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New Garage build - 30 X 40 Pole Barn in NJ

Dadofour

Well-known member
Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
I live in Middletown, NJ about a mile from the ocean. Not the “Jersey Shore” some are familiar with, but the very northern portion of the Jersey Shore, above Sandy Hook, for those familiar with the area. We are a few hundred feet from the evacuation line when hurricanes are expected and evacuation is required. For the most part, we all live on sand with soil on top for grass to grow. We generally do not have basements as you will hit water before you get deep enough for a decent height.

I started my “car guy” life in 2001. Since then I have learned a great deal about maintaining a street car and building a race car from the chassis up, starting with my first brake job in 2002. As a result of this growing passion, I have accumulated tools, cars, parts and the other assorted “****” from interests of my four kids (now all in their twenties).

My neighbors are awesome. They have tolerated three different cars sitting on jack stands for months while I either built them up or stripped them down for the junk yard. My daughter married a car guy and now I am contending with his collection of cars and parts as well. At the time of this writing we have 14 vehicles and an aluminum open trailer and a 28 ft enclosed trailer, all at my house with a 2/3’s acre yard. The street looks like we are having a party every day and the yard often has cars parked on the grass, especially when it snows and it is illegal to have cars on the street. We have kayaks, tree stands and tires piled along the side. We try to make the house look neat, but it is a losing battle.

I became aware of the concept of a pole barn in the late spring and started fantasizing about having my own. Fantasy led to reality and before I knew it I was seriously headed down the detached garage road with my wife’s blessing. I have many friends in the car community that are enablers and constantly “encouraging” the build so they have a local lift to work with and because misery loves company.

The serious part of the journey started with a visit to Town hall in June of this year (2015). My wife and I spoke with the head of zoning who shared all of the rules the barn would need to follow to be approved. She also shared that any structure or addition above 500 sq ft would need to be approved by the Township engineer. It seems that in the past since Hurricane Sandy, the town has been very focus on rain runoff management. This approval process is called a Grading Survey approval and requires I hire an engineer to do a site survey, including comparing my build against Zoning rules. The application is $250. I will save the gory details, but every application is rejected at least once and the town collects $250 each time you resubmit. The process takes 2 months per submission OR resubmission.

After speaking to the Zoning head, I spent the next month working with a Pole Barn company designing the perfect garage for my needs. 30 X 40 with 12’ 4” ceilings and an attic to store all of the **** that is currently in a 192 Sq Ft shed at the back of my property. I would have loved to go bigger, but there comes a point where you have to consider the aesthetics. The garage is designed to be three bays with a lift in the far right bay. Once we get further along I will share my plans for heat, lighting etc. My plan is to eventually convert the left two bays into a wood working shop when my racing decreases and/or I retire and want to get more into building furniture.

This is what the pole barn company and we (my wife and I) designed and moved forward documented with sealed plans per town requirements.

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To be continued...
 
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Bib Overalls

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Joined
Dec 4, 2006
Messages
3,318
Location
Jonesboro, Arkansas
Nice looking building. Hope you are able to get your plans through the bureaucratic process and approved quickly. There is nothing worse than a frustrated project and the bureaucrats practice frustration, or more correctly, the imposition of frustration every day.

You need to add a biffy at some point and plan ahead. When you reach the furitature building stage of your life the one in the house will be three to five steps too far away.
 

vintagelifev8

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Joined
Apr 7, 2014
Messages
103
Location
them thar hills
Getting gouged by local government does **** the life out of a person. I hope you are able to get what permission you need and build. This build caught my eye because it is similar in size to mine. You can check it out if you want ideas or have questions. It's under 30x48x12 Attic Truss Pole Barn. I started it in April 2014 and spend so much time out there. I enjoyed the build and continue to make improvements. Just added electric and a water hydrant. I'll be watching your progress. Good luck!
 

rlme36

Well-known member
Joined
Feb 17, 2008
Messages
331
Than,

Glad the project is starting to really take shape. I like to think in some small part that I've helped you down the path as I run ahead with the grease gun. Good luck and let's hope for s warm day for the pour.
 
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Dadofour

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Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
Nice looking building. Hope you are able to get your plans through the bureaucratic process and approved quickly. There is nothing worse than a frustrated project and the bureaucrats practice frustration, or more correctly, the imposition of frustration every day.

You need to add a biffy at some point and plan ahead. When you reach the furitature building stage of your life the one in the house will be three to five steps too far away.

Thanks for the positive thoughts. Wanted water and sewage but the distance added too much cost. The Barn is only 30 feet from the back door of the house for now.

Nice building. Good luck with the town.

The town experience is new to me and not one I am enjoying.

Getting gouged by local government does **** the life out of a person. I hope you are able to get what permission you need and build. This build caught my eye because it is similar in size to mine. You can check it out if you want ideas or have questions. It's under 30x48x12 Attic Truss Pole Barn. I started it in April 2014 and spend so much time out there. I enjoyed the build and continue to make improvements. Just added electric and a water hydrant. I'll be watching your progress. Good luck!

Thanks will check it out now.

Than,

Glad the project is starting to really take shape. I like to think in some small part that I've helped you down the path as I run ahead with the grease gun. Good luck and let's hope for s warm day for the pour.

Rob, you have been a constant source of enablement. Radiant heat, Lifts, etc. Keep up the good work. My bank account is whimpering.
 
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Dadofour

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Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
We submitted the application with four copies of our barn plans (sealed - $500 charge from builder) on the last business day of August. We were declined (expected) with a number of required changes, the most impactful being the requirement to install a drywell with 130 Cu Ft of storage to handle the water from the 1200 sq ft roof. Once we received final approval in October (ahead of schedule) I was told that all additional Township approvals would be a rubber stamp as Zoning approval was received for the Grading Survey approval.

Fast forward to Halloween week and I receive a letter from Zoning declining our application to build because our 22’ 10” high Building exceeds maximum regulation by 6’ 10 inches.

What? What requirement states we can only go to 16’? Must be an error as we spoke with the Zoning head when we started and she gave us all of the regulations and the plans followed those to the T. I sent an email and followed it up with a visit the next morning. Seems she neglected to share an obscure (to me) regulation that prohibits detached garages from exceeding 16’. She seemed unconcerned and asked if I wanted to apply for a variance. Of course I headed up the hill to the building where variances are handled and spoke to the woman there who outlined the hoops I would have to jump through and the additional application fees. Nice lady. She asked what I was applying for and when I told her informed me in the nicest way possible that no detached garage had ever received a variance as the town wants to prevent illegal apartments from being built above garages. Game over for my dream garage. I called the pole barn company and told them the township had killed us. I started adding up the money I had spent to date including tree trimming, the drywell unit I had shipped from NC.

I went home and fumed, sulked and generally was pissed off. My wife and son-in-law asked the simple question. “Why not lower the roof and eliminate the attic storage?” I called the Zoning head who is now my best friend since she “messed up”. She said since the footprint was not changing I would not need to getting another Grading Survey plan approved. She also said just drop off new plans and she would ensure I received expedited processing of my application. After about 5 minutes I was back on the phone with the Pole Barn company. After a week we had plans for scissor trusses, a lowered wall height to 11’4” and a low pitch roof that can withstand the snow loads for our locale.

The architect redid the plans and sealed them. He overnighted them and my wife dropped them off for the township. After not hearing from the town for 2 weeks I went into Town hall before Thanksgiving and found the Building Inspector was “just going to call me”. The plans sent had every page sealed except the new truss design. He rejected them. (rightfully so). The architect did a new set of plans and sent them along a couple of days later. These were approved on the spot and we were off to the races.

New Design minus attic with very shallow pitch roof and walls 1' shorter.

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In advance of formal approval I moved forwardng with Trimming the two large Oak trees that were saplings when we vought the house.

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Dadofour

Well-known member
Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
The Pole Barn company ordered scissor trusses and during the three week lead time I installed the drywell. The engineer who did the survey suggested Storm Chamber which I had ordered and received a month or so before. I use a skid steer operator who charges by the hour and is very good. We spent four hours together digging the ditch 5 feet deep and eight feet wide.

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Jim_No_Garage

Well-known member
Joined
Jan 15, 2011
Messages
3,340
Location
Millington NJ
Sorry to hear about all the town roadblocks but it's good you regrouped and are moving forward with the project.

Consider yourself lucky you have the type of soil you do - if I need a dry well of that size I would almost have to blast! My neighbor put 2 or 3 concrete tanks in his back yard for rainwater management when they put an addition onto the house.

Keep posting as things progress

Cheers

Jim
 

jbaccell

Active member
Joined
Jan 19, 2012
Messages
30
Location
NJ
I live in Middletown, NJ about a mile from the ocean. Not the “Jersey Shore” some are familiar with, but the very northern portion of the Jersey Shore, above Sandy Hook, for those familiar with the area. We are a few hundred feet from the evacuation line when hurricanes are expected and evacuation is required. For the most part, we all live on sand with soil on top for grass to grow. We generally do not have basements as you will hit water before you get deep enough for a decent height.

I started my “car guy” life in 2001. Since then I have learned a great deal about maintaining a street car and building a race car from the chassis up, starting with my first brake job in 2002. As a result of this growing passion, I have accumulated tools, cars, parts and the other assorted “****” from interests of my four kids (now all in their twenties).

My neighbors are awesome. They have tolerated three different cars sitting on jack stands for months while I either built them up or stripped them down for the junk yard. My daughter married a car guy and now I am contending with his collection of cars and parts as well. At the time of this writing we have 14 vehicles and an aluminum open trailer and a 28 ft enclosed trailer, all at my house with a 2/3’s acre yard. The street looks like we are having a party every day and the yard often has cars parked on the grass, especially when it snows and it is illegal to have cars on the street. We have kayaks, tree stands and tires piled along the side. We try to make the house look neat, but it is a losing battle.

I became aware of the concept of a pole barn in the late spring and started fantasizing about having my own. Fantasy led to reality and before I knew it I was seriously headed down the detached garage road with my wife’s blessing. I have many friends in the car community that are enablers and constantly “encouraging” the build so they have a local lift to work with and because misery loves company.

The serious part of the journey started with a visit to Town hall in June of this year (2015). My wife and I spoke with the head of zoning who shared all of the rules the barn would need to follow to be approved. She also shared that any structure or addition above 500 sq ft would need to be approved by the Township engineer. It seems that in the past since Hurricane Sandy, the town has been very focus on rain runoff management. This approval process is called a Grading Survey approval and requires I hire an engineer to do a site survey, including comparing my build against Zoning rules. The application is $250. I will save the gory details, but every application is rejected at least once and the town collects $250 each time you resubmit. The process takes 2 months per submission OR resubmission.

After speaking to the Zoning head, I spent the next month working with a Pole Barn company designing the perfect garage for my needs. 30 X 40 with 12’ 4” ceilings and an attic to store all of the **** that is currently in a 192 Sq Ft shed at the back of my property. I would have loved to go bigger, but there comes a point where you have to consider the aesthetics. The garage is designed to be three bays with a lift in the far right bay. Once we get further along I will share my plans for heat, lighting etc. My plan is to eventually convert the left two bays into a wood working shop when my racing decreases and/or I retire and want to get more into building furniture.

This is what the pole barn company and we (my wife and I) designed and moved forward documented with sealed plans per town requirements.

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To be continued...

I find this post quite fascinating as I too have dreamed of having a detached garage built for all my machines and toys. And, I'm also a Middleiwn, NJ resident. I look forward to future post with great interest.

Good luck,

Joe
 

jbaccell

Active member
Joined
Jan 19, 2012
Messages
30
Location
NJ
Have you calculated what the increase in property taxes will be? I'm already payin $12,000.00 a year.....
 
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Dadofour

Well-known member
Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
Sorry to hear about all the town roadblocks but it's good you regrouped and are moving forward with the project.

Consider yourself lucky you have the type of soil you do - if I need a dry well of that size I would almost have to blast! My neighbor put 2 or 3 concrete tanks in his back yard for rainwater management when they put an addition onto the house.

Keep posting as things progress

Cheers

Jim

Thanks Jim. We live about a mile from the ocean so our soil is sandy. We were surprised how uneventful the drywell install was, but very happy. More posts coming. This build will run into February for sure.

Have you calculated what the increase in property taxes will be? I'm already payin $12,000.00 a year.....

I haven't. My taxes are similar to yours. I needed the space and am tired of the clutter so I never even considered estimated increased taxes (Maybe I should have).
 

jbaccell

Active member
Joined
Jan 19, 2012
Messages
30
Location
NJ
Thanks Jim. We live about a mile from the ocean so our soil is sandy. We were surprised how uneventful the drywell install was, but very happy. More posts coming. This build will run into February for sure.



I haven't. My taxes are similar to yours. I needed the space and am tired of the clutter so I never even considered estimated increased taxes (Maybe I should have).

Thanks for the reply, I too am so tired of the clutter as I have so much equipment stuffed into my two car garage that I have no room to work. I have been reluctant to build a detached barn/garage in part out of concern how much my taxes will increase. Heck, they will go up if you put a shed over a certain size up...

Thanks again for the reply, I appreciate it.

Joe
 
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Dadofour

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Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
A tentative date was set for the week of December 17th. I got the call and was told Tuesday December 15th would be the start date. I got up early to meet the truck with the supplies necessary for the barn. The truck wasn’t much bigger than a big flat bed tow truck.

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Everything went without a hitch except for a number of fairly substantial hunks of concrete where two of the poles needed to go. They got them out and things moved along without a hitch.

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Work progressed over 5 days with the most obvious progress made on days 2-3.

At the end of Day two my wife took this picture to give some scale to the size.

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Work began Day 3 with the exterior being completed

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Over the next two days the interior details were completed and the gutters installed. Rain was predicted so connecting the downspouts to the drywall became a priority.

To be continued...
 
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Dadofour

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Joined
Jul 14, 2015
Messages
107
Location
Middletown, NJ
Haven't posted in a bit, so I figured I would catch you up to current times

The week before Christmas we dug all the trenches for the Gas, Electric and Water lines to go to the Barn. I did not anticipate the destruction and havoc it would reak on my yard. Of course it rained every other day collapsing the trenches, flooding the yard and generally making it impossible for the two planned concrete trucks to get into the yard.

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We finished the drainage of the downspouts to the drywell.
Drainage
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Drainage Complete
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The township requires the floor to be pitched 1/8" a foot. That required a 4" drop back to front which really was not what I was looking for. I wanted a flat floor to allow me to align and corner balance my race car.

Spoke to the inspector and he indicated a 2" drop would be sufficient.

Gravel and Plastic
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I never anticipated that the 2" pitch would change the amount of gravel required, but it did. After a couple of emergency trucks of gravel were delivered Christmas eve morning we were done.


I bought a package from Radiance and have been very pleased with their support.

They recommended wire remesh, tubes and another layer of wire remesh to distribute the heat from the tubes.

Recommended 2" foam below and around concrete pad.

Starting Foam for Radiant
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Starting Tubes accommodating lift
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Radiant Manifold
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Radiant Tubes
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Wife and Daughter installing Radiant
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Radiant Tubes Complete
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Another 20 tons of gravel delivered to create a temporary driveway that would prevent the concrete trucks from sinking into the dirt. Added 10 3/4" sheets of plywood to dissipate the the weight. It worked and both trucks had no issues.
Concrete Pour
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Once the concrete was poured there was a lot of waiting for it to set enough to start finishing it.

Watching Concrete Pour
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Once the concrete was down my wife, son and I started putting up interior horizontal 2 X 4's to allow Sheetrock to be installed.

Sheetrock Framing
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At the same time my son's friend and his dad (John and Joe)
Electrical Rough-incame to run electrical from the house to the barn and then do the rough-in.

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Today the Spray foam insulation guy showed up and started the spray foam process. I got a family and friends discount thanks to my son-in-law and it was only $500 more than the Pole Barn company wanted to fiberglass.

R13 on the walls and R26-R33 on the roof.


Insulation 1
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Insulation 2
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Insulation 3

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Insulation 4
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Insulation 5
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Insulation Ceiling Complete
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I have some time lapsed videos of the build, Radiant tubes and concrete pour I will post later. This is now the current status of the build. I have an inquiry into the township engineer to see if I can pour a 12' apron in front of the doors....More to come.

Sheetrock next week.
 
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yeldogt

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Joined
Jan 2, 2012
Messages
18,184
I feel you pain ... my project has been delayed 6 months over township ****. The wasted $$ is unbelievable.

You will not regret the spray foam ---
 
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Dadofour

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Messages
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Middletown, NJ
I feel you pain ... my project has been delayed 6 months over township ****. The wasted $$ is unbelievable.

You will not regret the spray foam ---

I hope I am getting past the delays. Now I can worry about the hoops I will need to consider to get my C of O. We used a propane heater in the barn today and got to warm. In the past the sae heater did not even take the edge off the cold.

Bummer you couldn't do the 8/12 pitch with some attic space - but it looks awesome nonetheless.

Your original plan is very similar to the garage I'm building.

Thread Here

I am finally past it, but agree the 8/12 with the attic would have looked awesome!

Nice looking project. Looking forward to see the progress.

Jeff

Can't wait to see the change that will happen after the sheetrock is in. Thanks
 

Power Sedan

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Joined
Nov 15, 2015
Messages
287
Location
SE Wisconsin
Really great looking garage! Wish I could be granted a permit via local municipality to build a structure equivalent, on my property. Looking forward to future progress with the interior.

Keith
 

Jim_No_Garage

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Joined
Jan 15, 2011
Messages
3,340
Location
Millington NJ
Wife and Daughter installing Radiant

View media item 57080

At least one of the ladies has her Civil Service Work Gloves on!

Structure up - check
Rough Electric - check
Spray foam - check (very jealous)
Radiant floor complete - check (bummer about the 2" pitch requirement)
Doors installed - check

This will be a great garage on it's all done. . .

What are your plans for making the hot water for the floor? Gas, oil or electric?

Are you going to leave the ceiling open or sheetrock it?

So many questions . . .

Cheers

Jim
 
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Dadofour

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Joined
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Messages
107
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Middletown, NJ
Gas tankless water heater. Trusses cannot support weight of sheetrock so I am looking at a stiff soffet material to put up between the trusses.

So much progress and so much left to do!


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bullnerd

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Joined
Sep 17, 2012
Messages
5,690
Location
Jersey
Wow, very nice!

Congrats on your new shop!

What is the reason for the pitched floor in a garage? What do they think is going to happen? My inspector never even mentioned pitching the floor. Good thing, because I would have said no way.
 

mygarageone

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Joined
Oct 16, 2013
Messages
2,691
Location
Munising , Mich
I really feel for you that have to deal with all those permitting issues. Stamped plans , etc ,etc.
Great looking build , you'll sure love the floor htg.
It makes me very thankful to live were I do.

When I built my 30x40 , I needed a water shed review took 10 min's , zoning took 15 minutes and I waited , the inspector wanted a drawing which I did on a 8x11 sheet of paper .
Inspector ask me a few question when I went to file for the permit and I was out of there in 10 min's with permit in hand. I did all of this the same day . Yes it a small county and we are still living like it was 1980 and it's not going to change and time soon.
 
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Dadofour

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Messages
107
Location
Middletown, NJ
I stayed home a little late yesterday to meet the sheetrocker to go over the details of his work. Left an hour late with plans to fly to Boston. My awesome wife who has been my digital recorder (picture taker) and framing partner sent these pictures after the sheetrockers finished hanging rock. This morning they show up to tape and spackle.

Spackle again Friday and then finsihed coat Monday. The timing should allow the expected snow storm to pass us without impacting the sheetrock schedule.

I have a very cool plan for the ceiling. No one understands when I explain so will wait until I have pictures.

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Dadofour

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Messages
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Middletown, NJ
Looks great. Did they frame between the poles?


"They" was my wife and I.

We did horizontal framing 24" Oc. Had some challenges making sure there were nailers in the corners. The sheetrock really did quality work. I have been very lucky with the quality of the subs.




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Dadofour

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Middletown, NJ
Yeah, nice!



Are you going to paint the wood frame around the doors or..?


Bullnerd

Great eye. We are going to paint wood headers and garage door frames same color as the base moulding. Should look fairly finished.

My amazing wife and I are doing the painting.


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Colonel Clank

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Nov 21, 2013
Messages
4
Looks awesome! I also live in central nj (South Plainfield)....have probably bumped into you at the Etown swap meet. Lol!
 
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Dadofour

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Messages
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Middletown, NJ
Over the last two days the sheetrocker has come back to tape and spackle. We have been running a propane heater to keep the garage warm enough to allow the spackle to dry. Over the next couple of days we will be contending with a heavy snowfall. Monday hopefully will bring the final coat, then paint and electrical and heat.

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bullnerd

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I only noticed because I have to do something with my own building. I wish I trimmed it before the doors were installed, but I didn't know what I was doing.
 
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Dadofour

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Middletown, NJ
I only noticed because I have to do something with my own building. I wish I trimmed it before the doors were installed, but I didn't know what I was doing.


I understand. Felt the same way. Too bad I only plan to build one. I have a learned a lot along the way I won't be able to use again for myself. The painting is a best effort solution
 
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