BARN BARN PLANNING PLANNING GUIDE GUIDE
A G A GUIDE TO THOUGHTFULLY UIDE TO THOUGHTFULLY DESIGNED BARNS DESIGNED BARNS
YOUR LIFESTYLE
INTRODUCTION
Contrarytopopularbelief,planningandconstructinganewbarncanbechallenging.This statementappliestoeventhemostexperiencedequineenthusiast.
It’snotdifficultbecauseit'scomplex,butit'sdifficultbecausetherearemanythingsto consider.Variablesbegintostackupasyouthinkaboutyourbarn’sarchitecture,geography, animals,andthepeoplewhooperatethebarn.Therearemanyfactorsthatcontributeto buildingasuccessfulbarn.
What do we mean by a “successful” barn?
AtAmericanStalls,asuccessfulbarnisabarnthatworkslikeawell-oiledmachine.
Thatmeansthatthehorsestallsarebuilttogracefullyworkwithyourworkingstyleand yourhorses’behavioraltendencies.
Thatmeansabarndesignthatnaturallypromotesventilationandamplesunlight.Itmeans selectingmaterialsbasedonyourbarn’sgeographyandclimate.
Simplyput,a“successful”horsebarniselegant,safe,andbuilttoserveyouforgenerations.
Asyouflipthroughthisguide,werecommendkeepinganotebooknearby.Whilenota definitiveguide,thisguidewillpromptquestionsabouthowyoudothingsandyourhorses’ dispositions.Makenotes.Writedownquestions.Annotatecertainpagesthatpiqueinterest. Thiswillthenallowyoutomakelogicaldecisionsthatwillserveyouwellforyearstocome.
YOUR LIFESTYLE
YOUR HORSES WHERE TO BEGIN?
Onceyouconsideryourworkinglifestyle,itisequally,ifnotmore,importanttoconsiderthehorses Thebarnisultimatelythehomeforyourbelovedhorses,andbuildingaroundtheirneedsand tendenciesisessential.
Wehaveworkedwithclientswhoknowhowmanyhorsestheywantandusethatasaself-limiting factor.Thisworkssometimes,butnotalways.Forexample,youcanplanfor8horsesbutendupwith 19ontheproperty.Forthisreason,thinkingaheadonthisissueisequallyimportant.
Belowaresomepreliminaryquestionstoconsider:
HowmanyhorsesdoIintendtokeepinthisbarn?1. Whatbreedarethehorses? 2
Whatistheaveragesizeofourhorses? 3
WillIbebreedinginthisbarn?Willtherebeastallionontheproperty?4.
YOUR HORSES
BUILDING TYPES
Intoday’smarket,therearevarioustypesofbarndesigns,buildingmaterials,andbarntypes Thatbeing said,thereare3to4basicstructuresthataremostpopularforhorses
Thefirst–andmostcommon–isthepostandbeambarn.Thisbarnisalsoreferredtoasapolebarn,a framedbarn,andapanelized,orpre-fabricated,barn.Secondly,wewilldiscussclear-spanbarn structures.Thirdly,wewilldiscusstheincreasinglypopularblockbarnsfoundinhotterclimates.Lastly, wewilldiscussotheroptionssuchasstablinginsideindoorarenas.
Post & Beam Barns
Itislikelythatyouhavebeenthroughhundredsofhorsebarns.Ifso,itislikelythatyou’vewalkedin numerouspost-and-beambarnsgiventheirpopularity.Thepost-and-beambarn(alsoknownasa“pole barn”)isespeciallypopularalongtheEastCoast.
Thisparticularstyleisverypopularbecauseitcanbeinstalledcost-effectively Sometimes,ageneral contractorputsuptheshell,andthebuilderdoestheremainingwork
Additionally thepolebarnhascostadvantagesbecauseitisusuallypre engineeredformostlandsites
YOUR HORSES
Panelized Barns
Panelizedhorsebarnsarealsoreferredtoas“prefabbarns.”Theseparticularbarnsaresoldunder commonbrandnamesandareoftenfoundinCalifornia,Oregon,Washington,andTexas Panelized barnsarecost-effectiveandsatisfactoryagriculturalstructuresthatdothebasicjobofhousingyour horse Thesestructurescanalsobebuiltquickly,withfewerpermitissues Thatbeingsaid,these barnsofferlittletonoflexibilityforalternativeusesandarearchitecturallyuninspiring
Clear Span Barns (Steel & Wood)
Clear-spanbarns(bothwoodandsteel)mayormaynothaveaframedwall Theydousethetrussto clearthespanintheshortersideofthebuilding.Thetrussesareusuallyoneofthreetypes:timber trusses,metaltubetrusses,andscissortrusses.Theseengineeredbuildingstendtorequiresavvy buildersduetotheneedforafoundation.
Oncepermittingandthefoundationarecomplete,aclear-spanbuildingcanbebuiltquicklyoff-site andassembled(bolted)togetheronthejobsite.Intermsofbudget,clear-spanbuildingscanbe utilitarian,usinginexpensivesidingandroofingmaterials.Theycanalsobeextremelycostlyifyou addstonewalls,slateroofs,andsteeperroofpitches
Clear-spansteelbarnsarefantasticintermsoflongevity,ashorsesdonothaveplacestochew They alsoofferclientsflexibility,asthebuildingcanbemulti-purposeintheeventofafuturesale
Framed Barns
Framedbarnsofferthemostflexibilityandfunctionalityinpost-and-beamconstruction These particularbuildingsarecommonlyusedwhenanupperstoryisneededforabarn,suchasforan apartment,office,orotherpurpose
Framedbarnsarebuiltsimilarlytohomesbecausetheyuseadoublewallconstruction This constructionallowsformorearchitecturaldetailandcreativityintheuseofbuildingmaterials The sky(andaclient’sbudget)istrulythelimitinthesebuildings
Indoor Arenas with Stabling
Coveredenclosedarenasaregainingpopularity,especiallyinregionswithharsherclimates. Althoughyoumighthaveabarninadditiontothearena,itcanbeworthplanninglimitedstablingin thearena.Horsestallscanbeinstalledoffthearena’slongsideorshortside,dependingonyour quantityneeds.Anindoorarenaalsooffersflexibilityasthesidespacescanaccommodateeverything fromstallstoofficespacetovehiclestorage.
Block Barns (CMU) YOUR HORSES
Forstarters,“CMU”isalsoknownascinderblock.Block(CMU)barnsareincreasinglypopularin geographieswithwarmerclimatesthatarepronetoinclementweather.Blockbarnsareverypopular inFloridabecauseoftheirstrengthagainsthurricanesandtropicalstorms.
CMUbarnsmakeforagreatstructurethatwilllastagainsttheelements,includingweatherandthe day-to-daywearandtearofhorses Wedorecommendfindingahigh-qualitybuilderforanybarn structure,butespeciallyblockbarns Thisisbecausetherearecertaindetailsthatneedtobedone righttoensureyourbarnissafeforyourhorsesandbuilttolast Forexample,somehorseowners expressconcernsabouttheblock’shardness Cinderblockwallscanbecoveredwithpaddedrubberin thehorsestalls Additionally,blockedgesandcornersmustbeeithergrounddownorcoveredwitha steelangleiron
Ifyouareconsideringablockbarn,wealsorecommendloopinginourteamwellinadvancetoensure soundcommunicationbetweenthebuilder,ourteam,andthearchitects Thisensuresthatopenings areaccurate,sostalls,doors,partitions,windows,andothercomponentsarecorrectlybuilt
PUTTING TOGETHER THE RIGHT TEAM
Asequestrians,weunderstandjusthowmuchtime,energy,andfinancialresourcesgointobuilding yourdreambarn.
Formanyclients,adreambarnisaonce-in-a-lifetimeproject Thatiswhyitiscrucialtoworkwiththe rightindividualsandcompaniestoensurethebestbarnbuildpossible
Anyhorsebarnisbuiltprimarilybytwoparties,includingtheclient(yourself)andthebarnbuilder (orcontractor) Althoughmanyotherindividualswillbeinvolved,yourbarn'ssuccesswilllargely dependonyourrelationshipwiththebuilder
Forstarters,let’scoverthedifferenttypesofconstructionhelpavailabletoyou Understandingthe differenttitlesandtheircapabilitiescanbequiteconfusing Herearecommontypesofconstruction contractors:
HANDYMAN –
Ahandymanisusuallygreatforfixingandinstallingsmalleritemsaround yourbarn(orhome)aftertheconstructioniscomplete.
FRAMER –
Aframerisusuallybestfortheskeletonstructuralpartsofyourbarn(orhome).The framerisusuallynotinvolvedwiththebarn’sfoundation,northeexteriororinteriorfixings We sometimesseeclientshireaframertoinstallexteriorwindowanddoorcomponents,butthiscan leadtoconfusionduetotheframer’sexpertise
GENERAL CONTRACTOR (GC) & BUILDERS –
Thisisthelastandfinalcategoryof industryprofessionalsforbarnconstruction Theyarealsoexactlywhowerecommendtohirefor yournewbarn’sconstructionorevenrenovation Bothtypesofindividualswillmanagethe constructionofyourbarn
Finding the Right Contractor and Builder
Onceyouhavetheabovebasicunderstanding,wefindthebestwaytofindahigh-qualitybuilderisto useyourownnetwork Werecommendaskingyourfriends,family,coworkers,andevenrealestate agentsforrecommendations Referralsarealwaysagreatwaytofindtherightpartnerinyourbarn project
Onceyouhaveafewreferrals,werecommendlisteningtotheirexperiencesbeforespeakingwitha contractor.Somequestionstoaskyourcolleagues:
1.
Which builder or contractor did they use for their project?
2 What is the quality of their workmanship? (“Good” differs person to person We always recommend asking the client’s contractor for more references so you can see their work in person.
What particular work did the contractor perform? (This question is key because a contractor could work on a high-quality shed row barn, but lacks experience building a high-quality enclosed center barn aisle Hence, it is possible that a contractor is highly skilled in one type of build but not as skilled in another type
3 How was the communication before, during, and after the barn build? (Good communication will make your life 1,000x easier and help give you peace of mind)
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4. Did the contractor provide a timeline and stick to it? 5 What was the payment structure of the build? 6 Did the contractor provide suggestions on the build’s safety, materials, and other considerations? (A good contractor will provide their recommendations based on their experience)
YOUR TEAM
Onceyou'venarroweddownonacontractor,werecommendhavinghonestandtransparent conversationsabouttheentireprocess Dependingonvariables,abarncantakeanywherefroma monthtohalfayeartobuild Belowaresomediscussionpointsandquestionstotouchupon:
Discuss the barn site’s location, topography, and climate
Anexperiencedcontractorwillmakemanysuggestionstailoredtoyourspecificsite,ensuringthe barnisbuiltforsuccess
Discuss and understand the barn builder’s “lead time.”
Intoday’sever-competitivelabormarket,itissometimesdifficultforabarnbuildertoprocureproper labor.Thismighttranslatetolongertimetablestobuildyourbarn.Whetheryouhaveasmallorlarge barn,it'scrucialtounderstandyourbuilder’stimetableandanypotentialvariablesthatmightdelay yourproject.
Understand the builder’s crew.
Itisgoodtoaskaboutthesizeofthecontractor’steamandtheirexperience.Itisalsobeneficialto understandwhetherthecontractor’screwistheirownoriftheyareusingsubcontractors.
Discuss how long the builder will stand behind their work
Thisisequivalenttoawarranty Likeanythinginconstruction,hiccupswilloccur Howwillyour builderreacttothose?Willtheystandbehindtheirworkforyearsaftercompletion?
Discuss your hopes and wishlist for the barn
Thisgoeswithoutsaying,butitisbesttodoyourresearchonyourwishlistandshareitwithyour barnbuilder Althoughastallandbarndoormanufacturer(likeAmericanStalls)willprovide
Working with an Architect
Selectinganarchitectisjustascrucialaschoosingtherightcontractor.Anarchitect’sbenefitsare immeasurable,asthethoughtfulplanningwillsaveyouinthelongrun.Anexperiencedequine architectwillhelpwiththeaesthetics,butwillalsohelpyoudesignanefficientandfunctionalbarn. Thebestequinearchitectswillhelpyouthinkaboutyourbarnsite’slocation,thesurrounding topographyandclimate,andotherdetailsthatwillimpactyourbarnexperience.
Onceyouspeaktoanarchitect,besuretocommunicateyourvisionandneeds Asisthecasewith anything,themorehonestyouareupfront,theeasiertheprocesswillbeintheend Itiseasyforyou orthearchitecttogetcarriedawaywithouthavingproperdiscussionsofyourbarn’svision,budget, horses’breeds,andhowyouseethebarn’sfunction
Whilewerecommendthatclientsworkwithanarchitectiftheirbudgetallows,sometimesan architectisunnecessary Forexample,yourproject’sscopeorbudgetmaynotrequireanarchitect Anotherexampleiswhenaclienthasadiscussionwithanarchitectandrealizestheywantasimple, prefabricatedbarn Inthiscase,youdon’tneedanarchitect
Anarchitect'sinvolvementistrulydependentonyourbarn’spurposeandtheproject’sbudget.No twoprojectsarethesame.Forexample,wecanworkwithaclientwhowantstobuildan18-stallbarn withanindoorarena,office,laundryroom,washarea,tackroom,andclientlounge.They’dlike Europeanstallfronts,DutchDoors,shutterwindows,andrubberpaversasflooringfortheir stabling.Theconversationwillinevitablyleadtoaquotationwhenaclientasks,“Whatwill somethinglikethiscost?”
Thetrueansweristhatsuchaprojectcouldcostanywherefrom$80,000to$3M Thefirstamount
YOUR STALLS
SELECTING YOUR STALL FRONTS & DOORS
Yourchoiceofastallfrontiscrucialtoyourbarn'ssuccess Thehorsestallfrontanddoorarethemost usedcomponentsinabarn,openingandclosingdozensoftimesperday Yourchoiceinthestallfront willgreatlyvarydependingonyourpersonalpreference,yourhorses,andotherpersonalfactors
Tostart,therearetwobasictypesofhorsestalldoors:slidingandhinged Bothtypescanrange drasticallyinpricefrom$400tomorethan$6,000 Avalue-engineeredstallfrontwillusuallyentaila "kit" Thissimplydescribesakitofhardware,lumber,grills,U-channels,andothercomponentsthatyou mustassembleon-site Thisalsousuallyincludesframingthestallwithyourownlumber Incontrast to akit,our"fullywelded"productiscompletelyframed.Theseproductsareusuallyreadytoinstallon-site, butstillrequiredoorpostsinmostcases.
Intheindustry,youwillseeawidevarietyofstallsystemsintermsofquality,design,andsafety.The lower-endoptionswillhavewidebarspacingandusesolidsteelgrills.Ataglance,mosthorseowners can'ttellthedifference,butthesesolidbarsareactuallyveryweakbecauseoftheirtensionpoint, comparedtoourhollowbars
Additionally,thebarsareusuallyspacedveryfarapart,creatingasafetyhazardforhooves Bewareof these,asthebarsareweakandthespacingisincorrect Lastly,inexpensivestallfrontsmayalsobemade fromblack(carbon)steelorgalvanizedsteelandthenspray-paintedonthewelds Bewareofthisfinish, asitcancausetheweldandjointtorust (seesectiononcoatingsforsteelstallfrontsandpartitions)A higherqualitystallfrontsystemwillincludepre-galvanizedsteelwithalong-lastingpowdercoatfinish Althoughthesepointscomewithacost,theseare"upgrades"thatshouldnotbecompromised
BelowarespecificationsthatwefeelstronglyaboutandarestandardatAmericanStalls:
Thepreviouspageissimplyastartingpointforthebasicsofhorsestalls.Similartoour philosophyforbarns,yourchoiceinstallswillbeuniquelydrivenbyyourlifestyleandyour horses.Wehighlyrecommendspendingtimemakingacomprehensivelistofquestionsthat helpyouunderstandhowyouliketouseyourhorsestalls.
Cost Drivers in Horse Stalls
Beforewemoveon,we'dliketocovercostdriversinhorsestallfrontsinmoredetail.Wehavemultiple phoneandemailconversationsperdaywhereaclientwillsharephoto(s)ofastallfrontdesign.Often, clientswillshareaparticularphoto,buthavelittleexpectationofthestall'sactualpricingoran accurateballparkestimate.Asaluxurystallmanufacturer,wecompletelyunderstandthis,andwe'd liketoaddressitbyexplainingthecostdrivers
Whileweworkwithclientswhohavefewbudgetrestraints,wealsoworkwithclientswhohaveavery firmbudget.Inanycase,weunderstandtheneedforvalueforanyproject.Tobegin,twofactorstend tobethemaincostdrivers:
YOUR STALLS
SlidingStallFronts Thefirstdriverofcostisthe distinctionbetweena"kit"stallandafullyweldedstall front Asmentionedearlier,astallkitincludesa weldeddoor,trackhardware,alatch,channels,and grillwork Buildingthestallrequireslaborandtime on-site
Thecostisdrivenwhentheclientchoosesourfully weldedsystem,whichincludesacompleteframe, removingtheneedtobuildandframethestallon-site
Thenextcostdriverinaslidinghorsestallisthe additionofayokeinthedooritself.Yokesarethe openingthroughwhichyourhorsecanhangtheir headout.OurbasicyokeisaV-shapedyokeopening thatrequiresthesteeltubingtobebentintoshape. Thecostcanbedrivenupfurtherifaclientchoosesa hinged,drop-downyoke,whichispopularinbarns
Drop-downyokesaremoreexpensivedueto additionalwelding,hingehardware,theadditionofa stainlesssteelplungerlatch,andanextra-filledyoke piece
Drop-downyokesaremoreexpensivedueto additionalwelding,hingehardware,theadditionofa stainlesssteelplungerlatch,andanextrafilledyoke piece.
Fully Welded Stall Front
Kit Stall Front
V-Shaped & Rectangular Yokes (Left)
Hinged Drop Down VShaped Yoke (Right)
YOUR STALLS
EuropeanStallFronts–Thefirstdecisionthatdrivescostinahinged,EuropeanStallFront("Euro") istheheight.Webuildboth"low"EurosandhighEuros.
Themaindifferencebetweenthetwoissimplytheheightoftheleftwing,thedoor,andtherightwing
Theadditionalsteelmaterialisthemaincostdriverbetweenthetwotypes
Theseconddecisionthatdrivescostisthearchandradiusbendoftheleftwing,therightwing,and thetop-mosttubingofthedoor OurEurosstartwithastraightdiagonaldesignorabentdesign
Laborandspecializedmachineryisthenrequiredtofurtherbuildlargerswoopsandarches
Theverylastcostdriveristhefinishingtouches,suchasendcapsandfinials.Thesecanbemade outofeitheraluminum,brass,orpowder-coatedtomatch.Eachcap(left)orfinial(right)ishandpolishedin-housetoensurethemostelegantfinishingtouchonyourstall.
Diagonal Design
Bent Design
Arched Design
YOUR STALLS
AllStallFronts–TherearedecisionsthatimpactbothSlidingStallsandEuros.Apopularoptionis toplace1"roundbarsorsteelmeshinthestallbottom.Thisbottomfillcanbeplacedoneitherthe doorbottomoracrosstheentirestallfrontbottom.Thisaddition(i.e.1"roundbarsormesh)isone ofthelargestcostdriversforanystall.Thisisbecausethisdesignusesasignificantamountofsteel.
Additionally,unlikemanymanufacturers,ourmeshandbarsareweldedateverysinglejointfor extrastrength Whenaddingameshorbars,clientswillalsoaddaShavingsGuardtokeepbedding insidethestall ThisShavingsGuardcanbeeitherasteelsheetoraweldedHVHthatisreadyfora woodpiece Thisisanothercostdrivertothestallduetotheadditionalsteelmaterialandwelding
Theabovecoversagoodmajorityofthingstoconsider,butitisnotacomprehensivelistof upgrades It'strue–itcanusuallybedoneifyoucandreamit Wehopetheabovehelpsyou understandhowtochooseastallfrontthatdrivesthemostvalueforyourbarn
Lastbutnotleast,optionsforfeedingandwatering Feedupgradescanincludeafeedholeopening, agrilledfeeddoor,arevolvingfeeddoor,andothercustomoptions.EachoptionrequiresCAD design,additionalsteelmaterials,welding,andhardware(i.e.hingesandlatches).Thisisequally trueforwateringoptions,suchasaddingwaterspigotsforwaterbucketsorinstallinganintegrated automaticwaterer.
Theabovecoversagoodmajorityofthingstoconsider,butitisnotacomprehensivelistof upgrades.It'strue–itcanusuallybedoneifyoucandreamit.Wehopetheaboveallowsyouto understandhowtochooseastallfrontthatdrivesthemostvalueforyourbarn
Mesh Door Bottom & Wood Shavings Guard
Bar Door Bottom & Wood Shavings Guard
YOUR STALLS
CHOOSING THE LUMBER
Yourchoiceoflumberisimportantbecauseitmakesupsomuchofthehorsestall Theselectionwill dictateyourhorsestall'sstrength,safety,andlongevity
Tostart,belowisanoverviewofthecommonlyusedmaterialsandlumberinhorsebarnproducts:
1.
Softwoods – This includes our most popular option for stalls, Southern Yellow Pine. We always recommend using the highest grade of wood that is possible for your project’s budget. Softwoods are generally not recommended for use inside horse stalls. They are prone to warping, twisting, and shrinking over time. Southern Yellow Pine lumber is the only viable option in the softwood category for barns and stalls
3.
2 Exotic Hardwoods – Exotic hardwoods are extremely dense when compared to domestic hardwoods and softwoods. This profile allows them to withstand the rigors of a horse stall. This makes exotic hardwoods well-suited for horse stalls and barn doors. This option lasts longer and provides your barn with a higher quality aesthetic, but it is also one of the most expensive lumber options. Exotic hardwoods include options such as Brazilian hardwood.
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Domestic Hardwoods – Hardwoods are more expensive than softwoods, but last much longer due to their density Many domestic hardwood options are also available in FSC-certified versions Domestic hardwoods include Douglas fir, mahogany, and oak
Plastic (HDPE) Infills – Lastly, a growing alternative to wood is plastic (HDPE) infills These are synthetic materials designed to resemble wood The benefit of plastic HDPE is its longevity and durability The synthetic fill keeps its finish longer It is also easier to clean, so it is a more sanitary material compared to wood Lastly, HDPE fillers primarily use recycled post-consumer plastic, which has a more positive environmental impact.
Giventhewidevarietyofwoodandfilleroptions,itcanbedifficulttomakeadecisionaboutthebest materialforyourbarn.Althoughtherearesomebestpractices,eachbarnisuniqueduetoitslocation, surroundingclimate,andthebarn’soveralldesign.
YOUR STALLS
AbarnlocatedinNewEnglandwillexperienceheavysnowandheavywinds ThisNewEnglandbarn willoftenrequiredifferentconsiderationsthanabarnlocatedintheSouth,whereissueswithinsects, humidity,andrustarise Belowisalistoffactorstoresearchandconsiderwhendecidingonlumber:
Doesthelumberhaveagoodnailingholdingpowder? 1
Istheremoderateandreasonableshrinkage? 2
Isthelumbereasytoworkwith,finish,andclean? 3
Willthelumberresistdecayandwarping? 4
Doesthelumberwithstandsplitting? 5
Theaboveisastartingpointforyourdecisionregardingthewoodforyourhorsestallsandbarn doors.
CONCLUSION
Whilethisguideisfarfromcomprehensive,wehopeitservesasagreatstartingpoint Thereareso manyotherthingstoconsider,includinglighting,heating,andflooring Thatbeingsaid,wehope thatthisguideservesasastartingpointforthinkingaboutyourbarn,itsstructure,andthehorse stallsystems
Itisourhopethatthisguidehasmadeyouabitmoresavvy,ensuringthatyourbarnissetupfor success Atourfirm,wetrulybelieveinthephilosophyof"builditrightornotatall"
Wegotogreatlengthstonotonlymanufacturetheverybestmaterialsbutalsoprovidethebest educationtoourclients.Eachbarnisspecialandunique.Itisourprivilegetohelpyouensureyour dreambarnisbuiltrightandbuilttolast.Ifyouhaveanyquestions,youcanalwaysreachateam memberat(855)957-8255orsale@americanstalls.com
