Stall Flooring Specification

Horse Stalls – Rubber Mat Flooring System

For Architectural & Construction Documents

1.0 GENERAL

1.1 Scope of Work

Provide and install a complete rubber stall mat flooring system for horse stalls, including sub-base preparation, mat layout, cutting, fitting, and final installation, suitable for long-term equine use in private, commercial, and institutional horse facilities.

This specification applies to:

• Individual horse stalls
• Box stalls
• Wash stalls (dry areas only unless otherwise specified)

1.2 Design Intent

The stall flooring system shall:

• Provide a durable, non-slip, shock-absorbing surface
• Support daily stall cleaning and periodic deep sanitation
• Prevent mat movement, curling, or edge lift
• Minimize moisture retention beneath mats
• Support equine joint health and staff safety

2.0 ACCEPTABLE PRODUCTS

2.1 Approved Manufacturers

Stall mats shall be the following pre-approved products:

• Red Barn Stall Mats

No substitutions permitted without written approval from the Owner or Owner’s Representative.

2.2 Material Requirements

Mats shall be manufactured from:

• Solid vulcanized rubber
• Non-foam, non-laminated construction
• No recycled crumb infill exposed at surface
• Suitable for continuous equine traffic

2.3 Physical Properties

• Thickness:
  • Minimum ¾” (19 mm)
• Size:
  • Minimum 4’x6’
• Surface Texture:
  • Slip-resistant, non-directional texture
• Edge Profile:
  • Straight edge or tight interlocking edge
• Water Absorption:
  • < 1%

3.0 SUB-BASE REQUIREMENTS

3.1 Subgrade Preparation

• Remove all organic material and unsuitable soils
• Proof-roll subgrade to identify soft areas
• Correct and recompact any deficient zones

3.2 Granular Base

Provide a compacted granular base as follows:

• Material: ¾” minus crushed stone or limestone screenings
• Thickness:
  • Minimum 4″ compacted
  • 6″ recommended on clay soils
• Compaction:
  • Mechanically compacted to refusal
• Finish:
  • Laser-leveled, flat, smooth, and firm

Note:
Sand, screenings without compaction, bedding material, or loose fill are not acceptable substrates.

4.0 MAT LAYOUT & INSTALLATION

4.1 General Installation Requirements

• Mats shall be installed loose-laid
• Adhesives are not permitted in standard stalls
• Installation area shall be clean, dry, and at ambient temperature

4.2 Layout Pattern

• Mats shall be installed using a staggered / offset seam pattern (brick-bond layout)
• Continuous seams running front-to-back or side-to-side are not permitted
• No seams allowed within 600 mm (24″) of stall door openings

4.3 Doorway & High-Wear Zones

• Door threshold area shall be:
  • One continuous mat where possible
  • Free of seams directly under door swing or sliding path
• Mats shall terminate tight to door frames or thresholds
• No raised edges, ramps, or lips permitted

4.4 Cutting & Fit

• Mats shall be cut cleanly and tightly to:
  • Stall walls
  • Columns
  • Door frames
• Gaps greater than 6 mm (¼”) are not acceptable
• All cut edges shall be square and smooth

5.0 CLEANING & MAINTENANCE CONSIDERATIONS

5.1 Cleaning-Oriented Layout

Mat layout shall allow:

• Partial mat lifting for sanitation
• Independent removal of rear (wet-zone) mats
• No requirement to remove full stall flooring for routine cleaning

5.2 Moisture Control

• Base shall remain firm and dry under normal use
• Mats shall lie flat with no rocking or voids
• Installation shall not create moisture traps beneath mats

6.0 QUALITY CONTROL

6.1 Installation Tolerances

• Mats shall lie flat with no rocking under foot
• Adjacent mat height difference shall not exceed 3 mm (⅛”)
• Finished surface shall be smooth and continuous

6.2 Inspection

Prior to acceptance:

• Walk entire stall surface
• Verify no movement under load
• Confirm tight perimeter fit
• Confirm seam alignment complies with specification

7.0 WARRANTY & CLOSEOUT

7.1 Product Warranty

• Manufacturer’s standard warranty shall apply
• Warranty excludes damage due to improper base preparation or misuse

7.2 Closeout Documentation

Provide:

• Product data sheets
• Maintenance guidelines
• As-built layout reference (recommended for large barns)

END OF SPECIFICATION

Red Barn Stall Matting – Material & ASTM Test Data

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Author: impdigital