Stall Project Tips

Tips from Yash Balasaria of American Stalls

by Lisa Kiley – Published in Horsemen’s Corral February 2023

American Stalls is one of the world’s premiere stall manufacturers. If you have been in the industry long enough, chances are that you have been in a barn that utilizes some of their products, from gorgeous European style stall fronts to safe portable stalls that line the aisles at your favorite event venue. American Stalls makes everything from the basic components to the finishing touches to make a barn safe and user friendly for horse and human alike.  I got the chance to talk with Yash Balasaria who is the CEO of American Stalls and second generation in stall production which started back in 2005.  The company’s roots in steel manufacturing go back to the late 1990’s, bringing decades of experience using sound construction techniques to build some of the best stalls on the market.  

I asked Balasaria to describe some tips that he would recommend for someone starting out the planning process of a stall project.  He advised that while no two barns are the same there are some things that everyone should consider when starting to make plans for their facility.  First, it is important to think about the key functions of the barn and what the daily flow of work in the barn will be.  This can be the difference between making chores an easy experience or truly a chore.  Balasaria advised that when his team works on a project, they ask the barn owners to take the time to really think through layout and flow in the barn, they provide resources that can be used to work through different options to make the facility uniquely their own.  Exploring these options helps the client get what they really want and avoid things that could be a pain point down the road.  In addition to the interior flow of the barn, it’s also important to look at the geography and topography of the land in general for more insight on how a project should be laid out.  

Balasaria stressed the importance of ventilation and sunlight in the barn which add to the overall health and safety of the barn.  He suggested adding windows that can be opened providing natural light and better air quality for the horses.  Where appropriate, he encouraged using glass windows as a great option for barns.   Grill work and mesh on stall fronts and gates can also allow for more ventilation with the added benefit of being able to see the whole horse when walking through the barn, which can make it easier to spot any issues that need to be addressed.  Adding grillwork on the sides of the stall not only increases airflow but depending on how the horses in the barn get along, can create opportunities for socialization providing enrichment of the horses day-to-day.  

Dutch doors on the exterior of the stall are something else that Balasaria strongly recommends.  The doors not only add light and air flow but provide additional options for egress.  This is beneficial not only for easy pasture turnout, but also in the case of fire. In critical times sliding doors can often be easier to manage than swinging doors.  While traditionally Dutch doors often swing out, American Stalls offers a sliding Dutch door option which can not only be easier to open but is also a space saver.  Balasaria added that having strong reliable latches and high-quality hardware in the barn can make a dramatic difference in the ease of moving through the barn space.  Being able to trust in the construction of the product when you need it the most is important whether you are just looking to make chores run along smoothly or need to make fast moves in the case of an emergency. 

Safety in construction is also on the top of Balasaria’s list when it comes to materials selection.  He advised that when sizing up products for your facility, take the time to educate yourself about the differences in materials construction.  He urges potential customers to ask about how the materials are fabricated.  Is the steel galvanized? Is there a powder coat to help protect against rust?  How are the welds done? He explained that interior welds and seamless welds provide additional strength and durability vs. components that may be tack welded and are prone to breakage over time or under stress.  He also urged people to invest in items that have been welded vs.  components that are bolted together.  Any area that is bolted vs. welded will have weaker points and don’t hold up as well over time. Safety also comes into play when thinking about bar spacing, making sure that bars are close enough together to prevent a horse from getting a hoof caught up is very important.  

Balasaria provided some tips for setting up a barn on a budget.  He advised that going through the process of really planning out the space can help prevent regrets further down the line which can result in costly renovations.  Similarly, investing in the best quality materials can cost more upfront but will provide long-term durability that will save money over time.  He also urged the budget conscious customers who are handy to consider kits that require some DIY. Putting in some of the construction work on your own is a great way to save money vs.  buying totally prefabricated fronts and partitions.  Want to add a wow factor to your barn?  Balasaria suggested investing in beautiful stall doors which can really create that show stopping look without having to replace the whole stall front.  Updating the lighting and fixtures in the barn is a great way to highlight the facilities features as well as add safety.  Hardware is another great way to update the look of your barn and add that luxury feel.In closing Balasaria stressed the importance of working with a company that you can trust.  He shared that all the members of his team are horse people and have many years of horse experience in different facets of the industry.  This experience can be invaluable when working through a project because they have the background to understand the specific needs of each customer and be able to offer thoughtful insights on every project from a four-stall home barn to a 1500 stall event facility.  Having a good relationship with the company you are working with is key to creating the barn of your dreams.