PROJECT.... BARN RESCUE

[Builder]

One of my customers has a mid-80's vintage 25' x 50' 2 story barn with 8 stalls, hay rolls stored up in the loft. Doors weren't closing correctly and barn needed some electrical work & stalls cleaned. I adjusted the doors and did some checking around.
Upon closer inspection of the posts, I noticed significant rot. Out of the (28) 4x6 & 6x6 posts, 24 of them were rotted 50-80% through!!
Much to my surprise, the posts were made out of untreated hemlock or locust. She had no idea how bad it was because years of hay, dirt, etc were packed around them.

After reaching agreement with Customer on costs & how to proceed, I began to think about how this job would be done. How would a barn of this size support itself while posts were being repaired and how would I repair them?

I decided to use post hole diggers and dig the rotted piece of the post out from under the healthy parts that remain above ground. The posts were approx 5' deep and wouldn't budge even after they were dug out wih PH diggers. Plus I had to contend with only being able to dig on 1 or 2 sides of each posts since they were trapped in corners.

I used my "oooopsie" (RE: Drago) Milwaukee 28V cordless drill equipped with "$5 batteries" and a 5/8" auger bit and drilled a sideways hole about 2' down into healthy post. Then I inserted a 5/8" carriage bolt into the hole. I threw a heavy chain on the carriage beam above the post then used my trusty come-along (high torque !) to extract each post piece stuck in the ground. Since they had some remnants of concrete stuck to them, they were difficult to remove. It was difficult to pull them out in such a tight space.

 

[Builder]

Next: the pieces I extracted were still healthy. No surprise, but only the 6" part of the post that was just above the ground rotted. I couldn't believe that even with treated lumber available, they used untreated posts. They didn't even dip the posts into tar.

 

[Builder]

Much to my surprise, there was VERY LITTLE concrete used under the posts. In some holes, I couldn't find any. Also, the barn had sagged somewhat from its' loss of structural support and some posts were easier accessed from the outside. How was I going to raise the barn to re-level it?

First I cleaned the holes out then mixed new concrete for each footing. I put a new 15" thick x 24" diameter footing in each cleaned-out hole.

I used my New Holland LB115 "walmart excavator" (thanks 20/20)to lift the barn up a few inches in spots that had sagged. Try that with a mini ex!!! :laughing:

I then installed new 8' ground contact 4x6" posts next to the existing posts on the dry concrete footings and bolted them next to the existing posts with 3 5/8" galvanized carriage bolts at about 2', 4' & 6' above ground into healthy existing post.

I did about 4 posts per day. Allowing concrete to dry, it took the better part of 2 weeks to complete the project. She's all done now and for a fraction of the cost of a teardown, I was able to rescue this barn.

Amazing how some contractors cut corners and leave the customer with huge problems to deal with later. Be sure you hire someone who will do job right the first time and be prepared to pay a little more for it.

 

[framer]

Rescuing that barn looks like a lot of work. Nice to have the right equipment.
I rebuilt my old 1930 two stort barn. It had 2x6 studs rot at sill plates. Setting
on two layers of limestone foundation. Cut off 3 foot studs dug footins with
skid steer. Sliced with 8 foot on each side. Roof rafters are 2x6 also in very
good condition dispite leaking roof for years.Removed 3 layers of shingles
put metal over 1x4 decking. Resided with smart start, New sliders. All said
and done probably could have built bigger and useful barn for the mony
spent. But it was work for the crew when we slow.Good luck with yours.

 

[Builder]

I was amazed to see how healthy the posts were below ground. Stating the obvious, but it takes moisture/drying cycles to rot wood.... just above ground level is where the damage is done.

In picture below you can see a sistered post. I added another one to that same posts since it is one of the direct support posts for the 2nd floor beam on the front wall. The come along was the tool to extract the posts. Couldn't have done it without the "high torque" version.

 

[EddieWalker]

Looks like one of those projects that is all labor!!!!!

Thanks for the tips. I've never done anything quite like this and don't know if I would have thought of a come along or not. The eye bolt is genius.

Eddie

 

[davygp38]

I was amazed to see how healthy the posts were below ground. Stating the obvious, but it takes moisture/drying cycles to rot wood.... just above ground level is where the damage is done.

In picture below you can see a sistered post. I added another one to that same posts since it is one of the direct support posts for the 2nd floor beam on the front wall. The come along was the tool to extract the posts. Couldn't have done it without the "high torque" version.

You got me thinking about my Dad, when you mentioned the come along. Dad Had his own business fixing semi trailers up here in the north east. He would use his come along almost everyday. He could straighten a frame, set cross members adjust a bogey, To this day I keep a come along with me no matter what the job. Probably one of the top ten hand tools you could have. PS. You're right,you could not lift the side of a barn with a MINI

 

[hobie]

Nice save!

 

[aczlan]

Looks like it was an interesting challenge.

Aaron Z

 

[Builder]

Thanks guys.

Scary part was trying to keep the barn from collapsing while removing load supporting posts. I made sure to only do one under each of the 4 supporting posts at a time.

You got me thinking about my Dad, when you mentioned the come along. Dad Had his own business fixing semi trailers up here in the north east. He would use his come along almost everyday. He could straighten a frame, set cross members adjust a bogey, To this day I keep a come along with me no matter what the job. Probably one of the top ten hand tools you could have. PS. You're right,you could not lift the side of a barn with a MINI

Definately ranks up there as a must have in the utility body.

 

[powerstroke444e]

I have a barn at my new place here that needs the same thing, and they used old power poles for the posts. You seem like you get called when everyone else says it can't be done. Amazing things you find to work a TLB.

 

[Builder]

I have a barn at my new place here that needs the same thing, and they used old power poles for the posts. You seem like you get called when everyone else says it can't be done. Amazing things you find to work a TLB.

UGH, round poles. That would likely mean complete post replacement. Square (or rectangular) posts are easier since you can sister posts.

I do get calls from Customers that can't find anyone else to fix "the impossible" problems. :laughing:

 

[srs]

In picture below you can see a sistered post. I added another one to that same posts since it is one of the direct support posts for the 2nd floor beam on the front wall. high torque" version.

What are your thoughts on placing a piece of new post directly under the old post? Assuming you cut the old post square. That way the old post can rest directly on the new post? Basically you would have 3 posts down, 2 new ones, and the old one.

 

[Builder]

What are your thoughts on placing a piece of new post directly under the old post? Assuming you cut the old post square. That way the old post can rest directly on the new post? Basically you would have 3 posts down, 2 new ones, and the old one.

Yes, I considered doing that as well. If you and I are thinking the same thing, you mean place a block under the freshly cut existing post, then a sister post next to it to hold both pieces in place? That would be even better, but in my case overkill since we were also at customer's very upper end of budget. Also, it would be difficult for my situation because many of the posts were in corners where it would be tough to get a clean, square cut on the bottom.

If you can get access to them and a clean cut, go for it. This barn was poorly built in the first place by the cheapest bidder, I'm sure. It probably won't get much more money dumped into it without just knocking it down in favor of a better design.

 

[two_bit_score]

Interesting project. Thanks, Builder, for the pics and the instructive posts.

 

[srs]

If you and I are thinking the same thing, you mean place a block under the freshly cut existing post, then a sister post next to it to hold both pieces in place?

That is exactly what I was thinking. Thanks.

 

[buckeyefarmer]

My dad has done many posts by digging next to the post and putting one beside it, then bolting new and old together. I think if I was doing fixing rotted off square posts, I would pour the hole with concrete and put a bracket to the post, and not have to worry about it rotting again.

Nice job.

 

[Builder]

My dad has done many posts by digging next to the post and putting one beside it, then bolting new and old together. I think if I was doing fixing rotted off square posts, I would pour the hole with concrete and put a bracket to the post, and not have to worry about it rotting again.

Nice job.

Funny you mention that. My first strategy was to remove rotted posts ends, cut the remaining posts square and nail a galv post anchor to the bottom, then fill the holes full of concrete.

I actually did one post like that before I realized the corner posts would be almostr impossible to do that way and the concrete tends to pull away slightly from the bottom of the posts while drying. In this picture, you can see a sonotube post I tried in the backround.

The way I did the rest worked MUCH better, although at some point, even a treated post installed correctly may need to be replaced. I'll prolly be in a rocking chair by the time they need replaced again.

 

[Ranger Rick]

When I had an old timber frame barn restored at the park I was in charge of the contractor did a lap joint on the posts that were rotted at the bottom. He then screwed it together with big lag bolts. These posts only went down to a sill plate and not into the ground. Rick