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Above 1200 Sq/FT Take 2! 40x60 shop build

Wokspaces above 1200 squarefeet.

86scotty

Member
Joined
Apr 19, 2018
Messages
8
I've been mostly a lurker here for a few years, starting a new project and wanted to share. Feedback appreciated. Sorry for the novel but there's a bit of backstory.

Long time car guy and woodworker. Raised a family in my home of 20+ years and built a great 24x36 shop there. We were on a hefty .6 acres in a growing small town and wanted more space but then a fire helped us rush that a bit just about the time our last child headed to college. Insurance deemed it an electrical fire from an outlet that got hot. A dorm fridge was the only thing plugged into or running on that outlet, untouched in a year or more. I built and wired the building and it was all good for 5 or so years. We didn't lose the house but I lost the shop, thankfully unattached to the house. This pushed us over the edge to move. After looking at lots of land we lucked out on 10 acres, about 4 acres of fairly level field for a shop and 6 acres of woods where we will build a house eventually. More on the new shop later.

I lost lots and lots of lifetime tools, my 2 post lift, all my Dad's classic Craftsman stuff, lots of memorabilia, motorcycle and car parts, heavy truck parts (my work), my pristine Jetta that was only insured liability, etc. etc. I built that shop myself with one friend and one piece of rented equipment and thought I would be there forever. I had outgrown it though. Here are some pics of what fire does to a general workshop full of all the stuff your shop probably has in it. Automotive fluids/lubricants, paint, wood stain, plastic plastic plastic tools and parts. The fire was caught quickly and we have (or had) a great city FD very close but still the hot gases and melted and destroyed everything above waist level.

Here are a couple of before shots but I have no recent shots with the finished woodshop in the back, dust collection, mini split I added, etc.

54259155534_b6b50ee508.jpgScreenshot 2024-07-20 at 9.51.37 AM by E A, on Flickr

54258029882_23f8eb6bd7.jpgScreenshot 2024-07-20 at 9.52.15 AM by E A, on Flickr

54258030837_defe3b8864.jpgScreenshot 2024-07-20 at 9.49.00 AM by E A, on Flickr

54259341140_0ea030de20.jpgScreenshot 2024-07-20 at 9.50.36 AM by E A, on Flickr

And here's what fire can do:

54280392042_ca7bc8b314.jpg20240704_164120 by E A, on Flickr

54281275031_00cb6eaa56.jpg20240704_164000 by E A, on Flickr

54281705120_49b1d801c7.jpg20240704_163842 by E A, on Flickr

54281518679_b260f7a31a.jpg20240704_163622 by E A, on Flickr

54281518719_c8c3be3580.jpg20240704_163834 by E A, on Flickr

54281274981_7df53ed642.jpg20240704_164022 by E A, on Flickr

54259340355_5ec511372a.jpg20240704_164057_Original by E A, on Flickr

What the pics can't show are what the fire department did. Until you have a fire I don't think most people realize that the fire dept's job is to put out fire, not to save your stuff. All parts bins, tool drawers, anything that could possibly hold water was full of water. Also, smoke is much more acrid and destructive than most think. All my woodworking tools in the backroom, most only with minor smoke damage, quickly rusted very badly. They're STILL more rusty than before every time I check one out. I kept some of them that I hope to refurb. Smoke kills the wiring and diode boards/chips. It's awful stuff. It took me a couple months of filthy labor to get the pool of paint/lubricants off the floor to where I could even walk safely and to clean up and inventory everything. I wish this on no one. Anyway, moving on. PRIORITIZE FIRE PROTECTION for your shops! Solvents cabinets. Fire alarms. Shut down power when you're away for a any period of time.
 
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86scotty

Member
Joined
Apr 19, 2018
Messages
8
So, the fire above happened on July 4th. Fireworks all around my house (I wasn't home) and initially we thought it was caused by fireworks but that was pretty quickly ruled out. There was no way fire could've gotten IN to that big steel box. It was pretty obvious where it started.
We had lived there 20+ years and had been looking for land closer to the mountains and family so we amped up the search and found our dream property, more or less, by mid August. It was no fun trying to clean up the mess from the fire, deal with insurance and get our house listed but we did it, here's how.

Once found our land we bought it outright with partial financing. I also bought an 8x24 covered ramp door trailer, a car hauler, to move my self but at first to move the salvageable contents of my shop to. The day we closed on our land I leased two 40' shipping containers and had them dropped on our land and started slowly moving my shop stuff, then basement stuff, then house contents to those containers. We knew our house would sell pretty quickly and it did, to the first people that looked at it.

By November we had purchased an older diesel pusher MH to live in on our land though it was a bucket list purchase anyway. No plans to sell. It will be going into the new shop as soon as it's completed.

Our land is 10 acres which is 3-4 of flat meadow/field on a 2 lane road and about 6-7 more up on a bluff. We decided to put the building near the road in the field since it was more or less flat. We'll eventually build a house up in the woods. There are already several roads/trails on the property.

The Plan:

54258030422_273d8d2dff.jpgScreenshot 2025-01-09 at 6.48.57 PM by E A, on Flickr

I'm going with a Troyer Post Building. They have a great reputation here in East TN and a couple of locations, the newest location is building in my area.

- 40'w x 60' enclosed pole barn on 6" monolithic slab w/ floor drains
- Steel trusses on 6'x6' wooden post frame
- 2'x6' purlins & girts
- Thermaguard insulation (R9-ish, I'll add more)
- 16' sidewalls w/ 6/12 pitch on main building
- 12'x60' lean to w/ gravel floor, 2/12 or so wood frame
- High transom windows for natural light
- Two 14'x14' residential garage doors on front of shop, one 8'x8' in the right rear corner
- Plumbed for 3 floor drains, sinks, RV drain, one bathroom/shower/washer and dryer
- 200A electrical service
- Loft in the back to be built by me as soon as I can get the building up. This will be woodshop on garage level with 10' (approx.) ceiling and upstairs will be storage and rec space.

Here's a pretty low-rent rendering of how I plan to lay it out:

54258029502_302bee1404.jpgScreenshot 2025-01-03 at 7.32.58 PM by E A, on Flickr
 

Xti04

Well-known member
Joined
Nov 11, 2016
Messages
2,345
Following! Where in East TN are you located? I built a loft in my shop and it made quite the difference in storage and getting stuff out of the way.
 
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86scotty

Member
Joined
Apr 19, 2018
Messages
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Tri Cities area.

I looked through your thread yesterday. Good stuff. I noticed the Knox County tag. We used to live in Blount County.
 
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Xti04

Well-known member
Joined
Nov 11, 2016
Messages
2,345
Tri Cities area, Unicoi county. The land of few people, few codes and lots of snow......apparently.

I looked through your thread yesterday. Good stuff. I noticed the Knox County tag. We used to live in Blount County.
Nice area up there, like you said no where near as busy as Knoxville has become. Im as far west in Knox county as you can get and what used to be a quiet area full of farms and pasture has become a boomtown ran by code nazis. Look forward to seeing this come together and sorry for the loss from the fire. My grandfathers shop burned down years ago and got into the house. I still remember finding wrenches and sockets that had turned blue and gold from the heat. I was excited as I thought I had re covered tools he could use. He made me trash them saying they had lost their temper and would break if he tried to use them. Still have a couple of those sockets I kept.
 
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86scotty

Member
Joined
Apr 19, 2018
Messages
8
Man I could make a thread with thousands of pictures of what fire does to all the stuff that's in all of our shops. It's insane. I wish I had done a time lapse. I've got stuff that looked fine the day after the fire and as time has passed rust has covered it like kudzu. I mean thick rough rust that feels like sandpaper. And even the 'quality' tools like perfect old school Craftsman sockets, etc. Stuff that didn't even get wet. I have all kinds of respect nowadays for fire and fire safety.
 

roadrunner255

Well-known member
Joined
Mar 17, 2011
Messages
235
Location
Driftwood, Texas
I know that this is an older thread but we are thinking of moving to some where in blount county.

Is the permitting that bad there?

Looking to build a 1400 square foot metal garage.

Thanks!
 
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