Finally started pole barn - 40x50

[cowpen]

I found this site a couple of months ago searching for tips and techniques as I planned my pole barn project. What a fantastic resource TBN is! I've literally spent hours on end reading and learning about the various projects the members here have undertaken and were generous enough to share on the forum. Good stuff - I'm learning a lot.

I've been planning to build a barn for a long time. But life always seemed to get in the way, and the barn just kept slipping down the ol' priority list. Now, between the swamp buggy, ATV's, boat, other toys, and soon a tractor, I've got no choice but to get busy! I have lots of questions, but first I'll explain where I'm at in the process.

The barn will be 30' wide by 40' deep by 12' high under trusses, with 10' wide sheds on each side. Total is 40' x 50'. It's hot & humid here almost year 'round, so I'll be closing in the north and east walls only - leaving the other two sides open to allow some breeze. I'll also have 2 foot overhangs on the eaves and gable ends.

I've been hashing out the design using a free program called Google Sketchup (very slick, very easy check it out). Here's what the basic frame will look like:

[cowpen]

I'm building this mostly on my own, and at my own pace (slooow). I'm also doing my best to do it "on the cheap" without compromising structural integrity, appearance or utility. I checked with the county building department to pull permits and discovered I don't need any as long as no septic is involved. I'm zoned agriculture, and this will be an ag outbuilding. Lucky me I'm off the hook in this regard, but I still want to build it to last, and build it safe.

I've been gathering (plundering) materials for the last six weeks. A friend had some 8.5" square marine-treated pilings that he salvaged from a house on Captiva Island. I bought 16 of them for $50 each. They ranged between 19 and 25 feet long. I expect that I will rot before they do.

Then I found a crap-load of nice lumber locally on craigslist.org. Got 21 No. 1 grade 2x10x16ｴs, and ten each 2x8x16 PT and 2x6x16 PT, plus a 5-gal bucket full of Simpson truss brackets, hurricane straps, and rafter brackets, all for $300.

Trusses were harder to find, but 84 Lumber gave me a decent deal on a set in the yard that were exactly what I was looking for - 30' span, 4/12 pitch. Those were $900 delivered; about $400 cheaper than if I'd had them built to order.

I'm still looking for metal for the roof and poly foil insulation. Any suggestions for S. Florida metal dealers? I'll probably go with a 26 gauge 5-V crimp since that's what almost everybody around here uses, but I'm also considering one of the 36" ag panels.

[cowpen]

Here's a shot of the posts - they're monsters.

[cowpen]

Here's a view of the site looking northeast. The pad was created a couple of years ago when I dug a pond to improve drainage and build a road around the back of the house to the barn site. The house is about 100' to the right in this picture.



You can barely make out the corner stakes I jabbed in the ground to see how it was going to fit the pad. I'll have to fill in a bit on three corners, and take out a couple of pine trees on the left side so that I can drive around the back of the barn.

Also looks like I'm going to have to move the burn pile.

[cowpen]

My friend Dustin is a contractor and he helped me set up batter boards to keep everything semi-square. After we finished and checked the cross measurements, he says "Uh oh! - we're an eighth-inch off". He had me going for a minute until he let on that was as close to perfect as it gets with string on a 40x50.

I'm fortunate to have some good friends willing to lend me the tools and equipment I need for this project. Dustin had a PTO driven PHD, and another friend Tod loaned me his TC55DA to run it. There's no way I could set these monster poles without it. Luckily, he hasn't needed it back yet!

Tod also offered his laser level (with detector), and a framing air hammer. It's great to have good friends.

[cowpen]

Half of the poles up!

Here I've finished setting half of the big-honking-*** poles; mostly in the right place and level. The tall ones weigh at least 500 pounds. They're set 4' in the ground.



It was a challenge getting the chain around them in just the right spot so that the FEL could lift them vertical. Once everything was balanced I could drive over to the hole. One tall post had to be chained close to the center in order to clear the ground. Turned out to be top-heavy and it flipped right over! I got off and spun it back like a big airplane prop, and had my son hold it down while I guided it in with the tractor. That was fun...

Once the post was in the hole, I'd heave and slam it into one side of the hole or the other to scoot the base toward or away from the string. There was a lot of grunting during this part of the operation. I no longer feel guilty about skipping the gym.

[cowpen]

Since I had no extension, the three-point PHD was only good for the first three feet. Plus, it was only an 8" auger for 8.5" posts! I had to finish the last foot and "waller" out the hole with a set of the long-handled manual variety. They're very efficient - it feels like you're getting a 5-gallon bucket of sand with every bite. These things will make your shoulders scream!

[Tororider]

Well, I am going to jump in here before you can post again, hehe. Looks great, lots of work. I will definitely be watching your progress.

You are definitely right about the site, there are a ton of really smart people on here who I have learned a bunch from.

[rexcramer]

Are those posts treated? I would hate to see a great barn with rotted footings.

Whats your plan on getting the trusses up? My barn has 12' walls as well. I used a steel boom off my 580 Case front bucket, it was about 15 feet long. With the boom chained to the top of the truss I only cleared the headers by a foot or so. With your tractor you would need a little longer boom I believe

[cowpen]

I set the last of the poles but ran out of 2x4 bracing. Will have to make a run to town.

I read the threads here about poles and concrete with great interest. So many different approaches and opinions on that subject. I chose not to use any concrete in the holes. Our sandy soils stay sopping wet a good portion of the year and I've had bad luck with concrete against wood of any kind. I'll tamp them well when the tops are tied together - I'm confident they're not going anywhere. I'll also wrap the posts with felt before I pour the floor around them.

The metal shed in the background normally just stores junk. I ran an extension cord to it and set the compressor and all my tools in there for the project. Sure beats hauling everything back and forth from the house.

The tarp canopy is covering my swamp buggy. I'll be glad to finally have her stored under proper shelter when this is finally done.