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Between 705 & 1200 SQ/FT 30x40 OH Car Barn

Workspaces between 705 and 1200 squarefeet.

salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
I've been here for a little over a year. I posted a planning thread last May and I signed the contract to have it built in December. Construction started a few weeks ago and has progressed nicely, I figured I should start a build thread.

I'm building a 30x40 pole barn with a 12' interior height. I'll have a concrete floor to support a 2 post lift, 2 10'x10' overhead doors for vehicles and one 8'x7' door to get my mower out. No plumbing and no heat yet, but I'm am insulating (R19 bats in the walls, blown to R38 in the trusses). I looked at a number of builders, including well known national companies, and building kits to do it myself or have hired done. I liked the idea of DIY, but I'm at a stage in life where I can afford to hire it done and, realistically, DIY was going to take years to complete. In the end, everyone was within 10% of each other, so I went with a local builder with a great reputation, JD Construction.

Once the contract was signed, he estimated it would be May before he could start. That meant I needed to get my prep work done in the spring. I started in March. i needed to clear 3 trees, 2 pines where the driveway would be and an Ash where the building would be. I also needed to replace the 3' wide man gate with a 12' wide vehicle gate.

I stared with the Pines. I had only helped with dropping a couple trees, never done one myself. The first went smoothly, dropped right where I wanted to. Got it cut up and piled neatly.

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The second was a bit more trouble. Its natural lean was to the rear, toward the fence. In my inexperience, I didn't properly evaluate the tree and tried to drop it the opposite direction. I had the notch cut and was well through the trunk and it wasn't going anywhere. I was concerned to cut more, so I quit and called a friend who knows what he's doing. His first comment was "You're going to lose the fence". He came up with a plan that, if everything went perfect, would drop the tree parallel to the fence, but he still felt it was likely to land on it. But, fate was with us and it came down parallel.

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Next, was the much larger ash, which was half dead from the ash borers. I learned my lesson and took a real good look as to where it was leaning before I started and then called my friend in for his opinion. We agreed upon a direction and it came down without issue. This was in early May, so I was pushing it, assuming my builder's estimate was correct.

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Then there was the small issue of clearing the branches. It took 3 loads with my truck and a friend's 16' landscape trailer to get rid of them. Thankfully, my builder was not correct on his start date because I had brake issues with my truck and didn't get them cleared until the first week of June.

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Literally, the day after the last was cleared (the truck was actually still loaded) the lumber bundle arrived.

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Construction began the following week, I'll pick that up in the next post.
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Construction started on June 14th and progressed pretty quickly.

My fence contractor didn't have the gate yet, but they did come out and made an opening in the fence (which my dogs exploited to escape, despite my attempts to close it with construction fencing). On the 14th, they laid out the location, cleared the sod and and dug most of the holes.

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On the 15th, the final corner holes were dug and concrete poured in the bottom of each. Things didn't really look much different.

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On the 16th, a lot happened. Gravel was delivered and spread, the trusses were delivered, all the poles went up and the 40' walls were largely framed.

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The 17th was either a rain day or his crew was needed on other projects, but by the end of the 18th it was looking like a barn:

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That's all for now, I'll post more later.
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
By the end of Monday the 21st, the framing was mostly done:

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Tuesday the final framing was done, the roof was on, the man door installed and the trim begun:

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By the end of last week the siding and trim were complete, the trench for the electric was dug and the back fill around the building was done:


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Here are a couple of the interior shots I took of the framing so I'd have reference of what it is once the insulation goes in.


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More to come ...
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
The 12' wide gate in my vinyl fence was installed Friday too. I used Yoder's Vinyl Fence and they did a real nice job, even replacing and moving one post they really didn't have to in order to make a nicer looking slope. Here's a before and after (the old sections really need a power wash):

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Monday they filled in the electric trench (I had laid my shielded Cat6 ethernet cable over the weekend) and moved the rest of the dirt to fill along the driveway and out behind my existing shed (in the background above). Once that comes down, I suspect I'll need it to fill in after I remove the gravel it sits on.

And that's where it sits. Right now, we're on hold waiting on his electrician and concrete guy. Everyone's super busy right now and he's got 3-4 other buildings waiting on concrete too and he's having a hard time getting commitments. In the mean time, I figured there's no reason for my car and truck to sit in the sun. :giggle:

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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Yeah, they made quick progress. He initally said it'd be about 2 weeks or so once they started, and that's pretty close.
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
So, we're 2 1/2 weeks later, and progress has slowed.

Since my last update, the wiring has been run, the breaker box and all the outlet boxes installed. They've tied into my house breaker box, but not punched through the garage wall to connect to the outside wiring yet.

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When he was cutting the garage drywall, he noticed it was a bit soft to the left of where he was cutting, so he decided to cut that out too and replace it all. Behind that section was a large, thankfully dormant, bees nest. It was the full width between the stud and probably 16"-20" tall. I wish I had snapped a picture before I took it out.

He's installing 6 of these 150w LED warehouse fixtures. Should be plenty bright!

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Concrete was poured early Wednesday AM and cut the next day. They brought in a pump trailer because it would have been difficult to get the concrete truck back to the building, plus they would have to drive it over my septic pipe. I asked them not to seal it as I'm planning on using Ghostshield in a few weeks once it is at least 80% cured.

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They cut at almost every pole, since that's where it's likely to crack.

They will also be pouring a 3' apron across the front of the building and in front of the side door, but they'll do that later with an expansion joint in between.

It's getting closer, but the pace has slowed. It's been rainy for the past week or two as well, which I'm sure has slowed them down. Hoping it'll pick up this week, not that it matters a lot since I've got to wait 4 weeks to apply Ghostshield.

Ironically, I need to do brakes on a couple of cars and the barn isn't ready and my garage is a mess with the wiring, so I've got no place to work! I'll figure it out, I'm sure, the timing is just frustrating.
 
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ScottW

Well-known member
Joined
Mar 9, 2021
Messages
109
Location
WA State
Nice work, any updates? Would be interested in which Ghostshield products you chose and why.
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Yeah, I'm over due for updates. The building is done and I'm very pleased.

I'll try to catch up on the work.

Toward the end of July the insulation went in. R19 batts in the walls and a metal ceiling with R38 blown in on top.

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By the first week of August, that was complete as was the electric, the garage doors and the aprons were poured. Since this is just a workshop, I elected not to finish the walls. I may finish them later. For now, just plastic on the walls.

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He came and buttoned up some details a bit later, and I sealed the floor later that month. By the end of August, I put my T'bird and the truck in the barn and so was able to do something I hadn't done in my adult life - put both daily drivers in the garage and have all my vehicles inside.

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I went with the Lithi-Tek 4500 densifier and Ghostshield 8510 based on recommendations here. I wanted to protect the concrete, but didn't want to spend the $1500 or more that epoxy would have cost to DIY. This was about $500.

I bought them from Garage Flooring LLC and they were fantastic. Not only with pre-sale advice and application recommendation, but with post application advice when I was concerned that perhaps I hadn't applied them correctly. The connected me with technical staff from the manufacturer who was able to assure me that everything was fine. Water beads up on the floor nicely and my concrete should be well protected from gas and oil, which is good because my T'bird is leaky right now. :giggle:
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Once the sealer cured, I was ready to load in. Before I could, my daughter's car needed brakes and boy was it nice having all that room around it to work.

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Since then, I've added 2x8s around the base to finish off the walls a bit and loaded all the stuff from the shed. It's a bit chaotic right now as I figure out a good strategy for organizing things and determine what kind of shelving, cabinets and benches I need.

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Right now I only have the small work bench and one wall cabinet that I removed from the garage when we put a fridge out there. Dad's got a very nice work bench that he's getting close to parting with. It's 7.5' long and 30" deep with a 3" thick butcher block top and a welded steel frame. Was my grandpa's and has probably been in the family for 70 years, so that'll be coming in hopefully next year some time. And I've been shopping CL & FB for old kitchen cabinets and such. And once my budget recovers, I'll be putting in a lift. All that will probably be next summer.

Here are a few more shots of the finished product. The last shot was taken this morning, even have grass growing around it now.

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Kevkx125

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Joined
Dec 26, 2013
Messages
3,394
Location
DOUGLASSVILLE, PA
Build looks awesome , I like the older t-bird bet it is a fun cruiser . 30x40 is a good size to work with, heres a link to my 30x40
 

Openroad98

Member
Joined
Jan 23, 2021
Messages
5
Location
Loveland, CO
Beautiful shop, it'll be a few years before I can start but that is the exact size I want to build! Can I ask rough total cost for build, concrete, and insulation? I'm in Colorado so I know price is differ, but it's nice to have a rough idea since it was built in 2021 with all the changes in cost.

Thanks, ENJOY the space!
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Beautiful shop, it'll be a few years before I can start but that is the exact size I want to build! Can I ask rough total cost for build, concrete, and insulation? I'm in Colorado so I know price is differ, but it's nice to have a rough idea since it was built in 2021 with all the changes in cost.

Thanks, ENJOY the space!
More than I wanted, lol, but when is that not true.

It was just shy of $60K. That's the building, insulation, 3 insulated OH doors (two with side mount openers), 4 1/4" concrete plus aprons at each door, electric, gravel driveway and a gate in my vinyl fence (not done by the builder). His original quote was $53K and change, but the gate was $2500, I think the driveway added about $1K and there was a $2K adjustment for Covid lumber prices.
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Build looks awesome , I like the older t-bird bet it is a fun cruiser . 30x40 is a good size to work with, heres a link to my 30x40
It is fun. My grandfather bought it in California in 1978, I inherited it in 2000.

I took a nice 2 hour drive to nowhere in it this afternoon. This week looks like it'll be the end of the top down weather.
 
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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
Minor update. I've since installed TP-Link Kasa wifi connected light switches so I can turn on my lights from inside the house. The garage openers the builder installed are wifi enabled Genie wall mount openers, so I can turn on the outside & inside lights and open the door from my phone, which is really handy.

I've also done a number of car maintenance projects and it's very nice having the extra space and to not have to shuffle cars around to make room to work. Even with no heat, the insulation makes it bearable to work out there in sub-freezing temps. That said, heat is definitely still on the plan at some point.

One concern I have is that 2 of the stress relief saw cuts they made will end up between the legs of the two post lift I will eventually install. Reading some of the instructions for the lifts I'm considering, it seems that may be an issue. I hope not.

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salguod

Well-known member
Joined
May 8, 2020
Messages
45
Location
Columbus, OH
what are the plans for covering the walls? Maybe I missed it?
Post #11 - "Since this is just a workshop, I elected not to finish the walls. I may finish them later. For now, just plastic on the walls." ;)

I will probably put something up behind the workbench, (pegboard? drywall? Sheetmetal? Not sure) once I get that, but for now I'm cool with unfinished walls.

I do have these to hang up now now, so that'll be cool. Plan to get more.

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So far, I'm really loving it. The insulation, even without any heat, meant that working out there down to about freezing is doable with no issues. It also seems to heat up more slowly in the summer.

One small regret is that I specified 12' clear ceiling height for my lift and the builder put the joists at 12'. With the corrugated metal ceiling I lose almost an inch. That inch may be the difference in making some lift brands work. It has meant missing out on some FB Marketplace lift deals because I can't verify the specific model and therefore can't determine if it'll work. I should have asked for 12' 2" or something just to me sure. If it becomes too prohibitive, I can always go with a base plate lift, but I prefer the clear floor solution.

I really need to get on organization, stuff is still scattered around the floor. I was thinking of doing that after I got the workbench from my dad, but that looks like it might be a while.
 
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