Above 1200 Sq/FT 60' x 60' x 18' Hangar / Shop Build Thread

[Jmatlock88]

Like most of you guys, it took 20 years to get to this point. I've been hanging out here on garage journal for 9 of those years too, gathering up all the amazing ideas from across the country and all over the world. Thank you very much - this build is highly influenced by the members of Garage Journal.

This is a build thread for a 60' x 60' x 18' Hangar / Shop.

Let's start with the layout drawings.

Below is the layout of the aerobic septic system sprinklers I made in 2010 using old school Google Sketchup. When we were building the house, I had to show the Septic Contractor, County, and Department of Environmental Quality where all the aerobic sprinkler heads go in relation to the house, property easements, and the future shop site. I also had to show there was enough "wetted area" in the yard for the number of bathrooms in the house. I am showing you this so you get an idea of how to plan your shop layout based on the property and the easements. The lot size is just shy of an acre.

 

[Jmatlock88]

It's important to establish all the Rough Opening sizes for doors and windows before ordering the building. In order to firm up the rough opening sizes, I had to make my door and window selections first. Since I plan on air conditioning the building eventually (Southern US), I spent a lot of time searching for walk doors and overhead doors that would be very energy efficient and would pair well with closed cell spray foam insulation.

I started studying Kyle from the RR Buildings Youtube channel, who is based in in Franklin Gove, IL. He has built some amazing post frame shops and buildings. Since he is in a more northern climate, his customers often choose highly efficient doors. I ended up taking his recommendation on the 92 Series Plyco doors.

The Plyco 92 Series Doors are really high performance walk doors that have thermal breaks in the jambs, header, and threshold. The jambs can be ordered fully filled with spray foam in addition to the door panel itself. There are a million options to consider on these doors to make them customized for you. One of my favorite options the interconnected lockset/deadbolt. If you pull up on the door handle, you lock both the deadbolt and the door knob with that one action. I bought a lockset with wifi, RFID, and code entry seprately from a third party. Enter the code and the door handle and deadbolt unlock together. But regarding the doors, I also added a wheelchair style door threshold so I could easily roll carts in and out of the shop without opening up the big overhead door. I was able to mail Plyco a swatch of the wainscot metal, and they are going to match the paint to the metal. The doors will also have a commercial grade door closer with hold open and 10" x 34" aluminum kick plates. In one of the doors, I added a custom window and they were able to match my house windows.

 

[Jmatlock88]

Kyle from the RR Buildings Youtube channel also recommended the Raynor TM200C overhead door. These doors can be ordered in large sizes up to 20' wide. It's an amazing door with 2" thick R-18 spray foam insulation inside. It also has thermal breaks at the sheet seams. However, my garage door guy pointed me also to two other competitor doors, the Clopay 3720 and the Haas CHT-2033-20. Both of these doors are very similar in thermal performance to the Raynor door. The Clopay 3720 ended up being the least expensive of the 3, and, as a bonus, also was available (Pre-Packaged) with a Liftmaster H50 L5 commercial door opener. This means that it will play nice with the Liftmaster 828LM Internet Gateway and the MyQ stuff. However, Clopay wanted $2,240 more (YIKES) to custom paint match the door. So I will be painting it. Sherwin Williams Emerald exterior paint.

 

[Jmatlock88]

After a lot of google searches, I finally figured out what windows were installed in my house and where I could order them locally. These too were available in a thousand options. One thing I learned here is that windows need to be a 36" X 60" (at least here) to be considered an egress window for a bedroom (if you have one). I ordered my windows with sheet rock returns so you can die the sheetrock into a groove without having to caulk to the windows. Also there was an option to have a J-Channel filler because the metal would not fit inside the exterior channel. These too were available with foam inside the window frame.


After establishing the rough openings, I made these views of the building in AutoCad and handed it off to the building supplier for quote.

 

[Jmatlock88]

The building will be red iron construction. It has 8" girts and 4 large beam assemblies spaced every 20 ft. There is some additional bracing for the hangar door side, and that particular beam assembly is oversized compared to the others.

 

[Jmatlock88]

Next we have the building rendering. The dark color is "Burnished Slate", sort of a dark bronze color. The light color is Sahara Tan, a medium brown. These are selected to closely match the house. The building will have gutters, wainscoting, two windows, two walk doors, 1 overhead door, and provisions for a hangar door.

 

[Chrisb62]

Your layout of the aerobic septic system sprinklers doesn't open. Awesome looking build so far ,can't wait for more.

 

[Jmatlock88]

Your layout of the aerobic septic system sprinklers doesn't open. Awesome looking build so far ,can't wait for more.

Thanks for letting me know about that - now fixed.


While I'm doing all this digging in the backyard and running all the utilities, I am also going to be adding the infrastructure for a 16-Zone sprinkler system with master valve. Tonight I finished setting up the piping for the Pressure Vacuum Breaker (Zurn 1-720A).

In the background are 12 rolls of 1/2" Oxygen Barrier PEX for the Radiant Floor Heating.

 

[mattmus4357]

You had me at airplane hangar…cool looking build! And Kyle at RR does some amazing work, not a bad source of inspiration at all!

 

[Jmatlock88]

Digging the sewer line today

 

[Jmatlock88]

BuyAction.com manifolds and valves arrived. Assembled those this evening, short of a couple fittings.

 

[BlakeTheCarGuy]

Looking forward to seeing the progress.

 

[BoxedWino]

BuyAction.com manifolds and valves arrived. Assembled those this evening, short of a couple fittings.

All that just to water the grass? It looks more like the beginning of a maker build for an electric pipe organ. Have you picked out a suitable controller for your turf quenching pipeapalooza? I keep telling myself I'm going to put in a system, but by August the grass matches the color of the rocks so it looks pretty natural.