When Planning Your Barn Building Project, Watch Out for These Common Mistakes
Stalls That Are Too Small
As you plan your barn, carefully review your Horse Stall dimensions. Your horses may be unable to comfortably move around and relax in stalls that are too small, and small stalls can increase the risk of your horses getting cast. If you find that you’re trying to squeeze enough horse stalls into your barn’s dimensions, you may need to rethink your plan and build a larger barn. Otherwise, you might come to regret your small stalls, which isn’t easy to correct when working within a barn that’s really too small for the number of stalls you need. 
At American Stalls, we offer a variety of custom Horse Stall Systems designed to fit your barn’s size and vision. Whether you need spacious European Stall Fronts, Sliding Stall Fronts, or fully custom designs, our team will help you create a layout that prioritizes your horse’s comfort and safety. Our rule of thumb is that 12'x12' is a standard minimum and necessity. Our clients can then often choose larger stalls as needed - whether it's for foaling purposes, larger breeds such as draft horses, or simply personal preference to have a larger stall.
Popular, larger stall sizes include 14'x14, 16'x16', and even 24'x12. Continue on our website to explore our options and design the perfect stall system for your barn. You can also learn more about our thoughts on the ideal horse stall size here.
Slick Concrete Aisleways or Narrow Aisles
When you plan your barn aisle way, think carefully about how it will affect your horses’ safety. Concrete aisles are popular because of their durability. Still, concrete can be incredibly slick, especially when wet, and your horses wear shoes. Narrow barn aisles are another common mistake, and they can lead to injuries to horses and handlers if horses spook or get caught up on tack trunks or other objects.
Plan for a barn aisle that’s at least 12 feet wide. If you have to go narrower, avoid putting objects in the aisle, like tack trunks. To maximize traction, we highly recommend installing rubber pavers throughout the aisle.
Note: Below is an example of a barn renovation featuring concrete aisles with our green interlocking rubber pavers.
These pavers are slip-resistant, comfortable underfoot, and can help control bacteria. They’re an excellent way to maximize safety in the aisle, plus they have an eye-catching and elegant look that will elevate your barn’s style. Our clients rave about just how comfortable they are on their feet while also providing peace of mind as there is less slip and slide in the aisle on slick concrete. Often forgotten, one benefit is how they also help with the barn's acoustics - dampening the noise of hooves, feet, and machinery hitting the concrete. 
Most American Stalls projects incorporate our Rubber Pavers because they provide exceptional grip and traction, significantly reducing the slipping hazards often associated with concrete. Beyond safety, our pavers also enhance comfort, available in 7/8" or 1-3/4" thickness. While these measurements may seem minor on paper, our clients consistently tell us that the difference is remarkable—offering far greater comfort than both concrete and traditional rubber mats. Read more why we recommend rubber pavers in most horse barns.
Lack of Ventilation
Ventilation plays an important role in your horses’ respiratory health, so consider how you’ll create ample airflow throughout your barn. Our horse Barn Windows are one way to improve cross ventilation in your barn. They are custom-built to your specifications and can enhance airflow throughout your barn. They also increase natural light and are available in many styles to suit your local climate. You can order windows with or without glass in-fill, with customization options from glass designs to lumber fill; you can make these windows unique to your barn.
Consider investing in barn fans, too. Fans can help circulate air on hot summer days when there isn’t much of a breeze, and the air circulation can help keep your horses cool and discourage flies from spending time in your barn.
Proper barn ventilation and natural light are essential for maintaining a healthy and comfortable horse environment. Incorporating custom Barn Windows can help regulate air quality, reduce bacteria, and enhance overall well-being while adding to your barn’s aesthetic appeal. Explore our guide on Barn Window Designs & Options to learn how the right windows can transform your space.
Pasture Gates in Low-Lying Areas
When designing your pastures, carefully consider where to install the pasture gates. Placing gates in low-lying areas of the pasture will inevitably lead to mud problems, which can cause lost shoes, tendon and ligament strains, poor hoof health, and risks for humans trying to navigate the gates. If you can’t avoid placing your gates in a low-lying location, then be prepared to install mud control grids under and around the gate areas.
Mud control grids can be installed with minimal site preparation. They’re highly durable, weather resistant, and can withstand heavy traffic, including horse traffic. They feature an enhanced grip to help keep humans and horses safe in wet conditions, and they help keep you and your horses up and out of the mud. They’re ideal for persistently muddy areas in your pastures and around your gates.
Stall Grill Bars That Are Spaced Too Far Apart
The spacing between your stall grill bars is a commonly overlooked but vital detail. When choosing or designing your stall partitions, choose grills that are spaced to prevent hooves from possibly becoming stuck. Some lower-end grills can have four or five inches of space between the bars; if a horse kicks or rears, they could catch a hoof in the grill and sustain serious injuries.
At American Stalls, we use 1-inch bars in our grills for durability. We place the bars on 3" centers for the upper grills, meaning 2" of spacing from the end of end bars. Also, we space lower grills on 2.5" centers, meaning there are just 1.5 inches of space between the bars. This mindful spacing prevents even the smallest hooves from getting stuck and helps to keep your horses safe.
Too Little Storage
Remember to plan for plenty of storage space in your horse barn. There are many ways to maximize barn storage, such as taking advantage of the vertical space in your tack room or designing your feed room to allow for floor and cabinet storage.
Always create more storage spaces than you think you’ll need. Chances are you’ll fill those storage spaces and be glad you created them.
Weak or Inappropriately Spaced Lighting
Barn lighting plays a key role in your barn’s atmosphere and affects how well and safely you can work in your barn. Lighting that’s too weak or inappropriately spaced can lead to poor visibility and frustrating work in your barn.
In addition to maximizing natural sunlight with barn windows and skylights, look for products that will work specifically for your barn. We offer top-quality interior and exterior lighting for your horse barn. We’ve updated classic designs to create a range of Barn lighting fixtures that feature modern finishes and are exceptionally durable, so all your barn lighting is built to last.
Contact American Stalls as You Design Your Barn
At American Stalls, we’re here to support you through every stage of planning and building your horse barn. We can build custom products to your dimensions and your barn’s unique style, and we would be happy to help you determine which products are right for your vision and your barn design. Contact us today at (855) 957 8255 or email us at sales@americanstalls.com to schedule a sales and design consultation or complete our inquiry form.
