We recently wrote about muck pits and dealing with manure at horse facilities and received comments about stabling time; some saying that shorter times in stalls are better for horses. We completely agree. The longer a horse is stabled indoors, the more likely it is that the animal will be standing in urine-soaked bedding for at least part of the day. And we all know ammonia causes problems.
We want the air inside our barns to be as clean as the air outside the barn. Blackburn Architects’ designs stress aerodynamic ventilation, strategic natural light, and passive solar heating and cooling in our equestrian facilities.
When John Blackburn was beginning to design horse facilities more than 30 years ago, he found combining regionally-appropriate architectural elements with aerodynamic airflow principles created pleasing, healthy spaces for equines and their caregivers. Even early on in his career, heading into his barns was refreshing. “In August,” he has said, “in the dead of summer, when there was no wind – your hair would lift” from the natural ventilation created by the proper placement of the barn on a site, and the use of two engineering principles, which Blackburn Architects has employed in every design then and since:
1. The Bernoulli Principle – As air blows across a surface, e.g. a bird’s wing, it creates lift. Barn placement on a site is critical. If possible, a barn should capture the prevailing summer breezes (for horses you’re always more concerned with cooling rather than warming).
Inside the barn, air needs to move up and out. Blackburn frequently specifies ridge line vents in our designs. The vertical ventilation rids the barn of odors, pathogens and infectious bacteria that could otherwise be transported from horse to horse.
Even in cold climates like Montana, Blackburn Architects designs for maximum ventilation in the winter. “A horse gives off a tremendous amount of humidity; a lot of bacteria and in a contained area – like a stall – that’s an incubator for disease. I don’t care how cold it is where you live, you want to ventilate your barn year-round,” explained John Blackburn.
2. The Chimney Effect – Maximizing natural light in a barn creates a healthy environment by helping to “sterilize” the spaces. For example, as the sun moves across the sky and a band of light travels through a stall – perhaps through the upper portion of an exterior Dutch door left open – it helps to dry and evaporate urine. Blackburn Architects’ spaces have a lot of windows, and skylights. Vented skylights glazed with a translucent polycarbonate panel running the length of the barn are hallmarks of our barns. The light source provides a low cost, shatter-proof feature that diffuses the light, thus eliminating harsh shadows, which could cause horses to spook. “My barns are designed to function throughout the day without the use of artificial lighting, except in enclosed rooms such as bathroom/laundry,” John Blackburn explained.
“A horse is designed to live outside in the wild. If it wants to get out of the sun, it’ll run under a tree. If it wants to get out of the wind, it’ll run behind a hill. This natural, healthy way of living is what we strive to create with our barns so that our athletic partners have the best chance of long, healthy lives – indoors or out.”
If you want to learn more, Penn State Extension has a very informative article: https://extension.psu.edu/horse-stable-ventilation.
In this on-going series, John Blackburn offers insight into component parts of equestrian facilities. With more than 35 years’ experience in the design of horse barns, he’s seen his share of good, bad and worse. In this installment, he gives advice on stall flooring. Still as applicable as ever, we’re reposting Sushil Dulai Wenholz’ article from The Horse, Sept 1, 2001 (added a few updates, too).
By Sushil Dulai Wenholz
You give a lot of thought to your horse’s health and happiness. You groom him until he gleams, swaddle him in boots and blankets, carefully monitor his diet, and expend considerable effort and expense making sure he’s comfortably bedded. But have you thought about what lies beneath that soft bed? In essence, the stall floor is the box spring beneath your horse’s mattress, and it’s every bit as important as what goes on top–perhaps more so.
No matter how nice the bedding, a poorly constructed floor can lead to respiratory troubles from ammonia gases, thrush from trapped moisture, achy joints from uneven or too-hard surfaces, and injury from slippery or abrasive materials. In addition, a poor floor can mean wasted bedding and extra labor for you.
A good stall floor starts with a good construction plan. John Blackburn, senior principal of Blackburn Architects, a 34-year-old firm that has designed more than 400+ barns in 35 states; and Peter Gibbs, Extension Horse Specialist at Texas A&M University, outline the steps involved in building a floor that will keep you and your horse happy, whether you’re revamping an existing stall or building a brand new barn from scratch.
Starting From Scratch
1. Pick the location. If you’re building a barn, you have the luxury of choosing the best site. Look for an area that’s dry or at least easy to drain. Avoid steep slopes, areas that are consistently wet, and locations that are subject to water runoff during heavy rains or snow melt. In terms of soil, you’re basically stuck with whatever is normal for your region. But if you have it, soil that packs tightly is ideal, says Blackburn, because it will provide a tough surface that isn’t too hard or abrasive.
2. Dig to the base. Whether you’re starting from scratch or redoing an existing stall, you need to dig down to a well-draining layer of soil. This will give urine and other moisture a path to drain away from your horse. Expect to excavate at least one foot deep over the entire stall, says Blackburn. You might have to go deeper, depending on local soil conditions.
3. Level the ground. You should level out that base layer to help make sure the surfaces above it are level. A nice, even plane puts less stress on your horse’s legs than an uneven floor.
4. Compact the base and fill. Even if the floor starts out flat, Gibbs explains that extended use can create a holey or uneven surface, especially with dirt or stone-dust flooring. To form a firm foundation that can withstand daily wear and tear for extended periods, compact the floor. You can use a hand roller, a motorized, hand-held compactor or “settler,” or some other heavy pounding tool to do the job.
First, compact the layer you’ve uncovered and leveled. Then begin adding layers of dirt or stone dust. “The important thing is to install the flooring in layers and tamp it at each layer,” says Blackburn. He recommends using three-inch layers for dirt or one- to two-inch layers for stone dust. Compact each layer “until you think it can take the abuse of hooves kicking at it,” he adds, noting that there isn’t a standard measure to go by.
To ensure good drainage away from the building, add layers until your floor’s surface is 12 to 18 inches above the natural grade around the barn, says Blackburn. “You want to get the moisture to drain through the flooring and away from the stall and barn,” he explains. In addition, this protects the floor from high water levels outside that might otherwise easily flood the stall.
Now you’re ready to add the floor itself. Next you’ll find basic installation information for several common types of flooring.
Adding the Flooring
Dirt–If you plan to have a dirt floor, and local soil drains exceptionally well, you’re done. Most soils, however, drain moderately well at best, so you’ll probably want to help it along. One option is to grade the top layer of dirt slightly (no more than three degrees), so that moisture runs off to exit the barn or stall through an outlet in the corner (or through the stall door to the aisle).
You could also make a “leach hole,” or simple drain, inside the stall. To do this, dig a hole about three feet in diameter and deep enough to reach that bottom, well-draining layer of soil at the base you created. Then fill the hole with varying sizes of rock (or alternating layers of sand and gravel), starting with large gravel chunks at the bottom and working toward stone dust at the top. Tamp into place and cover with dirt to even out the floor.
Stone Dust–Blackburn believes that stone dust (also known as crusher run, screenings, or quarter-inch minus) makes a better floor than dirt, “because it can compact well and still permits drainage.” However, he does recommend adding a subsurface drainage system to enhance flow-through. To do this, lay filter fabric over the floor, top it with a layer of crushed gravel, then add three to five inches of stone dust. As you did with the base, compact the stone dust after each one- to two-inch layer. When you’re done, water the floor, tamp it down tight again, and let it settle overnight. Fill in any holes or depressions the next day.
Another idea is to install a drainpipe under the stone dust floor. “I feel that this helps drain the moisture away from the stall area and allows you to flush the stall with moisture to cleanse the flooring,” explains Blackburn. “Otherwise, it could drain into the dirt and stone and stay there, providing odor and a breeding ground for bacteria.”
To lay pipe, first dig a swale–a sloped ditch about one foot deep. Lay perforated pipe into the swale (you want a piece long enough to provide drainage away from the building, notes Blackburn). Cover the pipe with filter fabric, then fill the swale with crushed gravel. Now add and compact your stone dust as stated previously.
Plastic Grid–Plastic grid flooring comes in many variations, but the basic idea is the same for all floors: To provide a 100% permeable floor plus a level, stable, durable surface. Installation instructions vary by manufacturer; however, most recommend laying the grid over a well-draining subsurface (such as stone dust) so that moisture not absorbed by bedding will drain away. Usually, the holes in the grid (which create the excellent drainage) are filled with stone dust.
Rubber Mats–As with grid systems, rubber mats (and similarly, rubber pavers, which look like rubber bricks) vary in design, thickness, texture, etc., from one manufacturer to the next. Likewise for installation instructions, although most want you to measure stalls so that mats fit snugly against each other and the walls. Unlike grids, however, mats and pavers are meant to trap moisture above the surface, where it can be absorbed by bedding. Moisture can seep through the seams (or possibly the rubber itself). So, flooring experts recommend that you lay mats over a well-draining subsurface, such as one of the crushed stone systems mentioned earlier, or over relatively nonporous materials such as concrete and asphalt that can be easily disinfected.
Asphalt–You can lay an asphalt floor yourself, if you’re willing to find a supplier, rent equipment, and learn the proper way to apply, rake, and settle it. However, it can be a tricky process. As Blackburn notes, “The right mix of asphalt is important. It should be raked as it’s installed, then hand rolled. I would imagine that hiring a professional would be advisable.”
He also suggests that you grade asphalt floors with a crown of one-eighth inch per foot in order to sustain drainage. “With a flat surface, the urine puddles and leaves the horse standing in dampness, potentially causing all kinds of hoof issues,” he explains. The slope will also facilitate drainage when the stall is washed or disinfected. Blackburn recommends the use of aggregate, or “popcorn,” asphalt, which offers a non-slip texture. And he strongly urges the use of rubber mats or rubber pavers to cushion this relatively rough surface.
Concrete–Many people are comfortable mixing and pouring their own concrete–an easier process than laying asphalt. For larger projects, you might want to hire outside assistance. Although moisture can seep through concrete over time, this footing is not as porous as stone dust. So, Blackburn recommends grading it at a rate of one-eight inch to one-quarter inch per foot to allow for drainage. Concrete should be cushioned with rubber mats or pavers, he adds, to reduce the risk of injury and musculoskeletal stresses that this hard flooring could cause.
A Note on Cost
Before you begin stall floor construction, you should create a budget for the project. However, as Blackburn notes, “The cost of different options can vary dramatically based on the number of stalls, location, and the material used,” as well as the specific suppliers, consultants, and equipment rental agencies with which you might deal.
For instance, says Blackburn, “I have found that the cost of asphalt flooring can range widely from area to area. And some suppliers require that a large quantity be ordered of the type and mix you need before they will supply it at a reasonable price.” Therefore, it could actually be more expensive, per stall, to floor a smaller barn than a larger barn. It’s important to contact local companies for estimates before you start the job. (For mass-manufactured, nationally distributed products like most rubber mats and plastic grid systems, you can check pricing with the manufacturers, many of whom have web sites.)
As you start compiling price quotes and creating a budget, Blackburn cautions that you consider not just the initial expense of purchase and installation, but also long-term costs. A dirt floor might be virtually free to install except for labor, but could be expensive in terms of labor over the long run. Rubber mats might be pricey at the start, but could pay for themselves through longevity, ease of care, and reduced bedding.
Also consider the stall flooring material can greatly impact the amount of bedding you’ll need to use. For instance, a stall floor with interlocking rubber brick can cut your bedding in half which can save on barn operations, offsetting increased installation costs.
Additional options for flooring include adhered cushioned or foam filled. To conclude, all stall flooring has an impact on the comfort of your horse, the material cost of installation, bedding requirements and your ability to clean and sanitize the stalls.
ABOUT THE AUTHOR
Sushil Dulai Wenholz
Sushil Dulai Wenholz is a free-lance writer based in Lakewood, Colo. Her work appears in a number of leading equine publications, and she has earned awards from the American Horse Publications and the Western Fairs Association.
1. Blackburn designs stalls of all sizes, but the most common is 12’x12’. 16’x16’ is often requested for larger horses, but with more space comes increased maintenance, a need for more bedding and a bigger area to clean. Larger stalls can, therefore add considerably to the cost of building a barn by:
a. Adding to the overall length and/or width of a barn.
b. Requiring roof framing to be increased from 2×10’s to 2×12’s or even greater.
c. Increasing the span of the framing lumber.
2. Partitions between stalls should be at least 8 feet high, but they don’t have to be solid from top to bottom. Barred or mesh portions on the top enhance ventilation. This also has the benefit of allowing horses to see their companions — and provides easy observation of the horses by their owners. The down side is the increased ventilation between stalls can increase the risk of bacterial infection between horses. For the same reason, doors that are open on top increase light and ventilation. Bars must not be more than 2 to 3 inches apart, and openings should not be more than 2 inches across to prevent hoof entrapment.
3. Steel mesh or bar fronts on stalls allow an owner to look down the aisle or into the stall as they walk down the aisle and see their horses. The mesh is good for ventilation, too. The drawback is that bedding can be kicked into the aisles, so we recommend adding bedding guards. Welded steel mesh is typically stronger than bars but the horizontals tend to collect dust and can add to barn maintenance.
4. Doors should be at least 4 feet wide. This is wide enough for a wheelbarrow to enter the space or for a horse and handler to exit or enter the stall. Sliding doors are preferred over swinging doors. If you must use swinging doors, remember to install them to swing outward. You’ll have a major problem if a horse goes down and the door swings to the inside. Additional safety reasons for outward swinging doors include:
a. Prevention of an unlatched door swinging open accidentally, or the wind catching it.
b. Added visibility of looking down an aisle and recognizing that a stall is open and empty. (Handlers need to leave stall doors open when the horse is turned out. This also makes it easier when bringing the horse back to the stall – you don’t have to open it.)
5. We recommend rounded edges in stalls and anywhere in the barn where horses have access. A casting rail (which can be a groove in the wall or a 2-by-4-inch rail bolted low to the wall), provides something for the horse to catch his foot on when rolling to avoid getting cast.
6. Provide for easy access to the stall for feed buckets without opening and closing the door. Place in one of the front corners adjacent to the aisle.
7. Automatic waterers have the advantage of offering constant fresh water, but be sure to buy a model that is easy to keep clean. If you don’t want automatic waterers, install water hydrants between every couple of stalls and provide for ample drainage for drips and overflows. Don’t forget to frost-proof them in climates where pipes are apt to freeze.
Hi John. I hope you had a wonderful summer!
Q: Our covered arena has been put to good use throughout the last year, but we really need lights to make it even more beneficial to our program. Given your expertise and experience with equestrian barns and arenas, I was hoping you might be able to give us some guidance.
We are having a hard time determining exactly what kind of and how much lighting is necessary. Do you have a formula that you use?
Any help you can provide would be greatly appreciated. I look forward to hearing from you!
Dear Undercover Rider:
Glad to hear all’s well.
I would be happy to offer some guidance on lighting for your arena.
A: I typically recommend approximately 35 to 50 foot candles per sq ft of light on the arena floor in order to provide a sufficient amount of light for a variety of functions. It also depends on the amount of reflective surfaces you have and the color of those surfaces including the arena floor material.
If you are anticipating a variety of entertainment type functions such as charity events, parties, etc you may want to consider a variety of type mood lighting for different events.
There are also a variety of type lights to consider such as metal halide, LED, HD, etc.
There are other factors to consider as well such as initial cost, operating cost, maintenance or lamp life and also the design of the fixture (bird protection, fire safety, etc.)
We are beginning to use LED more often now. I hope that helps!
“When you take a horse out of its comfort zone—the wild—it’s your obligation to create an environment that protects its health and safety. A poorly designed barn can be worse than no barn at all.” – John Blackburn
John Blackburn knows barns. As Blackburn’s owner and senior principal for the past 25 years, John has designed over 150 equestrian facilities across the United States and abroad.
In his blog, Stable Minded, John rhapsodizes about the design process behind our horse barns and equine facilities as only he can. His blogs cover a variety of equestrian news and topics: from the story behind projects we’ve designed to equestrian and design issues, such as how to increase natural lighting in barns. For those of you with questions or comments about the nitty-gritty details we face when designing barns, John considers his blog an open forum to discuss what’s on your mind.
If you’re curious about the architectural process, like to view construction photos from start to finish, or have questions about how it all works, we invite you to read and comment at Stable Minded. It might not be literally straight from the horse’s mouth, but we like to think it’s pretty close.
Today’s blog comes from Macy Carman, an enthusiastic and talented student (and equestrian!) from Hollins University in Virginia. Macy, an environmental studies major who is considering graduate studies in architecture, spent some time with us to learn about what it means to be an “equine architect.” In turn, my staff and I got to spend some time picking her brain about her invaluable experience as a groom for Pollard Eventing. (On a sad note, our thoughts are with everyone at Pollard Eventing. Macy travelled back to be with her horse family after the tragic car accident that claimed the lives of three horses last week.)
I knew I had picked the right architecture firm for my internship when John Blackburn started out my first day with what he referred to as his “dog and pony show.” I love pony shows! I am a lifelong rider, member of the United States Pony Club, and looking forward to a career in designing equestrian facilities, so I knew I was in for a treat. And I was…the presentation he showed me displays many of the options that are available to clients as well as the principles he bases his designs around: natural light and proper ventilation. I think that he could convince anyone that these are the most important concepts behind a facility!
During my time with the Blackburn team, I was able to accompany John to a Virginia Farm where he was interviewed for a video (stay tuned for the final project). After spending so much time discussing the process to designing a barn, I certainly had a different perspective when touring the facility. While my practical experience with horses, combined with time spent in a variety of barns, has instilled in me the importance of a well thought out facility for the safety and well being of the horse and rider, I picked up on a lot of smaller details. John had a reason for why every detail was exactly the way it was, and was happy to answer all of my questions. Watching his interviews, I got a sense that he cares for the horses just as much as the owners, which is exactly what we horse people are always looking for.
Over the course of my first week here, I have talked to everyone in the office about their projects, their academic paths, and their thoughts on barn design. As interested as I have been in barn design over the years, I have never given thought to many things Blackburn consistently addresses, like making sure that vehicles, visitors, and horses are separated at all times. Who knew a driveway needed so much planning? Everyone in the office has been very welcoming, and I hope that I have been able to provide a slightly different perspective as a rider and a groom. I look forward to absorbing a greater understanding of equestrian design during the rest of my time here- and maybe some tips on my graduate school applications too. I would like to thank the whole office for having me.
I think that’s the top question I get (the gist of it, anyway) and it SHOULD be. Why should you hire an architect to design a horse barn? Or, Is hiring an architect to design a barn really necessary?
In short: no. However, hiring an equine architect can save you time, your horse’s health and safety, and even money in the long run. Allow me to state my case.
A horse is so much more than a pet: it’s a companion, a worker, a teammate, an athlete. Whether you ride for pleasure or compete, the horse—your horse—is irreplaceable. I wish not to gild the lily just to make my point, which you already know, that horse owners think the world of their horses and want to treat them with the utmost care and respect. If you keep a horse, it’s your duty to protect it. While a horse is perfectly pleased to graze outdoors most days, the barn is a necessity – so I say, let’s do our best to protect that horse and maybe make your life a little easier in the process.
Barn This Way – Product vs. Service
When you decide to build a barn, you have a few choices. The least costly solution is to purchase a prefab or kit barn. The prices range (rather wildly), as does the package itself. Labor is often an additional cost as well as nails, roofing, and concrete costs. Usually a contractor charges between 10 to 25 percent of the total cost of materials for construction services. However, this percentage may go up if your project is on the small side in order for it to be financially viable for the contractor. For many horse owners, a prefabricated or kit barn is a perfectly reasonable and cost-effective solution.
If you’re looking for a step above prefabricated, or can afford to customize your project a bit, you may then wish to research design/build contractors – but this is where I’d stop and suggest that you alternatively consider working with an equestrian architect.
Why? A design/build contractor is selling a product, not a service, and is not often a trained architect, which limits his or her ability to think creatively outside of the box. In most cases, thinking outside of the box eats up profits and costs more money (for the design/build contractor). For a design/build contractor, the goal is to build quickly above all else. I think this compromises your program and the overall result because the design/builder does not want to eat up time resolving special issues or conflicts. The design is usually cookie cutter, following whatever pattern the design/build contractor typically uses, and there is no one there to really represent the owner (you) and oversee the quality of the project and if it’s built as intended or promised.
To Serve and Protect
With an equestrian architect, you’re purchasing a service rather than a product. The architect is there to resolve the needs of the owner, from overall site planning, programming, phasing, and design to overseeing the entire construction to make sure the barn is built as intended. The service costs a bit more than a design/build contractor but, if your barn is your livelihood or your sanctuary, I believe that you’ll save time and stress, frankly by getting it done right the first time.
Typical services an equestrian architect (straight from the horse’s mouth here, if you’ll forgive my pun) will provide:
- Site planning: can reduce infrastructure costs (fewer roads, less fencing, better drainage, etc.) and improve the site to function at its best for your needs.
- Programming: ensures that the whole farm (not just the horse barn but the entire collection of structures on the site, if applicable: residence, guest house, caretaker’s quarters, hay/bedding, vehicle storage, etc.) operates efficiently and safely.
- Code analysis: certainly the codes vary across states/municipalities. We’ve designed horse stables in counties with very specific codes and regulations and understand what to look for and how to work with the various officials to resolve issues. The architect can save you a lot of hassle!
- Budget Development and Cost Control/Scheduling: I like to develop a budget as early in the process as possible and revisit it periodically during the project. My job is to determine if the owner’s programmatic needs and budget fit the site, and if the design aesthetic suits their personal design goals. We can also plan to develop the barn or various structures in phases, if applicable.
- Conceptual Design: Here we develop the character and massing of the structure(s) and prepare a preliminary floor plan and elevations to illustrate our ideas. At Blackburn, this is the final phase of what we call Master Plan Services (site plan, written program, conceptual design, and preliminary construction development). From here, we move on to more detailed design work.
- Schematic Design: After we complete a master plan that works well for the owner, we begin to prepare detailed drawings to give you an idea of the layout and general appearance of the barn (and possibly other buildings). We’ll talk about finishes, materials, stalls, tack rooms, etc. For a lot of people, this phase of design is the fun part!
- Design Development and Construction Drawings: Here we’ll really start to nail down the final design and specify the materials, stall systems, finishes, and other details and prepare construction drawings that instruct the contractor how to build the barn.
- Bidding and Construction Administration: Because construction drawings are open to interpretation, it’s important that the architect works with the contractor to oversee that the project is carried out according to the design intent. We’re the owner’s rep to make sure that construction is done well and done right.
I understand this may seem like a lot, but each is a valuable step toward designing a healthy, safe, and functional facility. As an architect, I want to study how you operate and design a barn that feels inviting and personal (because it is). No barn or farm operates exactly alike as each owner or barn/farm manager operates his/her facility in a particular fashion. While designing a barn from scratch is not realistic for everyone, if you are choosing between a design/build firm and an equestrian architect, I’d strongly advise that you approach both for more information and weigh out your options carefully. It could save you your horse.
As always, I invite your questions and comments. Thanks for reading!
An architect is trained to design as the great Louis Sullivan (1856-1924) states: “Form ever follows function.” After all, if your barn doesn’t function properly, what’s the point of a great design?
At the Blackburn office, we’ve been busy developing Blackburn Greenbarns®, a line of pre-designed barns that are sustainable, provide a healthy and safe atmosphere for horses, and are more affordable than custom design. We first introduced this line of barns last April, but the overall construction costs for the barns were a little higher than we would have liked. So, we decided to go back to the drawing board (literally) in an attempt to streamline the process without compromising our values. We are almost ready to relaunch Blackburn Greenbarns® (with a new and improved website on its way!) with a “kit barn” option, but I would really love to hear from you as far as what’s most important to you when building a new barn.
I know that cost is a huge factor—as it should be—for most barn owners. However, I also know that being a horse owner is quite an investment in and of itself—and that most owners just want a facility that protects their horses when they are in the barn, knowing full well that the horses would rather be lazing about in the paddocks.
What is the most important factor when building a new barn? Affordability? What about the style or look of the barn? Are you interested in sustainable products or incorporating green design?
I hope you’ll comment on this post and share your thoughts. Maybe there’s something that all the barn builders (or architects) forget to include/consider and it drives you nuts? Or maybe there’s a particular service (like site planning) that you’d find valuable but aren’t sure you can afford or truly need and would like to know more about it.
Hope to hear from you! More on what we’ve been up to soon.