PSA on Horse Stall Mat Flooring

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Jan 26, 2017
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Hey guys, hoping to s spare someone else the fiasco i am currently dealing with. Like a lot of people, I used tractor supply 4x6 horse stall mats as an economical gym floor for my home gym. However, some of my mats were contaminated with mold, and now I'm looking at a $20k decontamination effort to get the house back to a saleable condition. Suffice to say, any/all cost savings have been obliterated and then some vs buying a real vulcanized rubber floor.
 
Damn! I had thoughts of this before we redid our basement and I guess I am glad I just build an 8x8 platform in the gym area and did carpet in the rest of the basement.
 
They were contaminated when you bought them or they got moldy during the time in your home? Also did you have the version that has channels for air flow on the bottom of the mats to prevent this or the flat on both sides?
 
If you put any rubber mats on a concrete slab, moisture travels through the concrete slab and gets trapped under the mat, then mold grows. I suspect this is happening at commercial gyms but they use bigger rolls and weld the seams so the mold smell gets trapped.

I had mold growth happen with good quality vulcanized gym mats in 4'x8' size pieces, but luckily in a detached and well ventilated shed. I removed the mats, power washed, bleached and cleaned the concrete a couple of times, coated the concrete, and now only use two mats.
 
I'm a little confused how this could have happened. I use these mats indoor and outdoor in all kinds of harsh conditions (both actually IN horse stalls, which are perfect growing environments for mold, and as oddball things like to add a inch to my truck bed under my slide-in camper so it can clear my cab). I've never seen any mold on them. They're not porous. Mold can't grow inside them, and the Tractor Supply 4x6 mats ARE "vulcanized rubber."

So the obvious question is, since these are not vapor-permeable, did you lay them down on something like a concrete slab without first addressing concrete's natural moisture-wicking properties? Mold growth in concrete slabs is super common when folks do things like chuck a bunch of flooring down on it without proper prep, and it doesn't matter what you lay down. A different type of mat or material wouldn't have changed anything if you didn't prep it first.

If you have mold in your floor, pull up all that flooring and hit it with a gallon of RMR-141. If you have it in your walls you'll need to do more.
 
They were contaminated when you bought them or they got moldy during the time in your home? Also did you have the version that has channels for air flow on the bottom of the mats to prevent this or the flat on both sides?
Apparently contaminated with spores when we brought them in, my basement is typically very dry and the floor is never wet unless it's sweat or spills. There's visible mold now on the bottoms and on the surface in some of the darker corners. I have 2 versions, 1 with channels on the bottom, and another with circles that create some space.
 
What do you mean contaminated? How’d this get brought to your attention, during inspection? Who quoted 20k and for what work?
Mold is no joke but 95% of those mold remediation/water damage companies are straight scammers.

Scammer is a definite possibility, some of what's quoted seems entirely unnecessary, like ripping off all the insulation from my poured concrete walls and removing everything from my basement.
 
I'm a little confused how this could have happened. I use these mats indoor and outdoor in all kinds of harsh conditions (both actually IN horse stalls, which are perfect growing environments for mold, and as oddball things like to add a inch to my truck bed under my slide-in camper so it can clear my cab). I've never seen any mold on them. They're not porous. Mold can't grow inside them, and the Tractor Supply 4x6 mats ARE "vulcanized rubber."

So the obvious question is, since these are not vapor-permeable, did you lay them down on something like a concrete slab without first addressing concrete's natural moisture-wicking properties? Mold growth in concrete slabs is super common when folks do things like chuck a bunch of flooring down on it without proper prep, and it doesn't matter what you lay down. A different type of mat or material wouldn't have changed anything if you didn't prep it first.

If you have mold in your floor, pull up all that flooring and hit it with a gallon of RMR-141. If you have it in your walls you'll need to do more.

The concrete has been painted with cement paint that is tightly adhered and continuous. What other prep should I have done?
 
Mold spores are literally everywhere. Given the right conditions mold will pop up anywhere as well. Bleach works wonders. Not all molds are the same. Pull the mats, spray with bleach, wipe down to remove dead mold, figure out your moisture issue and no remediation necessary.
 
So for those of us with the horse stall mats on the concrete floor in our basement - how do we prevent this from happening? What is the proper concrete prep?

If the moisture is coming from the concrete, what's the difference between the stall mats and whatever commercial gyms use?
 
This is not an "I see mold and an freaking out situation." I actually didn't think there was mold at all, but paid for testing anyhow because my medical tests showed high internal mold levels and we needed to know the exposure source. The molds on my stall mats are airborne at significant levels in my basement. I'm hauling them out today, they won't be going back even though I'm able to technically decon them.

Like cornfed, I'm also interested in how to properly manage moisture wicking on a slab if anyone knows.
 
Last detail, the molds in my basement are not the molds in my blood. Go figure.
Then are they actually "bad molds" in the stall mats or what kind of mold we talking?

Seems like these are in every single home gym across north america and have never heard of this. Its like the #1 recommendation of every DIY gym build to put in stall mats first before getting and setting up equipment.
 
Then are they actually "bad molds" in the stall mats or what kind of mold we talking?

Seems like these are in every single home gym across north america and have never heard of this. Its like the #1 recommendation of every DIY gym build to put in stall mats first before getting and setting up equipment.
With appropriate testing one might find some form of mold in every home gym in N.A. with or without horse stall mats.

If ResearchinStuff has health issues related to mold I understand his concern but it does not mean his home gym caused the problem.
 
Yeah, these mats didn't cause my problems, but after rolling up 11 of my 12 and hauling them into the sun, they were absolutely quite moldy. I'm in a stage of trying to remove myself from as much mold as possible, I've been battling a lot of health stuff and finally got it traced to mold toxicity
 
Like cornfed, I'm also interested in how to properly manage moisture wicking on a slab if anyone knows.
If there’s liquid water under the slab it’s not uncommon to cut a hole(s) and install little permanent pumps to help reduce free water, usually on the side where water is making its way under the foundation footings. For instance a nice green lawn uphill of the house will be notorious for water migration to and under the foundation. However that isn’t always necessary if the moisture is better controlled before it gets to the house.

If there is water under the foundation and slab, there’s probably also considerable moisture on at least one of the foundation walls in the direction of where the water is coming from, usually the uphill side. Some foundations require digging out the dirt well enough to use better moisture proofing on the outside of the basement walls. Some clients paid their teenage boys to dig and were able to get it all dug out for pretty cheap, but they had no clue how dangerous cave ins can be at full basement depth. Another client paid landscapers to dig it their wet foundation wall.

If water is coming through the wall and pooling in the slab, it might not do any good to focus on anything other than foundation walls. Water test kits for foundations are often just poly sheeting you tape to the wall and look for moisture to condense. Might have to open finished Sheetrock in places to inspect and check for moisture. Lots of moisture leaves white residue from minerals so it can be easy to spot.

A retrofitted drainage perforated pipe outside of the foundation sometimes makes sense, such as when there is an entire hillside uphill of the house, or golf course uphill of the house is feeding underground water. These are pretty simple - a dude with a backhoe digs a trench low enough to intercept the water, and fabric and washed stone is placed in the ditch along with the perf pipe. Works great on hillsides where the perf pipe can gravity flow water around to the downhill side.

On a golf course house where gravity flow to get rid of the water wasn’t an option, the perf pipe went to sump pump that raised the water up above ground level so it drained.

If you or neighbors have ditches, ponds or swimming pools nearby that can be a major water source. One client had the auto water valve adjusted too high on the koi pond and water was flowing over the top of the pond liner.

I’ve also seen broken water lines feeding underground water to a foundation. Fixing the cracked line and the foundation dried up.

If you have a lot of rain, downspouts can saturate soil around a foundation. One house had downspouts connected to perf pipe around the footers, so rather than the perf pipe removing water, it was helping downspouts move water to the footers. Other times mold in a crawl space has been limited to areas where downspouts empty out and water just went down the foundation wall and under the footer.

Some places the soil is wet everywhere all the time and the options are ensuring waterproofing on the walls is intact, sump pumps for anything that gets under the slab, and good moisture barrier under the slab so moisture vapor can’t make it into the slab. When we’ve torn out a slab it basically gets fabric, layer of washed rock, concrete sump tank that free water would drain into and will hold the pump, and a layer of foam and maybe a second water barrier if the foam is crap, then the new slab.

Oh, one other source can be surface runoff. One client had water coming into the basement wall, but it wasn’t down low, but at ground level just above the waterproofing. There was a defect in the concrete and a pencil size stream of water would come through during rain storms. That side of the house was re graded so water flowed away from the house and detailing that defect solved the problem.

That’s all I know. Water flows downhill.
 
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