Above 1200 Sq/FT Barn Workshop build

[ururk]

Monday, October 17: Installed the second roof layer on one side, with some of the roof furring strips.

For each piece of foam, I know the exact position the 2x4 needs to be in so I can be sure to hit the beams and not blast through the 2x6 roof decking.

After screwing the furring strip into the foam, I lift them both up at once:

I only installed one 2x4 for each bent (total of 8 boards). I will be filling these in with other pieces, but in the interest of time I wanted to maximize how much I got done.

The inside is getting cleared out, but is totally messy. I have to figure out what foam to give to my neighbors (one has asked for some), and see if I can sell some of the larger - more interesting - pieces of 4" foam. I know people carve it, and I'm not looking to make my money back but I hate to just throw it out or give it away for free.

 

[matt_i]

Looking really good, lots of detailing with every piece I can tell. No way around it other than to keep nose to the grindstone.

I am curious what kind of heat you will use, Im guessing a 5kw electric space heater would keep it quite warm, although the heat will still rise unless its circulated back down.

Also I'm curious as to what your goal is to accomplish before the "season" ends. Thinking if the roofing was on you could still work on siding without much interference from the weather. We had, in my opinion, a very good winter for outdoor work last winter...I framed and sheathed, etc. But concerned with a dry summer we could get blasted a few times this year.

 

[hpw]

I am curious what kind of heat you will use,

I'm thinking a candle for the winter and a ice cube or 2 for the summer

 

[ururk]

Looking really good, lots of detailing with every piece I can tell. No way around it other than to keep nose to the grindstone.

Thanks! Sometimes I think I'm doing a terrible job. I know this sounds stupid - but there are areas of the work I've done that I could have done better.

I am curious what kind of heat you will use, Im guessing a 5kw electric space heater would keep it quite warm, although the heat will still rise unless its circulated back down.

The "plan" was a boiler or water heater and radiant in the floor and upstairs. Not sure - I have a propane water heater, but won't get it in until next year. For now I'll light a bunch of candles

Also I'm curious as to what your goal is to accomplish before the "season" ends. Thinking if the roofing was on you could still work on siding without much interference from the weather. We had, in my opinion, a very good winter for outdoor work last winter...I framed and sheathed, etc. But concerned with a dry summer we could get blasted a few times this year.

Sigh. Everything. But in reality, I don't think I will get that far. My goal - and this is a strong goal - is to get the metal roof on before the first snowfall, along with the windows. The machine goes back this weekend - I cannot afford to rent it again - so will be working from ladders to finish the eaves and any remaining furring strips, then hopefully I can attach the pump jacks to the eaves. From there I'll work from side to side.

 

[ururk]

Tuesday, October 18: Trimmed the foam and taped:

Installed one board:

 

[sean Buick 76]

Hi there, I have never seen a building like this with all the foam on the exterior but it is interesting! What siding are you using on top of that? Does it need another vapour barrier? I am really interested I like to learn about this stuff I am not trying to be rude at all... It looks WARM!! keep up the attention to detail, I have trouble with the details.

 

[rpenterics]

The snow last night had me wondering about your build, hope things have been going smoothly - how have you come along since October? Roof? Siding?

 

[ururk]

The snow last night had me wondering about your build, hope things have been going smoothly - how have you come along since October? Roof? Siding?

I have some updates to make, but have been delayed on working on the barn a bit due to issues unrelated to my project. I'm hoping that I can get back up to date with posts this week, and start working again. We did get a little bit of snow in our area - maybe 1/2". My tarp got destroyed in the wind storm that came through a weekend, ago or so, haven't replaced it. I'm having trouble deciding on whether I should get two smaller tarps and overlap in the middle, or one big one again. I did get my pump jacks set up, so there's that "win". Overall though, trying not to get too discouraged . Next on the docket are the eaves, as those still need to be constructed.

 

[drivesitfar]

UR: just saw your build and a very interesting design and roof so i'm hoping to see more good stuff as you keep finishing it up.

hard to say how you could have saved time or done more than one piece at a time going up to the roof. maybe if you owned scaffolding or rented another lift to just raise up the pieces since you don't have a level area to set them might have been an option. either time or money so if your time is cheaper than renting or buying more tools that's your call. it looks like you did fine.

 

[rusty1]

...just read your whole thread, amazing amount of work, nicely done, hope you never have to move from there after all that.
...looks like that type of building takes as long as putting up 3 or 4 "regular" buildings.
..what wil all the inside beams and ceiling be finished with?...surely they won't be left bare.

 

[Deezler]

Hey, how's progress? I just drove by the other day, was checking out Christmas trees just up the road. I kind of scared my wife when I yelled out "HEY I KNOW THAT BARN!". haha. It's.... so blue!

I didn't realize we were so close, you're about half way between where I work and live. I usually cruise roads further to the south, but occasionally come through your adjacent intersection.

 

[Grizz1963]

Just a quick Merry Christmas and Happy New Year o you.

May your progress continue at a pace that impresses us as you have to date.

 

[ururk]

Hey, how's progress? I just drove by the other day, was checking out Christmas trees just up the road. I kind of scared my wife when I yelled out "HEY I KNOW THAT BARN!". haha. It's.... so blue!

I didn't realize we were so close, you're about half way between where I work and live. I usually cruise roads further to the south, but occasionally come through your adjacent intersection.

Wondering when someone would recognize it on here. I don't know yet if I've reached 'notoriety' level in the township - probably not. Our house blew up when it was being built (back in 1983), so usually that's how conversations start out.

 

[ururk]

OK - updates will be starting again. A combination of computer issues (well... let's say syncing issues between computers, Dropbox, Google Drive, etc...) hampered my ability to post. I've sorted it all out and have a new process in place. I've also started doing stuff now that the weather is warming up (55 today!). Though, to be honest, it's going to get back into the 30's this week so I might peter off again .

I'll post photos, but progress so far... I've started on the eaves. I almost finished one side today, should finish tomorrow unless it rains. Once all the eaves are done, I'll order my roof metal. I'm getting an installation quote for both standing seam and flat sheet panels. I don't like the idea of the corrugated roofing - it will be cheaper, but all the washers over time will shrink/crack and I'd rather go with something that has a hidden fastener.

 

[ururk]

Wednesday, October 19: Finished the house side foam, and foamed the top seam:

 

[ururk]

Friday, October 21: Finished the strapping on the house side of the roof.

This may seem like a ton of wood. It is quite a bit, and is probably overkill. But, I was working from the manufacturer's design numbers for spacing - both screw spacing and board spacing for a given thickness of foam. Remember the 2x6 T&G decking I installed? I needed 1" penetration into that by my long screws. However, since my boards run vertically, if I were to screw through where two board meet, I'd get an ugly hole inside the barn *and* it wouldn't be in enough wood. I had to locate the boards at least an inch from any edge - for some of the bents this worked out pretty well, but still led to a few spots where I had to shift a 2x4 left of right. Frankly, if I were to do this again I'd rethink how I did the roof attachment.

(since I'm posting this months after I did the work, I might have mentioned this in an earlier post)

Staged the boards for the other side:

 

[AZ Pete]

Wow! Subscribed


Sent from my iPad using Tapatalk

 

[ururk]

Side note: I think I finished the road side roof boards on Oct 20, but I don't have any photos so I can't tell - sigh.

 

[ururk]

Saturday, October 22: This is the only photo I have from this day, but I think I installed all of the horizontal boards at the ridges on this side.

 

[ururk]

Sunday, October 23: Finished all the horizontal boards I could install. The next day they picked up the lift

This was a bad idea - tarp only lasted a few weeks:

After this day I took a bit of a break - the weather turned cold, I was out of town for a week+, and so on.

 

[ururk]

Monday, January 2: I'd been sick with a cold for two weeks, but was just getting over it. Even though I had the previous week off from work, I didn't get much done because I'd been sick. Everyone I knew who got it had the same symptoms and duration.

I made a mockup of the eave. I needed to check some measurements and verify the construction order.

 

[ururk]

Wednesday, January 18: It's been bitter cold, but I made it out at night to cut some wood for the eaves:

It's a start!

 

[ururk]

Saturday, January 21: Got the eave on one side 1/2 done. I think the temp got up to 55, I ended up de-jacketing. Provided tomorrow is just as nice, or at least 40, I'll finish the third roof pitch.

When I move the pump jacks to the other side of the barn, I'll set them further from the wall. They way I had them, I had to crawl/move around the angled boards.



That horizontal board is a bit ugly, but it was solid. In addition to those two screws (GRK R4), two get screwed into the angled board.





Front board installed:



Testing the strength of the assembly:

 

[Ak Mancave]

Inspirational build. I need to stop procrastinating and get my metal up on my interior walls.

 

[ururk]

Inspirational build. I need to stop procrastinating and get my metal up on my interior walls.

Ah, I know how difficult it is to be motivated.

 

[ururk]

Sunday, January 22: Almost finished the eave. Another warm, but humid day.

I'm not happy with how this side came out - but I think the amount the angled pieces rest on the upper board is sufficient, they also get two screws into the strapping. Overall it is pretty straight, but I'm too afraid to check it against the string.

This was the jig I used to cut the pointer end:

Supposed to rain all day tomorrow. If Tuesday is nice I'll try to finish up by adding the horizontal strapping (for the metal roof).

Then the ends have to be finished off - I'm leaving those for last because I have to insert a piece of wood into the roof, and trim the ends to the correct length. I'm trying to build up enough courage as I have to use the longer extension ladder (I might be able to do it from the roof).

Not that I'm afraid of heights... mostly afraid of that ladder on mucky ground. I'll probably build a wooden support platform. I bought a ladder stabilizer, which really makes the smaller ladder stable, hopefully it works as well on the longer one.

 

[matt_i]

Looking good! I really like the edge detail on the roof, that will add a lot of character from faraway. These long builds are like a marathon...I'm in closing in on 2yr since I broke ground, trying to get my interior finished. The mucky winter does leave a lot to be desired working outside..even if the temps are reasonable good...I recall that well.

Are you going to bring back the manlift to put up the roofing? I always wondered how those giant barns were roofed...

 

[ururk]

Looking good! I really like the edge detail on the roof, that will add a lot of character from faraway. These long builds are like a marathon...I'm in closing in on 2yr since I broke ground, trying to get my interior finished. The mucky winter does leave a lot to be desired working outside..even if the temps are reasonable good...I recall that well.

Want to swap builds ?

Are you going to bring back the manlift to put up the roofing? I always wondered how those giant barns were roofed...

Thanks re:edge. I'm hoping it is wide enough to look different from afar. I didn't like the look of barns in my area that go straight down, they look unfinished.

As for the manlift... I wish. Probably not. My hope is, when I install the horizontal strapping for the roof (every 18"-24" OC), I can use that to walk up and down the peak. The top pitches are safe to walk, those bottom pitches are too steep.

Provided we get minimal weather between Wednesday and the weekend, I'm going to try and tackle the front part of the side eave. If I can handle that from the ladder, I should be able to do the rest without the lift (famous last words). The problem - as soon as the weather breaks the ground will soften to a consistency of wet clay and the machine will get stuck. If I cannot work on the eave reasonably well from the ladder, I might rent some scaffolding from Menards. Their price is fairly cheap, and I could rent several bunks over a weekend for very little money. The biggest problem would be lifting the scaffolding by myself, as I don't have anyone who will help me up high.

 

[mike93lx]

Just read through everything... Wow, what a build. I love post and beam structures.

Out of curiousity, why didn't you go with Zip system? Seems like all the extra work of priming and applying that peel and stick stuff would hve been nice to cut out.

 

[ururk]

Just read through everything... Wow, what a build. I love post and beam structures.

Out of curiousity, why didn't you go with Zip system? Seems like all the extra work of priming and applying that peel and stick stuff would hve been nice to cut out.

I didn't know about that system when I started, and none of the construction guides I read talked about using it. That being said... I should have used it.

Even taping the seams of the OSB could have been good enough - provided the OSB itself had low permeability. However, not all OSB is created equal, some OSB will let vapor pass through.

Lesson learned! I think I have 10 bullet points for every step I took on this project on how I could improve the build process. I'm not in construction, so all of this is new to me.

 

[mike93lx]

I didn't know about that system when I started, and none of the construction guides I read talked about using it. That being said... I should have used it.

Even taping the seams of the OSB could have been good enough - provided the OSB itself had low permeability. However, not all OSB is created equal, some OSB will let vapor pass through.

Lesson learned! I think I have 10 bullet points for every step I took on this project on how I could improve the build process. I'm not in construction, so all of this is new to me.

well, the good news is, hopefully you never have to build another one

keep up the quality work. I would love to put up a small post and beam building in my backyard.

 

[ururk]

well, the good news is, hopefully you never have to build another one

Amen to that! Don't get me wrong - I do enjoy the construction work, but I really am itching to use the space for some projects.

keep up the quality work. I would love to put up a small post and beam building in my backyard.

I don't know what you mean by small - this is the website of the guy who cut my frame: http://www.mktimberworks.com

Also - there are differences in terminology. What I had made was a timber frame - all wood joints. Post and beam typically refers to metal plates with wood members. This site has a good description of the two methods:

http://www.vermonttimberworks.com/blog/timber-framing-vs-post-and-beam-construction/

 

[mike93lx]

I don't know what you mean by small - this is the website of the guy who cut my frame: http://www.mktimberworks.com

Also - there are differences in terminology. What I had made was a timber frame - all wood joints. Post and beam typically refers to metal plates with wood members. This site has a good description of the two methods:

http://www.vermonttimberworks.com/blog/timber-framing-vs-post-and-beam-construction/

realistically, I will be lucky to put up something 16x24. more likely it will be 12x20 if I am ever able to do it. silly things like windows and siding for my house and a new septic system at some point in the reasonably near future will probably get in the way.

Timber Frame is the style I was thinking of. Never really though about the difference, thanks for the link.

 

[lieutenant]

Wow! I just finished this whole thread. I'm a big fan of timber frame structures and the building science website. Your build is really explaining how to abide by the building science recommendations. Great job!

 

[Brunow]

Wow! good job!

 

[ururk]

Sunday, January 29: Cut and installed six 2x4's.

What's left on this side:

Three more 2x4's as strapping for the second pitch, and the ends have to be framed in and trimmed. Then... I think I tarp the roof and only work on warmer days. It was a "warm" 29. No wind, so it wasn't too bad. It was "nice" inside the barn.

Also - periodically I snag a nice pallet from work and break it up. I'm not really documenting that work, seems rather mundane. I'll be using the planks to cover the walls.

 

[drivesitfar]

UR: pretty impressive doing that sort work and the great quality too with snow on the roof. YOU ARE THE MAN.

BEE CAREFUL and keep up the good work

 

[ururk]

Saturday, February 11: Finally a nice day! 45ish. I had some freelance work to get to, so only got a few hours of work in. Picked up wood for the roof and got one section done:

Tape is in perfect condition. You can see the spacer block I used.

My target spacing was 18" OC, but had to go slightly smaller (14.75") as the next step would have been around 19", and I didn't want to risk incorrect spacing.

After getting this section done, I'm very confident I can finish the other sections in one day.

 

[ururk]

Sunday, February 12: It rained on and off today, only had a brief opportunity to get some boards up:

This leaves the middle section and then the second level.

 

[smschriefer]

Looking good! Winter weather is always a pain to do things, so I guess just the simple fact you are able to do roof work in February is a plus.