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Discussion Starter #1 (Edited)
I'm interested in barns and shops so I thought I would share my barn building experience. My house has a basement garage and a 3 car garage, but I have so much STUFF that I decided I really needed another building to help relieve the pressure.:lol: I built a larger barn in the early 2000's, but moved, so I needed to built yet another barn at my new place. After my first experience I told everyone that I would never do that again. It's a lot of work and takes months. I do 80% of the work myself. The only things I need help on are the siding and the roofing. I found the plans for both of my barns on the BarnsBarnsBarns.com site. They are plans by an architect in New York. I've talked to him on the phone and he's a good guy and helpful if you have questions.

Anyway, here are the two barns. The first barn had a shed at the rear where I stored my trailer, hence some very wide doors. The smaller barn has a shed on one side only and the photo you see is how it is in it's present state. I still have to build the doors for the shed. I have all of the material neatly stacked in my basement workshop area, I just need to get it done. About 3 weeks work at my pace.

When I'm in full swing on these projects it's 7 days a week if weather permits. Some days I don't work all day, but I do something, otherwise you'll never complete it.

Neither barn has a concrete floor. I just can't afford it. I fill the area with larger rock and then top it off with base rock and grade it as smooth as I can. I just store equipment in the barns. The larger barn didn't even have power to it, but my new barn has power, although I have not run any conduit yet.

The hardest part of the job on the larger barn for me was setting the 6x6 pressure treated posts. Very heavy. I had a larger tractor with loader at the time and used it to lift and set them. I have a 3 point concrete mixer and mixed every load in it. I think I had about 30 posts to set. It was so time consuming to plumb and brace each posts I did something entirely different for the new smaller barn. It was significantly easier. Curious?
 

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Nice barns, man that does look like a lot of work to do is spare time, or should I say what spare time....
 

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I'm curious too. Please share.:hi:


I'm still very much into my "information gathering" stage for my future shop. Any cool info you have could be great.:good2:
 

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Discussion Starter #5 (Edited)
I knew I would get some seekers!:thumbup1gif:

Because I don't really like to encase wood post, even pressure treated, in concrete because of water rot over time I was online searching for concrete admixtures to add to the mix to make the concrete impervious to water. I happened onto a two part high density foam product by GRAservices.com that comes out of Edmond, Oklahoma. I watched all of the videos (YouTube) about using the product and also videos showing the pull out force of posts in concrete versus posts in HD foam. I talked to the owner who is a nice guy and helpful and decided to go ahead and use the product. Yes it is more expensive than concrete, but it is infinitely faster and easier when working alone. The foam is used by utility companies to set large steel poles so if they have faith in it I do also. I liked the fact that the foam encapsulates the posts so NO water ever touches the posts.

You can set, align, plumb, and take your braces off in 20 minutes. The foam sets up in 15 minutes. This foam is very dense and it takes a claw hammer to dig it out. I'm sold on it and would do it again. I mentioned the foam in another building forum and someone pointed out that it may be a problem concerning building codes and that may be true, but if I was concerned about that I would call the company and ask them. They may have already addressed that issue. It was not a problem here because we have no building codes in my county! Sad, but true.

The braces for setting the posts are nothing more than 2x2's with cheap broom hangers on each end. No more driving stakes with sledge hammers with cross bracing etc. They are shown on the videos using the foam to set fence posts.

The first photo is a low life degenerate worker mixing the two part foam. The foam expands to 18 times the mixed volume so if the container shown was full it will expand to 18 gallons or 2.5 cubic feet. It took a couple of mixes for each hole. You have about 30 seconds or less to mix the batch and pour it in the hole. It expands fast once it gets going. And it's REALLY sticky so you need to wear the latex gloves and try not to get any on you because it very tough to get off. You wear it on your skin for a few days if you get any on you.

I included a photo showing my guard dog. She thinks she's a Rottweiler. The last photo shows the broom hanger I am talking about. One at each end of the 2x2 brace.
 

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Discussion Starter #6
Here are some job progress photos. The only reason for the Tyvek is to protect the plywood sheathing because it was exposed to the weather for a long period of time and I didn't want it to
delaminate. I had that happen on the first barn.
 

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Discussion Starter #7 (Edited)
More progress. I built the cupola in my basement woodworking shop, including the copper roof and siding and then set it on the building using a telescoping manlift like a crane. This is the first time I had ever worked with copper sheet and it was fun. I had the use of a 12 foot sheet metal brake the siding guy let me use and I had to buy a large soldering iron that would produce enough heat for the joints. I checked with copper fabricators in Springfield, Mo. and they wanted around $3000 for the roof. I did it for $1000 including the soldering iron. Expensive yes, but I wanted a copper roof that would never need maintenance. The doors are 2-3/8" thick and weigh right at 200 lbs each. The main structural strength of the doors is white oak. The outer layer you see is black locust. It is for appearance only. Each door is hung with welded hinges and using 3/8" thick bar stock. The rock veneer matches veneer I have in front of the house.
 

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WOW! is right, andy b!!

I am just blown away by this!!!!

I appreciate the sharing of the info too. I need to replace a few fence posts that have rotted at the top of the concrete, and this might make it my last time to need to do that! (When I finally get to that project!) Been thinking about a new barn too. I can only hope anything of mine turns out even half as nice as the photos shown!!
 

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Quit posting stuff like this, you are making me look stupid and lazy!:laugh:
 

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Discussion Starter #11
Thank you everyone for your kind comments. I really appreciate them all.:thumbup1gif:
 

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Very nice , thanks for sharing the photos.
 

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