Starting a Barn

[Sinecure]

I am not a horse person, but have always liked the look of a nice horse barn in a field. When we bought the property, we knew one of the projects on the list would be a barn for this particular pasture.

After finishing up some other higher priority projects around the place, this summer seemed like a good time to start the barn. I will try and keep this thread updated with my progress and post some pictures as I go.

Some background information before I get started:

The property is in the piedmont area of North Carolina. My current employment situation has me in Texas for the near (several year) future.

I am able to get to the property fairly regularly and stay from anywhere from a week or two in order to tackle some project related tasks. I debated about saving my update posts until I had several, but decided that it would be easier to just post them as I complete various steps within the construction. The downside to this will be that this thread will not be updated as frequently as it would if I where knocking the project out on a continuous basis. So feel free to hijack the thread and take it in any barn related direction it wants to go and I will update my progress as it comes about.

Since the property is not currently a full-time residence, I tend to do most of the projects myself and limit the number of people I bring on to the property. I have some good neighbors that keep their eye out for me while I am not there, but I don't want to have the word spread around town that the property is vacant for long periods of time.

So here goes. The first step was to determine a style and get a general idea about size. After searching via Google for various plans and images, I came across this basic plan:



This will be the largest structure I have attempted to build solo and I may come to regret my decision, but we will see how it goes. The positive is that there is really no rush and given the geographical distance to my home, I will have plenty of time between visits to form some sort of a game plan. The thinking is that this should allow me to focus on specific tasks while I am at the property.

 

[RetiredCarGuy]

Nice plans. Don't you think that this is a very big job for "solo."
What is your project timeline and budget?

 

[Sinecure]

After the boss approved the style and basic look of the barn, I did a bit more research to get general sizing ideas.

My initial desire several years ago (when I started thinking about potentially building a barn) was 100% Post and Beam construction. I have liked the look and wanted to try building something in that fashion.

However, after some research of the tools I would need and setup/guides required - I quickly concluded that I could not build a post and beam structure in the manner I wanted as a solo build. Or if I could, it would take me forever and the learning curve was something that could get crazy expensive.

So I decided to go with more of a Hybrid style of build and use a combination of Pole Barn and Stick Build ideas and methods. Other than the stall layout picture (first post), I don't have any real plans for the building. My BIL is a structural engineer, so I can always run some stuff by him if I need to (and I probably will need to at some point).

I decided to go with treated 6x6 posts for the posts. These will be bolted to post bases that our set in concrete. I initially had a desire to go with 8x8's for the posts, but the price jump was significant.

I came up with a post layout that looks like the following.



The barn will be roughly 72 by 62. 12 by 12 stalls with a 16 foot center aisle. In addition, I have plans for a loft/catwalk area, but have not finalized those yet. It will be 24 feet to the peak of the roof.

I will need 40 posts. The center aisle posts will need to be 20 footers.

 

[Sinecure]

RetiredCarGuy,

Thanks. Yes, I do worry that I may have bitten off more than I can chew. I am however excited about the idea of a challenge.

My biggest concern (at this point) is the roof framing. I need to figure out a realistic way to accomplish that in an effective and safe manner. If I got hurt or fell, I could lay out there for awhile before anyone came looking. I guess the coyotes would come, but that might not be a good thing.

I would like to try and keep the budget under 70K. There really is no timeline. I have an image in my head of what I want the inside and outside to look and "feel" like, so as long as the budget doesn't take a major hit, I hope to be able to pull off some really cool things and features.

 

[BitChin1]

Check out this link of a DIY barn (a bit smaller but similar sections as to what you are proposing)
http://www.tractorbynet.com/forums/build-yourself/244220-building-old-fashioned-appearance-new.html

 

[Sinecure]

BitChin1, Thanks for the link. There are several really good barn threads on this site. It is amazing to see the various talents people have and what they have created on their property.

I will be the first to admit that I do not have everything figured out yet and will hopefully learn a lot as this project goes forward.

I have some very specific ideas on what I want out of this project. The challenge will be seeing if I can pull it off and/or get close to the ideas in my head.

I will have to make some decisions based on necessity which may or may not be the best use of time or money. There are always some trade-offs that need to be made when trying to do something by yourself. How do I take a two person task and try and make it a one person task - maybe I can't. I don't know yet.

My current thinking is that I will use a form to raise the concrete footer level above grade. I will keep this in place until I am ready to install the flooring material (also so I don't chip the edge of the concrete with a tire tractor/etc).

The barn floor within the center aisle portions will be compacted gravel, a layer of sand and then pavers.

I got started on the forms last week. 20 shown and 20 more needed.

 

[Sinecure]

Digging the holes and grading.

I am trying to be as precise as possible during this task. My hope is that if I spend some time on the layout and get everything level and aligned, I will not have to be 20 feet up in the air trying to cut half and inch off some of the posts down the road.

Originally I had ideas of setting the posts in the holes and cementing them in; however, I would have needed about 26-28 foot posts for the center aisle portions.

I also looked at Perma-Columns (the posts that have the concrete already attached to the bottom of the post), but could not get them here in a length greater than 16 feet. I am not sure if that is a local thing or just their manufacturing sizing.

40 holes total. Needed a lot of string line and a laser level.

 

[lockhaven]

very good I built my house by myself and not only enjoyed it but saved a lot of money. As long as time is not a major concern projects like this are fun. Keep one thing in mind all the time, keep it accurate a slight bit of out of square or a little off level will only get worse as you go along. The earlier in a project that things are not correct the worse the final outcome will be.

 

[Sinecure]

I made an audible when I was digging the posts. After giving it some thought, I decided to initially only drill 32 post holes.

I did not dig the 7 posts in the rear of the structure which will make up the rear stall area / rear lean-to. The reason I decided not to dig these at this time is that I know I am going to have to bring a manlift in at some point and I want the room to be able to drive/move the tractor or a lift at the back of the structure. Once I start bracing all of the posts, I am going to run out of space to move the equipment around and still reach the top of the center aisle section.

I am also thinking that I may like to set the last section of posts into the ground and cement them in. Maybe the perma-columns since these columns will be less than their manufacturing size limit.

With all the other barn posts being bolted to concrete piers, I would like to have a section of posts that run down into the ground and help really tie everything together. I am not sure if this is needed, but it seems like a decent idea.

I plan on using post caps to secure my beams to the posts. This was a cost that could have been avoided if I went the route of notching the posts and then bolting the beams to them. I decided not to do this.

I am going to go with built-up LVLs as my beams and think it will be easier to set them in post caps as compared to trying to notch, lift and then secure them to the posts without a second set of hands. Might be a mistake.

I am going with a combination of CC66 and ECCL/R66 caps. ECCL/CCC/CCT Column Caps



I will post some additional updates tomorrow and bring the thread up to the current / real-time level of activity.

 

[Sinecure]

Lockhaven, Thanks for the advice. I do enjoy doing projects like this. The key for me will being trying to balance my expectations with reality and just to take it slow and make sure I do it right.

Keeping it aligned and square/plumb is one of my major concerns.

The 6x6 posts are not as bad as the 4x4s, but I do worry about them twisting before I can get everything tied together. I know I am going to need a ton of bracing, but at 20 feet in length some of these posts are going to want to twist in the sun.

Once I get all of the holes laid out/dug and the posts set, I am going to need to tie everything together fairly quick. We shall see how it goes.

 

[BitChin1]

Here is another link where an "older" gentalman build some useful tools to assist him building his own monitor style barn mostly by himself.
BUILDING THE BARN

I very much look forward to this project.
I want to build my own barn/workshop and have toyed with a full or partial timber frame to match my house but also like the simple nature of standard stick framing

 

[Sinecure]

Bitchin1,

Yes, I have seen his build. That guy and his wife are studs. The amount of "build support" associated with his project is incredible. (The derrick structure, the lift pulleys, the knee supports, the seating mats - I am 100% in awe).

I hope to do this with a lot less up front effort, but may regret that line of thinking. Those guys built one **** of a nice barn and I should probably take a ton of notes.

 

[Sinecure]

All of the footings/piers dug and poured. Not the best picture, but there was a lot of effort to ensure these were level, straight and squared up.

Close to three days of effort to get everything lined up properly. I had to use some concrete spikes on my individual pier forms to ensure they stayed level and did not suffer from any "blow-out".

The laser level proved its worth.

Simpson post bases installed in the wet concrete. I love the fact that these concrete truck guys will drive anywhere to complete a job.



In the above picture, the seven posts holes I did not dig - they would be to the left of the picture. The alignment boards show roughly where they would start. I chose not to dig them now so I had more room to move my equipment.

 

[ace10]

Best of luck with this project. This will be be a handful for one man... but nearly anything can be done with proper planning and tools.

I dread the thought of the 20' 6X6... I put up a free standing lean-to this past winter, and some of my posts were 16' 6X6, and I was absolutely at my limit getting those plumbed and properly installed.

For a solo project, one of the nice things about the monitor design you're using is the absence of really large (and completely unmanageable) roof tins.

You might want to start shopping for a smaller boom lift... I think you'd find it invaluable with a building of that size. A decent used one might depreciate very little during the months/years you own it.

 

[EddieWalker]

I absolutely love the pictures of the barn you are going to make and can't wait to see it done!!!! As a builder who works alone, I can appreciate what you are taking on and relate to some of the challenges you will face. I've found that just about anything is possible, you just have to plan it out and know when to rent the right piece of equipment. The higher up you go, the more you will need a lift. Get to know your rental yard and see what they have. Plan ahead and be sure to reserve it so it will be there when you need it. Crazy how often those things are already rented out when you need it right away.

Post lots of pictures. The advantage to sharing a build on here is that there are quite a few pros on here who can spot things that could be done in a different way that you never thought of. I can't even count how many times somebody has asked a question about what I was doing, or made a suggestion that I hadn't considered that changed everything for the better!!!

Good luck
Eddie

 

[Sinecure]

I will post a couple of updates today and get the thread caught up to current / real-time action of my progress. I will also try and post some cost data of things I am paying for as I go through the build. I am not going to document to the penny, but I will attempt to throw some costs out for specific components of the build.

I know there are going to areas within the build that I pay more than I should for certain items or the method I am using is not the most cost effective (so try not to rub it in my face ). Some of this will be for easy of construction, as compared to trying to get the lowest cost. The other driving factor is I want a specific look for the build and am willing to pay for it as long as it makes sense and/or is not simply just a waste of money. (I don't want to do that).

Hopefully some of the cost data can help anybody else planning on building in the future. I also think it is interesting to see what others are paying in their neck of the woods.

Initial load of 20 foot, treated 6x6 posts. I am locally paying $66 dollars each for these; delivered to the site.



I sent a few back with the truck right off the bat (Did not like the look or had already started to twist on me). I will wait to have these delivered as I need them so they are not laying in the sun or un-banded.

I also worked on a tripod device to help me hold the posts as I worked to align them and get my bracing installed. Ignore all that other clutter on the shop pad - I had a ton of other stuff going on that day.

 

[Sinecure]

Ace10 - Thanks for the advice on the lift. I would really like to make that a purchase. I know I could use it. I have trolled around AuctionTime a bit, but would have to have the right piece of equipment listed while I am at the property so I could coordinate delivery/etc. I haven't seen one yet that I would be willing to pull the trigger on, but plan to keep looking.

Eddie - Thanks for the comments and advice. I will be the first to admit that there is a lot I do not know. I am confident in my ability to get this project started. I can see it finished in my head. The challenge will actually be pulling it off. (LOL).

 

[ace10]

Craigslist aggregator sites, ebay, machinery trader.... I've gotten lucky with used equipment for my place.

uShip worked well the first time I tried it. These small haulers can work within your schedule pretty well. Seems to be plenty of guys working on the East Coast.


The sight of that pile of 6X6's nearly made me weep. So glad my current project is a small shed for my Ranger SxS. Only 8X14. LOL

 

[Sinecure]

I knew I would not be able to successfully move the posts to their location and "walk them up" by hand. I have done this with smaller length posts, but the 20 footers were not going to work that way.

I also have to be careful since the posts are not dropping in holes. They need to be placed on their concrete footer without banging the installed post base all out of whack.

I really was toying with getting one of these, but could not justify the expense for this one project and could not locate one locally to rent.

'The Brut' Skid Steer Post Grabber - Post & Pole Setting Attachment

My solution was to build an 8 foot long, three sided box or sled for the post to fit in. I then bolted this to the frame of my pallet forks. At first I was hoping to leave the forks on and use them as added protection/support, but with them on I was unable to position (tilt) the front of the loader down far enough to slide over the post.

I ended up removing the forks and then lifting one end of the post up on to a saw horse. Once the post was supported by the saw horse, I aligned the sled on the forks with the base of the post and moved forward to line everything up. I then used two timber screws drilled through the sled and into the post to lock it into position.

I then sent the safety police home and used the loader to attempt to lift the post up and get it vertical. It actually worked quite well and was not as dangerous as it may look. The post does make my tractor look small, however.

 

[Sinecure]

Once I had the post holder mounted on the pallet fork frame, I simply drove the post over to the concrete foundation and began to set it in place.

This process was not too difficult. It really involved a lot of small adjustments to the loader, getting the post plumb from front to back and then getting off the tractor and on the ladder to mount the tripod around the post.

Once I had the tripod mounted, I could remove the screws holding the post inside the sled and work on getting it lined up and braced. Basically just a lot of up and down the ladder with the level and drill/driver.

First post up and braced. 10 pounds of red clay stuck to each boot makes going up and down the ladder so much more fun!