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ComfortStall® Installation Instructions

If you have any questions about installation, feel free to call us at 888-307-0855

Your ComfortStall® system is designed for simple, easy installation in almost any stall, no matter what the construction. ComfortStall® is comprised of three different components—a layer of engineered, closed cell "water proof" precision padding, a pliable five-layer rubber topcover, and anchor strips that secure the topcover to the walls of the stall.

Basic Items Needed

• Sharp utility knife and extra blades
• Electric drill or cordless screwdriver
• Long retractable measuring tape
• Long straight-edge
• Pencil or marker
• 1.5-2" galvanized wood screws, non-rust self-tapping metal screws, or Tap-Con screws for concrete
• Duct tape


Stall Preparation

ComfortStall® is installed by laying the foam padding layer down on a level, firmly compacted base, covering it with the IronClad topcover, and then fastening the cover securely to the walls and doorway(s) of the stall. To ensure that your new ComfortStall® system is installed correctly, both the walls and floor of your stall need to be properly prepared. Please read the following instructions completely before starting.

Before installation, replace or repair any loose, broken or rotten boards in the stall walls -- this will provide a secure surface to which the topcover can be fastened. Also, fill in any holes in the existing stall floor and make sure it’s perfectly level, even and firmly compacted, so that it doesn’t shift under foot. The ComfortStall® system can be installed over any type of stall flooring, but it must be FIRM and LEVEL.

Once installed, ComfortStall® will add a little over 1.5" of height to the stall floor.


Preparing Your Materials

All of the components of the ComfortStall® System can be easily trimmed to fit any size stall—all you need is a sharp utility knife. Please use extreme care when trimming ComfortStall® components so as to avoid injury --- and don’t forget to measure carefully before cutting!

The ComfortStall® precision foam is manufactured in a 6' width and in lengths of 24' or 48'. Using your utility knife, cut lengths of foam from the roll to fit the dimensions of your stall. To allow for “load-spread” or expansion, we highly recommend leaving 2 inches between the edges of the foam and the walls. If at all possible, allow the foam to relax by opening it up and spreading it out for a few hours on a clean surface, (ideally with a warm ambient temperature of over 65 degrees). It has a “memory”, and will be easier to work with if it has this “relaxing” time to flatten out.

The IronClad rubber sheeting has been custom fabricated according to the dimensions of your stalls. Typically we've allowed approximately 4 inches of extra material on all four sides, in order to securely attach the cover to the wall, --- so for a 12' x 12' stall, the topcover should be 12'8"” x 12'8".

The anchor strips are found within the rolls of IronClad topcover. They can also be easily cut to fit the wall dimensions -- just score each one with your utility knife at the proper measured length, and then bend the strip at the score mark until it snaps. The anchor strips do not need to be pre-drilled.


Installation

Once you’ve cut sections of foam to the proper size, (remembering to leave the 2” of space between the edges of the foam and the walls) lay the pieces of foam side by side and centered on the stall floor, attaching them to each other by using several (at least 5 - 7) pieces of duct tape (about 2 feet long), crosswise of the edges between the sections, pushing them snugly against each other.

Next, bring the roll of IronClad topcover into the stall.

IMPORTANT: Center the topcover in the stall, and walk around the perimeter to press it down into place along the edges and make sure there is equal distribution of excess around all four sides.

Firmly press the whole topcover down onto the foam, and smooth it out to the walls, pressing the topcover down a bit into the space left between the foam and the wall, making a 90 degree bend. At this point, it might be best to cut a short slit in every corner, so as to “dovetail” the topcover down to fit deeply into the corners.

Start fastening the top cover to the walls, using the plastic anchor strips, placing them down as low as possible on the walls, where the floor meets the wall. Push the topcover slightly down into the space between the foam and the walls, so as to allow some “give”. It’s best to start in the center of a wall, placing the screws about 3” to 4” apart, drilling them in tightly to hold the top cover firmly against the walls. When the anchor strip ends (8’ along the first wall), measure the distance from the end of the strip right to the corner, and cut the next anchor strip to fit, by scoring it with the utility knife and bending and breaking it at the right length needed. Take care to “dovetail” the top cover into the corner and use enough screws to hold it firmly to the wall.

If there are any obstructions that protrude from the walls of the stall—like posts or water pipes—continue fastening the topcover with anchor strips right up to the obstruction, then use your utility knife to cut the smallest piece possible out of the topcover to accommodate the post or pipe. Continue with the anchor strips as close as possible on the other side. (If a water pipe is located “stubbed up” away from the wall, cut a small hole to accommodate it before anchoring too close, so that you can lift the topcover over it and have the smallest hole possible in the correct location).

Fasten the topcover to the walls all the way around the stall. On the thresholds of the doors, continue anchoring the topcover to wood or concrete across the doorway, just the same as it is on the rest of the perimeter of the stall. If the level of the floor of the stall is too high to do that, please call us for alternative instructions. It is advisable to push the topcover down into the foam to form a little dip of sorts along the door opening, so the topcover isn’t very taut right in that area, to allow a little “play” and help prevent the topcover from possibly being pulled out of the screws by the weight of a 1200 pound horse repeatedly stepping right next to the threshold. Once the cover is fastened all the way around, use your utility knife to trim off the excess along the top of the anchor strips to create a tidy finished edge.

Additional Installation Tips.

If you have any questions during installation, please don’t hesitate to call us toll-free at 888-307-0855 for assistance. It is our intention that all goes smoothly and that everyone is satisfied with the results and enjoys the benefits of our anti-fatigue flooring system.

 


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