11/8 and 11/9/2010. Here comes the concrete, all 80 yards of it. The concrete was the part of the build that I was fretting the most. The ground at my place gets rock hard throughout the summer. In the fall, we didn't have our usual rainfall and the ground where the delivery trucks were driving was staying flat and not becoming rutted and I was happy about that. Concrete trucks are another story though so if the concrete didn't get done in the fall, I would have to wait until the middle of the summer when the ground dried up again. With the frost and rainy spring here, there's just no way to bring a concrete truck in until July and that would be a bummer. With the weather getting colder, adding too much chloride to the mix was also a concern. I thought I had my concrete guy all lined up and when the builder gave me the thumbs up to proceed with the concrete, I called the concrete guy, several times and no return call! Ever! Oh **it! Now what!? In a panic, I called the concrete contractors with the next higher bids. They were all busy and the weather forecast was unbelievable for the next 7-10 days, no rain with high temps between 60° and 75°! It's November! In a last ditch effort, I called the excavator who put in a new septic system for me a couple years ago and he recommended a guy I had not talked to previously. I called this guy on Thursday, 11/4 and asked him if he would pour concrete on Monday. After a short chuckle, he said "well, I don't know, how much do you need" I said, "80 yards" He said "I'll be right over" LOL!!

He came down and gave me a quote, we agreed, and his guys were down on Friday to level, tamp, and set the forms. He was $4000 more than the disappearing guy but I had to do it, I didn't want to wait. And something else, the low bid was from a guy that poured concrete on the side. The guy that ended up pouring it, it's his business. So I guess it was meant to be because I didn't want a half-assed concrete job, especially on something this big.
The floor turned out just the way I wanted it, smooth and level. On Monday when they poured the interior portion, I think there were 7 guys working and the boss was working too, making sure it was done just like we spoke about. They used a laser level and three power trowels. On Tuesday, they poured the outdoor portion and the approaches and had four guys working.
The concrete is 4" thick and reinforced with wire. I don't like concrete reinforced with glass fibers because when I lay on it, it makes me itch. The floor is also insulated with a foil/bubble material that doubles as a vapor barrier. I know there are many opinions about in floor heat but here's why I didn't do it. First, I already have a heated workshop so I didn't need the new barn to be my primary heated workshop. Second, is the response time to warm up the area. My shop has a forced air furnace and I keep the temperature at 50°. When I want to work out there, I just turn up the thermostat and it's 68° in 30 minutes. Floor heat can't react that quickly and I couldn't afford to keep it warm all the time. The interior of the new barn is 4576 sqft. Third, the timing and expense. I don't know how long it would have taken to run the tubing or what that material would have cost. I was going over budget with the change in concrete contractors. The concrete trucks drove inside as they poured the floor so the wire and insulation were put down as they poured the concrete. That would probably have been a big PITA laying the tubing too. It would have probably been messed up and not done to my liking so it's probably better that I didn't go that route. A new 120,000 BTU forced air furnace costs $750 at the HVAC contractors warehouse. So, without further ado.