Over the years, Blackburn has been asked what we think of adding stalls along the side of an indoor arena. Sounds like a good idea, right? Well, we strongly recommend against it. The problems are many.
1. Air Quality. Forced to breathe arena dust many hours of the day, stalled horses live in an environment that isn’t healthy. We recommend instead that the stall portion of the stables be connected in a separate but attached structure running perpendicular to the barn. Not only does this arrangement help isolate the arena dust from the barn, it allows the barn to sit independently. The structure can then catch the prevailing breeze which permits two scientific principles (Bernoulli principle and the chimney effect) to provide natural ventilation and light to the barn.
2. Fire Safety. We always recommend fire separations by providing sliding doors to isolate the barn from the arena in case of fire. These doors may or may not be rated fire separations. The decision is usually driven by cost, and we often provide an automatic rolling fire rated shutter to isolate the two separate areas – this at least reduces the risk of smoke moving between structures. (Quite often it’s the smoke that is more dangerous and faster moving than the actual fire.) The isolation by sliding doors also provides critical time to get horses out of barn. If the arena and barn share the same space, there is less opportunity to isolate fire or smoke from the stable area. Furthermore, when the stables are parallel and part of the arena, the structure is generally shared – raising the risk it could collapse and trap horses inside.
3. Cost, Scale and Building Height. When stalls are designed as part of an indoor arena, the design requires a wider structure (often steel due to the long spans) which is typically more expensive. When it’s a separate but attached structure, it can be framed in wood with smaller spans reducing the cost of the framing. If the stalls are part of the indoor arena, then the building becomes wider which also means a corresponding height increase. In many areas, the local zoning codes restrict building heights. We have found typical restrictions of 35 feet. It’s difficult to get any height in the barn or arena if you are trying to build a 100 x 200 ft arena with a row of stalls and aisle way. Also, from an aesthetic perspective, wider and taller building begin to get enormous and have the potential to look like an airplane hangar and overshadow the entire farm.
4. Storm Water Issues. Finally, if your property is not flat, such a structure with a large footprint may require significant grading that can be expensive and create storm water issues. By breaking the barn and arena into two connected structures you can more easily work it into the natural slope of the land. Also, the isolation of the barn and arena permits opportunities to push the arena into the ground – helping to reduce the scale and height of the arena above finish grade. The entry to an observation area can be elevated above the arena floor (but entry level still at grade) for more easily viewing over the kick wall from a sitting position.
Blackburn has designed many arenas with this perpendicular arrangement. Rocana Farm, designed by us in 2002, is a great example of what we mean. Stalls at this hunter/jumper facility are attached to the enclosed arena with an elevated observation room, tack room, wash and grooming stalls.
Fences are one of the most common discussion points among the Blackburn team and clients when we’re designing an equestrian facility. The options listed below are certainly not exhaustive but reflect what we commonly find in many of our projects.
Some options are better suited for pastures, while others are more appropriate for small stall turnouts. We’ve tried to identify a variety of approaches that meet the safety needs for horses, limit maintenance needs, and often fall within neighborhood guidelines.
1. Steel rail fencing is an option for stable turnouts. The material is available in a thinner profile so it isn’t as visually heavy and it can be painted black or another dark color so that it does not have the “ranch” appearance seen with galvanized steel pipe corrals. The up-front cost is higher but the material is durable and will have little-to-no maintenance needs.
2. Woodguard polymer coated wood fencing is treated wood with a non-toxic, non-chipping surface covering. The wood grain is still visible but the finish has some of the plastic texture of the polymer. This product allows for fencing to be constructed similar to a wood fence, with the rails attached to the face of the posts. The result is a stronger, safer fence. Woodguard has a 20-year warranty. The cost is similar to wood board fencing but the maintenance needs are less. While the manufacturers state that this product is resistant to cribbing, we would recommend that a hot-wire be provided at the top rail to discourage the horses from chewing. This material would be acceptable to use for both stall turnouts and paddocks. It offers the appearance of a traditional 3- or 4-board wood fence without the significant maintenance demands. https://www.wood-guard.com/horse-fencing/
3. High Tensile Polymer (HTP) comes in both rail and wire styles and is typically mounted on wood posts. The rail is typically 5” wide and from a distance will appear similar to wood board fencing. Because wire fencing has a lower visibility, we suggest using a thicker top board so that the horses can more easily identify the barrier. The HTP materials’ inherent flexibility makes these products durable and resistant to horses leaning on or running into the fence. Typically, these are more suited to large pastures or for perimeter fencing and less so for stall turnouts. The darker colors tend to exhibit a chalky appearance over time.
4. Rubber fencing is a durable, flexible, and low profile fencing material and is similar to the HTP fencing. We’ve not seen this product used as often and we understand that there’s a risk that the strings of the fabric (which is an internal support for the rubber) can become exposed and offer a hazard for horses to chew on. A hot-wire at the top of the fence may combat this risk.
The advantages of rubber, HTP or any type strap fencing is the posts can be set further apart which is useful when its highly visible and you want to minimize the number of posts. The fencing is flexible and resists breaking when a limb or tree falls on it therefore it’s a good material for perimeter fencing large acreage and where it encounters wooded areas. This is safer if/when a horse runs into the fence; especially a problem on larger paddocks when horses can get some speed and not be able to slow down.
5. HDPE is a post and board fencing material. It’s stronger than PVC and performs better in all weather conditions, but the primary issue is in the assembly of the fence. The rails are set between posts, instead of fastened to the face, and can pop out if the fence is not secured properly. Its requires more frequent posts which tends to look busy and it’s difficult to bend or angle corners because of the assembly method. The Blackburn team isn’t particularly fond of this material because it can look clunky and isn’t the safest option. http://www.amberwayequine.com/products/hdpe-fencing-2/
I thought I’d take a minute and explain Blackburn Architects’ process for designing a new equestrian facility and overseeing its construction. While not carved in stone, for planning purposes, can easily become a two-year process.
The first step is usually a visit by me or another Blackburn architect. The initial meeting is our first chance to meet, walk the site, look at any existing buildings and discuss the project goals. I’m a firm believer in “a picture is worth a thousand words” but “being there is worth a thousand pictures” Following this, we’ll send a proposal for service, which outlines the process and fees.
Once a contract signed, we get to work immediately.
The timeline usually looks something like this:
• 6 to 10 weeks for Feasibility Study, Site Assessment and Master Plan
• 1 to 2 months for Schematic Design
• 2 to 4 months for Design Development and Construction Drawings
• 1 to 2 months for Permitting
• 12 to 16 months for Construction
At Blackburn Architects, equestrian design starts with the horse and ends with a building that fits the horse, the owner, and the surrounding environment like a glove. It’s as simple and beautiful as that.
Let’s explain the steps in greater detail:
Feasibility Study / Site Assessment / Master Plan
The goal of the Feasibility Study is to determine, as early in the process as possible, whether the intended project fits the owner’s program, the site, and the budget.
We assess any existing building(s) and the site. We take measurements to determine if an in-place structure will work for the goals of the project. We study the land until we come to a clear understanding of wind and solar direction, soils, changes in elevation – all natural and architectural characteristics that guide placement and design of any new buildings. Central to the success of the project, this “Master Plan” addresses all these things and more, providing a road map for the success of all future phases of our work.
The site analysis also includes a review of applicable zoning and easements for the property; we determine what (if any) limitations or restrictions may apply at the property. Land disturbance allowances? Height restrictions? Set-backs?
In tandem with the site evaluation (as soon as we have a contract), we send the client a unique Blackburn Architects questionnaire that we’ve developed over the years. Answers are collected and inform the design; starting off the process with clear direction from the client. It is extensive and though it covers about 25 pages, once it is completed it “paints” a picture of exactly how you would like your farm to operate. The efficiency of the operation is critical and can have a huge impact on your operating cost and maintenance budget.
Moving seamlessly from the master planning phase (often there is a fuzzy line here where one ends and another starts), we start schematic design. In this step, we help our clients visualize the project design with a variety of techniques using both computer and hand renderings to illustrate the scale and the relationship of the project elements. Ideas, concepts, goals take form at this stage.
Once we’ve worked up outline specifications for the work, we can begin to get a rough idea of the costs. At this point we will either develop a rough estimate based on our 35 years experience with over 300 farm projects, consult with a professional cost estimator or a builder who is familiar with the building type in your location.
Design Development and Construction Documents
Once we have the site layout, design, and budget, drawings and other documents give serious form to interior and exterior finishes, and firmly establish the size, character, and details of the project. These documents will be used by our professional consultants to design the electrical, gas, and other utilities. When these systems are defined, and we have a basic finish schedule and budget, we’re ready to file for the permit and start construct of the building.
Bidding and Construction Administration
With the construction documents complete, we can help clients select a contracting company through a “bidding” process for the work, or we can work with a client’s pre-selected Construction Manager. We work side-by-side with our clients to ensure that the best and most informed decisions are made during this process.
While in my experience this process typically lasts about 18 to 24 months, a lot of this depends on factors that are outside of either our control or our clients. The time of year and weather, for instance, can greatly influence how fast construction progresses, especially in colder climates. Pastures have a growing season, and they need at least a year (maybe two) to establish.
Designing and constructing a custom facility is a very subjective process, which is guided by all kinds of factors including the complexity and size of the structures, the time of year, the strictness of zoning regulations and neighborhood associations, state environmental regulations, and so on. But rather than let these things hold you back, I say, “Jump In” or give us a call to discuss how the process can work for you. When you slide open the doors to your dream facility and see the happy heads of your horses looking over the stall doors, all the time and effort will vanish. At least that’s been my privileged experience over all these years.
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.
Pat Raia’s recent article about the California barn fire blamed on exploding manure raises legitimate concerns about the dangers of improper waste management. Standing piles of manure contain rapidly reproducing bacteria and methane gas build up (as the internal temperature rises you might see smoke rising off the mounds!). The impending “explosion” could ignite any combustible material in proximity to it and you could be left with a devastating mess similar to the California barn fire.
Manure storage in the barn is a fairly rare occurrence in my experience and I agree with the recommendation that it should be stored outside and away from the barn. Not only to reduce the catastrophic events that could be caused by spontaneous combustion, but also to prevent flies, mosquitoes, and odors (not to mention the unnecessary risk to the safety of the horses from outside service vehicles and haulers tending to it). I find that most people store their manure in a dumpster or muck pit. As an alternative, I recommend and frequently specify a composting system close to the barn. A composting system like O2Compost is great and can be designed to accommodate large to small horse barn operations.
They’re also compact, customizable and can quell the influx of flies and mosquitoes. The heat created by the decomposing manure “cooks” it until it is reduced to a manageable amount. It can then be used in more productive ways such as providing fertilizer for the farm and paddocks (the cooking process has killed the harmful bacteria by this stage) and preventing weeds. Always be cautious, though, when handling or transporting waste materials so as to avoid mixing with other combustibles. This could increase your risk for fire as well. Most farms do separate them because the hauler typically objects to combining other trash with manure.
Spontaneous combustion is not limited to manure, however. Hay is a serious factor where barn fires are concerned, in my opinion. It is all too frequently stored in improperly ventilated barn lofts where it can easily ignite. Unfortunately, many owners house their horses alongside hay storage and have no idea how potentially deadly it can be. They think it won’t happen to them. With daily convenience in mind, I usually design a ventilated, isolated area to accommodate only a week’s worth of hay storage at a time. Generally, hay should not be amassed in lofts, but whenever it is stored there it should only be in small quantities. Special precautions need to be taken such as installing alarm systems and reducing exposure to electric lighting and equipment. I recommend natural lighting through a skylight or clerestory windows. I strongly encourage installing a sprinkler system in the barn. I know it’s expensive but think of it this way, “ can you afford to lose your barn, your horses, and everything else in there?” It may be worth the investment considering what’s at stake.
I want to thank Pat Raia for writing the article, as it will, hopefully, raise our collective consciousness to the presence of latent hazards around the barn.Whenever designing for horses, my goal is to find every way possible to make the barn (and the entire farm for that matter!) a safe and healthy home for them and their handlers.
John Blackburn, AIA, Senior Principal at Blackburn Architects, P.C. and author of Healthy Stables By Design has over 35 years of experience in the practice of architecture. He is responsible for the overall firm management. His award-winning designs include a full range of project types and services, from programming, existing facility evaluation, and master planning to new construction, adaptive reuse, and historic preservation. Please contact him here
After reading Stable Management’s recent article “Environment is Important in Planning Your Equine Facility,” I thought the topic would be perfect for this latest series of Barn Design Tips and Thoughts. You can find Stable Management’s article here (http://stablemanagement.com/article-archive/stable-management/environment-is-important-in-planning-your-equine-facility/) if you are interested.
The article is absolutely correct, “Environment is important.” Since you cannot change the environment, selecting the proper property and layout of your farm is critical to its success. The farm has to respect the land and environment in which it is placed. Sometimes people attempt to change the land to suit the farm they desire. That process is generally extremely costly and some spend more money manipulating the land than they do building the structures, fencing, etc.
A successful horse farm needs to respect three concerns: the demands of the site, the goals of the owner, and the needs of the horse. At Blackburn, we believe the needs of the horse remain paramount throughout the planning and design process. For over 30 years and in more than 30 states, I have seen an incredible range of properties and locations on which a horse-owner wants to “build” a farm. Most properties can be adapted in some way, but at what expense? One time, I had a conversation with a thoroughbred owner in which he had to decide between spending $100k to solve a site issue his way or accepting a lower cost alternative that could save him enough money to invest in a new foal. Like many equestrians faced with a similar choice, he chose the latter. This is one of the reasons why having an equestrian architect or planner evaluate a site before purchase may be extremely helpful and cost-effective.
In order to make the most of your land and stable, planning is necessary. The most important and critical step is to develop a master plan. This is where most of our projects start. A proper master plan will analyze the site to determine the property’s unique features, pitfalls, proper conditions, seasonal changes, etc. etc.
There are literally thousands of things to consider and they are not all the same for any two projects. As I have described it in terms of farm managers, you can get a hundred farm managers in a room and you will get at least 101 different opinions on how to run or operate a farm. The same is true for the site. Oftentimes, we present several site plan options to clients so they can see the benefits and negatives of different building placements. It may require an experienced equine planner, designer/architect, or landscape designer/architect to see the differences or to see “the forest for the trees.” For that reason, it is almost impossible for me to give general tips about site planning as each site differs. One generally applicable tip is locating the long axis of the barn perpendicular to the prevailing summer breeze for good ventilation. The key is determining the direction of the prevailing summer breeze. I recommend starting with local airport wind data, but following that with a site analysis to observe site obstructions that can modify the pattern. Every site has it’s own microclimate and it is important to gain an understanding of it before you design the overall site plan.
To make the most of your property, I highly advise hiring someone with experience. Sometimes this is where people have issues. Without considering all the influences of land and environment, they purchase a prefab or select a design/build solution. With many of these companies, their sole interest is selling a product, not a service. It is not very different from selecting a trainer for your horse. If you want to be a top dressage rider, selecting a general all-around trainer can only get you so close to your goal. Instead, you need someone with experience in high-level dressage. Someone that is able to understand your horse, you, and your goals. Similarly, what the owner of a horse property needs is the service of an experienced hand, the talents of a trained eye, and the concern for the long term success of the farm.
A few weeks ago, I was approached by a potential client who had selected a prefab barn/arena structure. Throughout the process, the prime concern was the cost and speed of erection. The supplier offered to adjust the size of her building components to fit the building pad, but didn’t look any further. When the owner complained that the barn stuck out like a sore thumb, the prefab manufacturer added a series of small cupolas that were not functional and out of proportion. Unfortunately, in these situations it is often the health of the horses that suffer. They are the ones that miss out on the prevailing summer breezes that your pre-fab structure never gets because barn placement wasn’t considered. It is the horses that have to live in a stall that smells and contains high levels of ammonia gas, since draining and the importance of natural light in reducing gas production was not a priority. They do not have the benefit of clerestory light entering or the light from a Dutch door removing bacteria from the air, since your pre-fab barn may lack Dutch-doors and abundant sky-lights. Of course none of these are extreme life-threatening problems and not every pre-fab structure or kit of parts is horribly designed (although there are definitely some out there). Yet, 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.
The last line of the article stating “Environment is Important in Planning Your Equine Facility” is absolutely correct. “Understanding what you want to develop, and planning for the success of that horse facility, will go a long way in making the project go faster and easier,” and if I might add, cost less and be a better long-term investment.
If you are interested in how stable design can make a healthy environment for horses, please consider checking out my new book Healthy Stables by Design. After practicing as an equestrian architect and concerning myself with ways to make stables safer and healthier for their inhabitants in all kinds of environments, I thought it was finally time to share some of my principles. In my book, you can start to understand these concepts as I explain them through large-scale pictures and drawings.
Attached are articles about something that we see all too often – another barn fire. I probably read somewhere between 10 and 20 articles every year about these tragedies. In virtually every one, there is no specific origin given for the fire or “it’s under investigation.” However, any person who has been around barns is aware of the probable answer. Usually, some electrical condition (light fixtures, heater, faulty fan, etc) ignites a flammable material such as hay, bedding, cobwebs, etc.
In the article about a tragic barn fire in Georgia that took the lives of 35 horses, it does not mention the origin of the fire but states, “The stable was filled with hay and wood chips for the horses’ bedding…. And those running the stable kept fans blowing on the horses to keep them cool through the summer night.”
Once again the issue comes down to ventilation, the use of fans, and the probable culprit of faulty wiring.
Please excuse me if I preach once again about the importance of “natural” ventilation, which in my opinion is the most critical aspect of barn design in relation to the health and safety of the animals. “Natural” lighting is also important, but when designed effectively, both work together to ventilate the barn. I am not familiar with the barn that burned or the conditions that may have caused the fire, but the article states that the fans blowing in the barn increased the intensity of the fire.
For thirty years, we have designed barns that incorporate the chimney effect and the Bernoulli principle to ventilate barns naturally. (Click here for explanation and to learn more). Neither of these will eliminate the use of fans entirely in a barn, but they will greatly reduce the need for electric fans (and electric lights as well). Reducing the need, will reduce the use and consequently extend the life (they won’t wear out as quickly) of the fans or lights. Ultimately, this will also reduce energy cost for the barn. Many farms use the cheap residential box fan for ventilation over extended periods of time. Not only are they cheaply made (I have seen them selling for as little as $10), but they are not designed to withstand the environmental abuse they can receive in the barn. Dust, dirt, hay, and/or bedding particles can clog the fans, easily creating potential for fire. In addition, the humidity can cause the fans to rust and deteriorate more rapidly. The less fans, lights, and other mechanical systems are needed, the safer the farm will be.
Although, these methods do not eliminate the possibility of one of these horrific events, they decrease the likelihood. Something that will make most, if not all, horse owners’ sleep a little more soundly at night. A well-designed barn needs to consider the heath and safety of the horse at every turn. Remember your barn does not have to cost you an arm and a leg, but neither should your barn cost you your horse.
Check out my new book, Healthy Stables by Design, at www.healthystablesbydesign.com. Not only does it discuss ventilation practices, but it will also feature other ways to make a stable safe and healthy for horses.
Times Free Press – www.timesfreepress.com/news/2013/jun/23/stable-fire-shocks-neighbors/
I wanted to share an oldie but goodie – an article I wrote originally for Western Horseman Magazine about designing for natural ventilation within your barn. This stuff is the bread and butter of our design, in that no matter where a barn is located, or what a client’s budget may be, healthy and natural ventilation within the stables is our priority. Read the article, Breath of Fresh Air, and let me know what you think.