and require immediate action.
4 FIELD GUIDE TO SLAT REPAIR INSPECTION GUIDE Top Surface • Walk every barn after wash down. • Mark cracks that run across individual slats. • Check around feeders/waterers for excessive wear or crumbling edges. Slat Underside • Shine a flashlight through openings. • Identify swelling, flaking, or rust staining—signs of rebar expansion. Support Beams • Sight down both sides of each beam—one side can fail while the other appears intact. • Look for cracks above columns or missing concrete from the bottom edge. Bearing Surfaces • Ensure beams have ≥4 inches of bearing at columns and end pockets. • If the building has shifted and beams no longer sit correctly in pockets, the structure requires corrective action and slat/beam replacement.
5 BEARING SURFACE REQUIREMENTS • Bearing Requirements: Hog Lintel beams require a minimum 3-inch full width bearing on square columns and 4 inches on round columns, per engineering specifications. • Buildings can shift over time—especially at end walls— causing beams to slide partially or fully out of pockets. • If a beam is not fully seated, remove slats and beams and correct the structural support before reinstalling. • Uneven, dipping, or rocking slats often indicate a beam has begun to slip. IDENTIFYING UNREPAIRABLE SLAT DAMAGE Signage of Beam Misalignment The appearance of uneven slats can be an indication of a beam starting to fall from a column or end wall pocket. At least 4” of bearing surface should be present on a column or end wall pocket • Slats appear uneven or dip across a span • Slats lift or rock underfoot • Visible shifting where beams meet column or end‑wall pockets UNREPAIRABLE SLAT DAMAGE 1) Underside Cracking (~2 inches above base) • Indicates moisture penetration and rusting rebar. • Expanding steel fractures the concrete from the inside out. • These slats cannot be reliably repaired and must be replaced. 2) Top‑Surface Cracks (Isolated) • If moisture has not reached the steel, epoxy products can stop progression and prevent corrosion. • Suitable only for early‑stage, non‑structural top cracks.
6 FIELD GUIDE TO SLAT REPAIR BEAM FAILURE INDICATORS Support beams are often the hidden source of catastrophic failures. Even when slats appear sound, compromised beams can lead to sudden collapse. Warning Signs: • Cracks forming above columns (most common failure point) • Moisture entering the beam, leading to internal rusting • Lower portion of the beam breaking away • One side looking intact while the opposite side shows exposed or protruding rebar • Separation or sagging along the bottom edges Rusting metal expands = Breaking concrete Causes the lower portion of the beam to fall off. A dangerous situation occurs as the structural integrity of the support lintel is compromised. Note circled area. The bottom of the beam has started to crack and separate. The damage has occurred even though the slats appear to be in good condition. How Beam Failure Progresses 1. Hairline cracks form above columns. 2. Moisture seeps through the cracks. 3. Rebar begins to rust. 4. Rusting metal expands. 5. Expanding steel breaks the surrounding concrete. 6. The bottom of the beam separates and falls away. 7. Structural integrity of the lintel is compromised → collapse risk. How to Inspect Beams Correctly • Shine a flashlight through slat openings. • Inspect both sides—one side may appear fine while the other shows damage. • Look for rust staining, swelling, flaking, separation, or exposed steel. If any bottom separation or protruding steel is visible, the beam must be replaced.
7 X=Axis: Age (Years) Age of slats & beams Y-Axis: Condition Rating Industry Curve: Typical aging progression Color Bands: Green=Good Yellow=Fair Orange=Replacement Recommended Red=Failing Plotted Point: Your facilities current score INDUSTRY INSPECTION TECHNOLOGY Independent digital inspection tools—such as Slat Vision—can complement traditional inspections by analyzing structural data generating condition ratings, and benchmarking a barn’s condition against typical industry aging trends. These tools can provide: • Quantitative scoring for slats, beams, columns and bearing surfaces. • Visual dashboards for multi‑site operations • Predictive modeling to estimate replacement timelines • Consistent documentation for long‑term maintenance planning • Benchmarking against industry aging patterns Hog Slat does not own or operate these inspection systems, information is provided for educational purposes only. Choose A Site Location ALL REPLACED INSPECTED OVERDUE UNPURCHASED ALTENBURG CONSTRUCTION HOME PAGE INSPECTION REVIEW ABOUT CONTACT MY REPORTS SLATVISION LOG OUT Rating Key (click to open) Site Owner Site Location Barn Slat Score Beam Score Column Score Overall Score Year Built Status RN Altenburg Construction Altenburg Construction Altenburg Construction Altenburg Construction Site 1 Site 2 Site 3 Site 4 2 1 East South 32 52 54 75 29 47 30 63 62 68 65 71 35 51 45 69 1997 2008 2000 2003 #106709 #106221 #106205 #106175 Inspected Inspected Inspected Inspected VIEW REPORT #106175 VIEW REPORT #106205 VIEW REPORT #106237 VIEW REPORT #106163 HOW TO INTERPRET YOUR BARNS AGING PERFORMANCE Assessed Barn Score Relative to Industry Standard by Age Industry Standard Actual Age Imminent Failure Replacement Threshold Rating Age 0 5 10 15 20 25 30 35 40 100 90 70 40 20 0
8 FIELD GUIDE TO SLAT REPAIR SELECTION OF REPLACEMENT SLATS Not all slats are created equal. Use guide to compare options and ask your slat manufacturer WHAT TO LOOK FOR Lower water-cement ration (dry cast) WHY IT MATTERS Denser, stronger concrete with fewer pores → better wear resistance in barn conditions DRY CAST WET CAST Lower water-to-cement ratio Longer lasting More resistant to wear ✓ ✓ ✓ Higher water-to-cement ratio Compromised slat strength x x WHAT TO LOOK FOR Flat, even top surface (machine finished) WHY IT MATTERS Easier for pigs to move; reduces foot/joint stress compared to uneven/hand troweled slats MACHINE FINISHED HAND FINISHED Provide consistent flat surface Aid in pig movement ✓ ✓ Inconsistent surface Stress on pig’s feet and joints x x WHAT TO LOOK FOR High strength steel in both the top and bottom of each slat. WHY IT MATTERS • Bottom steel reduces sag under load • Top steel allows safe handling during installation • Controls crack size for longer lasting slats STEEL REINFORCEMENT WEAK REINFORCEMENT 2 layers of 80,000 PSI steel ✓ Single layer low-strength rebar x
9 COST SNAPSHOT (EXAMPLE) For budgeting conversations only—actual pricing varies by barn, region, and timing. BARN SIZE: 1,200 HEAD 50’ × 192’ finishing room slats lintels, trucking $40,000 – $45,000 (example range) Removal & installation labor to remove/replace slats and dispose of old materials (varies) Why full replacement often wins: when about 40% of slats are damaged, total labor to replace piecemeal approaches a full job—leaving only slat cost as the difference. REPLACEMENT COST APPROX. $45,000 • Slats • Lintels • Trucking APPROX. $40,000 Removal/Installation Labor to remove and replace slats, dispose of old materials Contact your slat supplier or structural specialist for inspection support or replacement planning. A well‑timed replacement prevents injuries, improves animal welfare, and protects barn integrity for years to come. NEED HELP OR A PROFESSIONAL ASSESSMENT?
10 FIELD GUIDE TO SLAT REPAIR THE FIELD GUIDE TO SLAT REPLACEMENT
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