You would not believe the kind of questions I get during sales calls for our SmartStall™. How old is your oldest stall? (Our first one was installed in 2006!) How thick is your foam pad under the topcover? (1 1/8”) How thick is the full mattress system together? (Around 1 1/4”) The next question I normally get is “what flooring should be under the mattress system?”
When building a barn, you normally have a subgrade (your soil), then 2-4 inches of a subbase, composed of aggregate stone, and then 2-4 inches of a compacted crushed stone, such as limestone. There are a variety of floors that you can have in your barn. Some choose to keep this crushed stone base as the floor of their entire barn, some pour a cement center isle while keeping crushed stone in the stalls, while others will pour a cement floor inside the entire barn. Pouring cement in the entire barn, or at least a cement center aisle are the best options for horse owners. If you for some reason cannot pour any cement, there are ways to make crushed stone work. The most important thing when utilizing a crushed stone floor is to make sure that it is fully compacted. If you are using crushed stone as your entire floor, you will most likely disrupt only the top 1/2 inch in the aisle way. Everything under that 1/2 inch will not be disrupted if it has been compacted correctly. Both cement and crushed stone are not adequate enough for a stall floor. There should be some sort of barrier between your horse’s hooves and the hard surface. Think of how much our bodies hurt from standing on concrete all day, a horse is the exact same. They don’t want to stand or lay on a hard surface, and adding extra bedding for padding is not much help. The stall requires some sort of cushion for the horse.
Our SmartStall™ Mattress System works great with both crushed stone floors and cement floors. IGK SmartStall™ system is composed of foam and a rubber topcover. The foam lies directly on the floor, while the topcover is installed over the foam and attached to the stall walls, sealing the foam under a waterproof surface. When you have a crushed stone floor, we recommend that you have a plastic sheet under the foam, so the moisture that sometimes works its way up through the crushed stone, does not reach the foam.
If you have any other questions that you would like us to answer in a blog please let me know!