Another barn build

   / Another barn build #61  
That's a very ambitious barn build!!!! Do you already have a crew that you know to do the concrete work? For me, I go crazy when I see rebar not sitting on chairs or tied properly. For something like this, it has to be perfect.
 
   / Another barn build
  • Thread Starter
#62  
What is your plan for drainage where your walls are near the hillside?
I'll install a perimeter drain, just like you would do on a house. There is an easy run to daylight for the pipe. I'll also probably install gutters too and run them out through the same outflow pipe.
 
   / Another barn build #63  
I ran my gutters through a different pipe in the ground than my perimeter drain which was lower because of a partial inground basement. Didn't want any chance gutters would back flow into the perimeter. Also ran the gutters further down the slight slope we have. Jon
 
   / Another barn build
  • Thread Starter
#64  
That's a very ambitious barn build!!!! Do you already have a crew that you know to do the concrete work? For me, I go crazy when I see rebar not sitting on chairs or tied properly. For something like this, it has to be perfect.
It is, and probably the last big construction project that I have in me. The stone removal was brutal and took WAY longer than I expected. I figured 2-3 weeks and it was 7 weeks, 2 chisel tools for the hydraulic hammer, 4 hydraulic hoses, and one hydraulic steel pipe. Plus over 70 dump trailer hauls, though thankfully the distance was only 100 yds or less.

I have a concrete crew lined up - the same guys who did the concrete for the green building which is 48 x 60. That slab still has no cracks, even at the cuts, after nearly 20 years. And he uses chairs for the rebar. There will actually be a pretty extensive rebar schedule for this since each of the pilaster has a rebar cage in it, and the walls, slab, and pilasters are all tied together with rebar.
 
   / Another barn build
  • Thread Starter
#65  
I ran my gutters through a different pipe in the ground than my perimeter drain which was lower because of a partial inground basement. Didn't want any chance gutters would back flow into the perimeter. Also ran the gutters further down the slight slope we have. Jon
That's a good approach. I'll do the same.
 
   / Another barn build
  • Thread Starter
#66  
It’s now up to grade along the left end of the building, and within 2-6” everywhere else. And all the “islands” or rock outcroppings are now buried under compacted fill. That said, I did find one spot where the ledge was sticking up a bit more than I want, so I beat that into submission.

So far I’ve put in over 100 yds of compacted fill. And my 70 year old wife has been a real trooper running the compactor for several hrs each day while I move and spread fill.

IMG_8187.jpeg
IMG_8186.jpeg
 
   / Another barn build #67  
Wow, that's a lot of work!
 
   / Another barn build #68  
Sure looks like a great place to build a barn!!!
 
   / Another barn build
  • Thread Starter
#69  
Sure looks like a great place to build a barn!!!
I think it will be nice when it’s done, and less intrusive dug into the slope. But it sure didn’t feel like a good place when I was busting out all that rock :-(
 
   / Another barn build
  • Thread Starter
#70  
I'm patiently waiting for a call from the truck driver who is delivering my building kit today. I'm going to meet him about a mile from my house where there is room to unload, and for him to turn around. I'll then shuttle everything to the house with my tractor and trailer.

There is only one problem..... I don't have a foundation, and now the kit will have to sit over the winter.... Stay tuned for that saga, plus pictures of the unload.
 
   / Another barn build
  • Thread Starter
#71  
Well, I suppose I can tell the foundation saga while I'm waiting.

At first I hired a local engineer to design the foundation, but after the first meeting got pricing that was 3x what he originally told me. I interpreted it as "if you want to help" pricing, so I cut him loose.

The building company (Worldwide Steel Buildings) offers foundation design services, and in my meeting with them I hired them to design it. In the mean time, I lined up a guy who I have used before to built it.

My concrete guy and I met after I signed to purchase the building to look over the site and the various foundation styles that Worldwide uses. We picked one that made sense, and was actually the only approach that was plausible. You may recall from earlier in this threat that the building is dug into a hill side that is pretty much all rock. So a little over 2-1/3 sides have an 8' stem wall, and the remaining 1-2/3 sides are "walk/drive out". I documented everything and sent it to Worlwide as "guidance" for the foundation design.

A month or two later I got the final engineering drawings for the building, then maybe a week later I got the foundation design. The foundation design was ridiculous and bore no resemblance at all to what I had sent them. It was pretty clear that the info had not made it to the grunts who cookie cuttered the design. Plus, it was massively overkill. I showed it to a friend of mine who is the principal in a large commercial engineering firm is Vancouver, and he said it's more like you would build for a 20 story building. It all struck me as a case of an engineering firm doing cookie cutter designs with no consideration for the people who have to build them. And they are massively over designed to ensure they never come back to haunt them with structural problems.

I sent them back to the drawing board and they came back with a design that was in line with what we asked for, but still massively over designed.

In the mean time, my concrete guy said he would only do the project if it was massively simplified. Instead of stem walls with pilasters to support the steel frame posts, he wanted to just pour a really thick stem wall with no pilasters. Well, it would have to be at least 16" thick to provide a sufficient landing pad for the posts, so I said no to that. Meanwhile time was ticking away with winter approaching, and a complete shutdown for concrete work.

We then showed the new plans to another concrete guy who does more commercial buildings, and he also baulked at the plans. He said for similar buildings they always just do a thickened edge slab, then pour the stem wall on top of that. I asked him to price it and he came back with $80k (yikes), and could only do it next spring/summer. Now we are talking to a third concrete guy who comes highly recommended, but he's booking out next year too. So I finally called it, and we will sort out the foundation plans over the winter with a late spring start once the roads are no longer posted from mud season.

But I have the building kit - maybe. The truck still isn't here....
 
   / Another barn build #72  
ahhhh, dangit. Sorry to head of the foundation snafus. Was looking forward to this building going up after all the difficulty of preparing the pad!

Too bad you can't just build a simple pole barn and then pour a basic slab inside after the building is up.
 
   / Another barn build #73  
Here in Texas, we don't have permits or any sort of government involvement when building anything outside of city limits. But I grew up in California, and the government wanted to be involved in everything. I'm guessing Vermont makes you get a permit for everything too.

I'm shocked at how complicated this is. It seems to me that all you need is a strong retaining wall that will also function as part of your wall. My way of thinking is to just increase the amount of rebar and make the forms thicker. Then it's just a matter of paying for materials and a crew to get it done.

As a Contractor, I've learned that the most expensive way to get something done is to hire people to do the thinking for you. Then when you hire the crew to do the work, they change everything because the person you hired to do the thinking didn't actually know anything about what is being done. When I need to hire out work, I talk to the Contractor I'm going to hire and avoid all the thinkers. He's done it before, he knows what's needed, and he doesn't charge for planning it out. He just gets it done.
 
   / Another barn build
  • Thread Starter
#74  
Here in Texas, we don't have permits or any sort of government involvement when building anything outside of city limits. But I grew up in California, and the government wanted to be involved in everything. I'm guessing Vermont makes you get a permit for everything too.

I'm shocked at how complicated this is. It seems to me that all you need is a strong retaining wall that will also function as part of your wall. My way of thinking is to just increase the amount of rebar and make the forms thicker. Then it's just a matter of paying for materials and a crew to get it done.

As a Contractor, I've learned that the most expensive way to get something done is to hire people to do the thinking for you. Then when you hire the crew to do the work, they change everything because the person you hired to do the thinking didn't actually know anything about what is being done. When I need to hire out work, I talk to the Contractor I'm going to hire and avoid all the thinkers. He's done it before, he knows what's needed, and he doesn't charge for planning it out. He just gets it done.
A septic system is the only thing I would need a permit for, and I'm not building one of those, so no permits required. I can do whatever I want. Around here a pole barn just won't last because the poles will move with the freeze/thaw cycle. They are quick and easy, just just don't have the longevity of other approaches.

As for "thinkers" vs "contractors", I half agree. Maybe even 3/4 agree. I'm a former engineer myself, though a different kind, and I know all too well the phenomenon of engineers sitting behind desks looking at specs and drawings, yet having never seen a construction site, let alone actually built anything. Pretty much all trades rag on engineers for being clueless, whether it's mechanics, or contractors, and a lot of it is well deserved. But contractors also only have part of the puzzle. Yes, experience counts for a lot. But at the same time a lot of people just keep doing things wrong over and over again because they haven't seen it cause any problems. It doesn't mean it's not a problem, they just haven't seen it. And when circumstances change, what you did before somewhere else might not work again. In my experience, it takes both.

In this case, one issue is the force of the retained soil pushing against a tall wall and wanting to overturn it. And if that soil is saturated with water, the force goes up significantly. The tipped force is counteracted by the "toe" created by the thickened edge of the slab, both from its leverage, and also from its weight. In houses where there is a floor deck on top of the wall, that provides a significant amount of the required support. I don't have such a deck, so all the force has to be carried by the wall. The end result is just as you describe; make the wall thicker, add more rebar, and start pouring. But how much thicker, how much rebar, how thick for the thickened edge, and how wide does it need to be.

I'm listening to what contractors are suggesting, and our current thinking is MUCH more in line with what they suggest vs what the engineers came up with. I have pretty much discarded what the engineers came up with. But I do want to check what contractors are suggesting to make sure it passes some basic engineering checks.

As for wall thickness, that has become an interesting topic. I think I mentioned that one guy didn't want to form all the pilasters, and instead just make the wall as thick as needed. That's pretty much what you are saying, I think. The challenge is that the columns need an 18" landing zone, so that would force the wall to be 18" thick which strikes me as crazy thick. It might be OK to shrink that down to 16", but it's still a really thick wall, and a lot of extra concrete. But maybe that is the right way to go; just simplify the job by throwing concrete at it. What do you think about a 16" or 18" thick wall?

Where we are right now is to just pour a thickened edge slab floating on a bed of crushed stone. Then pour the stem wall on top of that. There will be a perimeter drain, but I have been worried about water coming in between the slab and stem wall seam. One guy mentioned some seal that they have used successfully. Maybe you know about that? Also current thinking is a 12" thickened edge for the slab extending 5' inward towards the inside of the building, tapering to a 6" slab in the interior. Then 10" thick stem walls with 18" pilasters.

I welcome any suggestions.
 

Tractor & Equipment Auctions

2019 CATERPILLAR 299D2 SKID STEER (A60429)
2019 CATERPILLAR...
2013 International WorkStar 7400 4x4 Altec AM650 50ft Material Handling Insulated Bucket Truck (A59230)
2013 International...
2022 Carry-On 5'x8' Trailer (A53316)
2022 Carry-On...
GRID SHAPED BUCKET FOR MINI EXCAVATOR (A58214)
GRID SHAPED BUCKET...
John Deere 1025R (A53317)
John Deere 1025R...
2016 CATERPILLAR 259D SKID STEER (A60429)
2016 CATERPILLAR...
 
Top