The Advantages of steel barns
How to find the Right Supplier for steel barns
Kits versus Custom Designs of steel barns
How to Erect a steel barn
Environmental Benefits of a steel barn
Insulation of steel barns
Accessories- Windows, Doors, Cupolas, etc for steel barns
Optimizing Energy Efficiency for steel barns

As the focal point of farms, barns evoke a sense of tradition and security, of closeness to the earth and the continuity of life. But the barns themselves have undergone a radical change in the past few decades, from traditional wood construction, to pre-engineered steel construction.

Pre-fabricated steel buildings are a perfect fit to meet the unique needs of the contemporary agricultural market. Modern barn structures, however, are more than just the classic red cow barn. Steel barns come in many shapes and sizes, providing practical storage for a wealth of equipment, supplies and inventory. Whether for storage barns, steel sheds, silos, and even greenhouses- modern steel construction provides the flexibility, features and economy you need.

The term, “pre-engineered or prefabricated metal buildings system” refers to the current design, engineering and manufacturing process of today’s metal buildings. This process has been greatly improved over the years, due to the implementation of sophisticated computer aided design and drafting (CADD) of the building. A pre-engineered building purchased today is highly technologically advanced.

The use of the word “system” refers to the fact that all the differing components of the building are engineered to the required specifications and load codes, and shipped together to the job site. Nothing needs to be out sourced from other vendors. Windows, doors, roofing, trim- all are custom fit to each building. This pre-designed system is therefore extremely efficient, and easy to assemble, as each part is a perfect fit to each other part.

For all these reasons and many others, metal building systems have significant advantages over more traditional types of construction...

SHORTER CONSTRUCTION TIME- pre-engineering makes steel barns faster and easier to erect than traditional barns

LOWER CONSTRUCTIN/ MATERIAL COSTS- it’s possible to save up to 60% on construction and material costs over traditional barns

OUTSTANDING STRENGTH AND DURABILITY- using the strongest building material on the market, able to withstand hurricanes and earthquakes

ENVIRONMENTALLY FRIENDLY- steel is a recycled material (for more info on the “green” advantages of building with steel, click here)

LOWER INSURANCE– steel is a fire, weather, mold and pest resistant material- you can save up to 40% on insurance costs over traditional types of construction

FLEXIBILITY AND EASE OF EXPANSION- if expansion is necessary later, it can be done with minimal cost and effort

LOW MAINTENANCE/SANITARY- easy to clean, no repainting required, long warranties on both the finish and the structure; no creeping, cracking, rotting, mold, insect infestations

KICK AND BITE PROOF- safer for animals’ mouths and legs. When animals kick a wall of brick or masonry they can break a leg. Steel panels, however, are strong enough not to break; and flexible enough to provide some give, rather than causing a break.

CUSTOMIZABLE- many different colors and exterior finishes available

RIDING ARENAS- clear span designs have no interior columns; options such as wall light panels and ridge vents are available to add to your comfort while riding indoors in all kinds of weather

HORSE BARNS- wash racks, hay storage or tack rooms are easily incorporated into your design

LIVESTOCK/STORAGE- freestall barns, transfer alleys, milking parlors, hay storage and livestock shelters are economical with steel construction

Did You Know…

• Look for a manufacturer who is AISC certified; this assures that every facet of their production has been audited and is the highest degree of technological efficiency and quality.
• It is always wise to comparison shop prices for metal barns with several different manufacturers.
• Another prudent idea is to check with the Better Business Bureau for any complaints, ask for references.
• Ask if any of the potential manufacturer’s barns are already erected in your area, so that you can visit the finished product.
• When price shopping, make sure you’re comparing buildings with the exact same specifications. Some suppliers might give a cheaper estimate, but they might not be offering all the same features and quality materials.
• Take detailed notes while doing your price comparisons.
• Watch out for any sales rep who seems more interested in giving you a hard sell and closing the deal quickly, than addressing your questions and concerns.
• Are your phone calls returned promptly? This is a hallmark of good service.

Steel building suppliers abound. By taking your time and doing a bit of checking, you are sure to find one who meets all your needs including: price, service, speed, building features and design, or whatever other individual requirements you have for your steel building.

Pre- engineered or prefabricated barn kits are designed for quick and easy assembly. They are cheaper than custom designed steel buildings because they are sold to the customer directly without commissioned salesman or new design/engineering costs, passing the savings along to you.

These types of pre-engineered kits are a major money saver for farm and ranch owners because they can be erected in a few days, even by those with little construction experience. The ease in assembling these buildings yourself provides a huge savings on the cost of hiring a contractor to construct your steel building.

Look for high quality kits with a good warranty, at least 50 years for the structure itself, and 20 for the painted finish.

Custom designed buildings are usually much more complex, larger, and of course, cost more. They can have amazing flexibility in design and incorporate any custom features that your needs dictate. They usually require a professional erector.

• 26 gauge, 80,000 psi. roof and wall sheeting (Resistant against dings and dents)
• PBR/R Roof and Wall Sheeting (Additional overlap stop leakage)
• Pre-cut framed opening (Industry standard provides `frame kits`)
• All girts, purlins, main frames, and end walls have pre-welded clips (Industry standards are not pre-welded).
• All parts are pre-marked (Industry standards have limited markings)
• Fully trimmed at gable, corners, and eaves for an attractive look.
• Engineer Certified Erection Drawings and Anchor Bolt Plans
• Solid I-Beam Construction
• 50,000 PSI High Built-Up Main Strength Steel Plate
• Submerged Arc/Welded Frames
• Girt and Purlin Overlap
• 26 gauge Commercial High Rib(1.25") Sheeting with Purlin Bearing Rib
• Die Formed Corrugated Ridge Cap
• Eave Closures
• Mastic Sealant on Roof
• Self-drilling and Self Tapping Screws with Pre-assembled washers
• Factory Trained Inventory of Parts at Jobsite

In a word, “Yes!” Metal roofs have been proven over time to remain intact during even the most extreme weather. Steel buildings are designed to meet local building code requirements for specific areas- if you live in an area that is visited by hurricanes, the building you purchase should be designed to have the strength to survive most hurricanes fully intact.

In areas of seismic activity, metal buildings have many advantages over traditional types of construction and have proven themselves over time. The low mass, superior strength and ductility of metal buildings provides the necessary qualities to resist seismic activity.

Numerous studies of the performance of metal buildings during earthquakes prove steel buildings as the construction method of choice for low rise building in areas prone to seismic activity.

Ready to do some good old fashioned barn raising? Or perhaps we should say, modern barn raising! Here is a condensed version of the steps to erect a basic steel barn…

1. Have the foundation poured and cured in advance of the building’s delivery date, so you can start the erection as soon as your barn is delivered. Never build on “green” concrete!
2. Have all access from the road to the building site cleared of obstructions, and prepared for an 18 wheeler to pass.
3. Unload the components off the truck, checking against the packing list that everything is there, and undamaged. If anything is missing or damaged, file a report with both the carrier and your steel barn supplier immediately.
4. Erect the primary framing, consisting of I-beams. These are the first components that you will bolt together and fasten to the anchor bolts already in your foundation.
5. As soon as some of your primary frames are in place, you can start to bolt the secondary framing, comprised of girts and purlins. Running horizontally the length of the building, they provide support for the wall and roof sheeting.
6. The wall and roof panels attach via the use of self drilling fasteners.
7. Weather stripping is installed with the wall and roof panels to keep the building from leaking.
8. Trim finishes off the building both in appearance and weather proofing.
9. Accessories, such as doors, windows, vents and gutters are the last step!

As the most recycled material on the planet, steel is a terrific choice for sustainable and green construction; a benefit that is becoming more and more important to people as the natural resources of our planet are increasingly depleted. Take a look at these impressive facts:

• Steel is 100% recyclable
• All new North American steel currently being forged contains recycled steel.
• 2 out of 3 pounds of new steel today are made out of old steel.
• Almost 76 million tons of steel were recycled in the US in 2006.
• Every ton of steel that is recycled saves approx. 2,500 pounds of iron ore, 1,400 pounds of coal and 120 pounds of limestone.
• New steel made with recycled steel is vastly energy efficient, needing only ¼- 1/3 (approx) of the energy required to make steel from raw materials!
• Greenhouse gas emissions per ton of steel shipped have been reduced by nearly 45% since 1975.
• More than 95 percent of the water used for steelmaking is recycled
• Almost all the hazardous waste once generated by the steel industry is now being recycled for beneficial use.

This highly efficient use of materials results in a lower “carbon footprint.” Just as steel itself is environmentally friendly, there are also many benefits to the environment and to the purchaser from building with steel.

• Metal buildings have a long lifecycle, they don’t need to be frequently repaired or replaced like wood. Some manufacturers guarantee their buildings structurally for 50 years.
• Steel buildings are energy efficient to operate and maintain.
• Research on “cool metal roofing” proves that the reflective properties of steel roofs provide significant savings in energy consumption. (“Cool metal roofing” uses heat-deflecting coatings that significantly decrease heat build up inside a building.)
• Heat and cooling loss, especially around doors, windows, foundation, and roofing, are significantly lower than other types of construction.

The insulation used in a steel barn makes a huge difference to the energy efficiency of the building. Of course, depending on the climate and use of your barn, you might need more or less (or no) insulation.

Radiant barrier insulation is ideal for steel buildings, which tend to get very warm and humid in the summer and cold in the winter. This is a reflective type of insulation, which offers a permanent way to solve these problems. The main advantage to this type of insulation is that it works by reflecting radiant heat energy instead of trying to absorb it.

A pure aluminum radiant barrier insulation is unaffected by humidity and will continue to perform at a consistent level no matter how humid it may be. The leading cause of damage to steel barns is condensation, which if not allowed to evaporate, leads to rust oxidation, mold, and fungus. This problem can be eliminated by the use of a vapor barrier such as radiant barrier insulation.

A radiant barrier insulation system is a layer of foil facing airspace and is installed in the envelope of a building. It is easy to mount and does not promote nesting of rodents or birds.

The installation itself could not be simpler:

1. Place double-sided tape on frame
2. Roll out insulation over frame
3. Allow insulation to sag slightly (approx 1 inch)
4. Attach your sheeting as if the insulation wasn`t there
5. Tape seams with metal tape

Click here for more info about insulating a steel building.

Accessories- Windows, Doors, Cupolas, etc

The addition of the proper accessories is one of the main ways to customize both interior and exterior of your barn and get exactly the features you need for the convenient, versatile and energy efficient use of your investment.

Although the nature of steel buildings allows for plenty of flexibility if you need to make changes in the future, such as expanding the building, it’s always easier and more cost effective to plan for what you need up front.

When ordered as part of the initial steel building purchase, accessories are guaranteed to fit the building exactly. This will save hours of time in trying to outsource accessories from other companies which might not be a perfect fit, leaving the building open to leakage and other problems.

Don`t cheat yourself and purchase aftermarket lumber yard products that will cause time consuming headaches and unattractive appearances because of struggles in retrofitting.

Windows

Walk Doors

Make sure your doors are designed to “flash” with your sheeting, a good reason not to outsource them a different supplier after the building has been purchased. Glass window insets are available options.

Overhead Doors

Aside from the appropriate size and amount of doors and windows, there are many other features you can add to a basic steel barn to customize it to your needs...

• Vents- Types for metal barns include wall louvers, ridge vents, cupolas (a small vented tower atop the building- adds great style as well as ventilation)
• Wainscoting- is an inexpensive custom item to make the appearance of the building more attractive. It consists of a different color panel on the bottom 3’ to 4’ of the building. This gives your building a two-tone look- the top of the building is one color and a small portion of the bottom of the building another color.
  

  It is common for most customers to do the roof, trims and bottom panels in one color and the top part of the wall sheets in another color. Wainscot is especially common in residential / business areas where appearance is of high priority.

• Gutters and downspouts- keep your building in top condition. Gutters are used for the same reason as on traditional buildings, to catch water running down the side of the building to prevent puddles from forming next to the building. They prevent separation in the soil and new concrete, and streaking on sidewall panels from rain or melt off. Find out if they can be color-matched to your trim.
• Colored Roof- another inexpensive way to add classic style and visual appeal to a barn, especially one with a high roof pitch.
• Skylights- Cut down on energy costs by letting natural light into the building. Although they can be custom made to any measurements, the standard size is 10’8”. This size can be used in one place or cut in half and used in two places. Great for extra light in places where there is no power.
• Exterior finishes such as “stucco panels” or brick and stone facades

Electricity accounts for half of all energy used on mechanized livestock and irrigated crop farms. A typical lighting system with inefficient equipment can waste more than 50% of the energy it consumes. Building your steel barn with efficient systems of lighting produces significant energy savings. Here are some ways to reduce energy costs on your farm:

Electronic ballast fluorescent lighting is the most energy-efficient fluorescent lighting; having very little flickering and excellent color. Fluorescents are known for having a long bulb life—as much as 6,000-plus hours per bulb—and come in a wide variety of shapes, sizes and wattages.

Metal halide is an excellent, high-efficiency lighting choice for milking parlors and freestall barns. It has a long life and provides the type of white light that is good for cow health and milk production.

Heating costs can be reduced up to 20% just by keeping a room 5° cooler. Adding insulation (6" for walls and floors, 12" in attics) can reduce heat loss by as much as 50%. Maintain the temperature for all water heaters at 120° and add insulation to both water heaters and pipes that carry hot water.

Disconnect electric service from heated livestock waterers during the non-winter months and seal openings around waterer bases to reduce cold air infiltration.

Ventilation can be the largest electrical cost on livestock farms. Switching to efficient barn fans can produce savings of 12% to 15%. Not all fans are made alike. Certain brands can be much more efficient than others and can move quite a bit more air. The strategic placement of the fans is also a factor.

Natural ventilation, which is built into the design of your barn, will be a major factor in cutting down energy costs for heating or cooling. Doors, windows, ridge and cave vents or cupolas can provide natural ventilation. Ventilation and insulation needs differ according to the climate, and the use of the barn itself. Dairy barns and cow barns have differing ventilation needs.

The optimum amount of ventilation depends on its size, shape and purpose. Generally, one 10’ ridge vent will serve 2400 square ft. of space, but this figure changes depending on what is inside the building. For example, if the barn contains animals, it will require more ventilation. Remember that an efficient system requires cross ventilation; ridge vents at the roof need corresponding louvers near the floor.

Freestall dairy barns that are properly designed, constructed, and managed for natural ventilation provide an excellent environment for dairy cattle with little energy cost.

Freestall barns must always have some portion of the sidewalls open and open ridge vents to allow air exchange for the removal of large quantities of moisture and heat produced by cows.

Horses don’t do well in drafty barns; the challenge is to design an effective ventilation system that doesn’t create drafts at the same time. Read up on the subject ahead of time, or consult with an expert in horse barn planning.

In summary, not only will a modern pre-engineered steel barn save you money upfront on its purchase and construction costs, but putting some fore-thought and planning into it’s design and features will continue to save significant amounts of money on energy costs in the long term!

References:

BuildingsGuide.Com, http://www.buildingsguide.com/horse-barns.htm

Guide to Barn Structures, by Matt Alderton http://www.business.com/directory/agriculture/barns_and_structures/#guide

National Park Service, http://www.nps.gov/history/hps/tps/briefs/brief20.htm,

The Preservation of Historic Barns, Michael J. Auer http://www.straightdope.com/classics/a1_382.html

How to Cut Farm Energy Costs 1/24/2003 Jeanne Bernick, http://www.agweb.com/get_article.aspx?pageid=94690&src=gennews

Horse Barn Ventilation, Fact Sheet http://www.omafra.gov.on.ca/english/engineer/facts/96-031.htm

Natural Ventilation For Freestall Dairy Barns, by Susan Wood Gay, Virginia Tech, Publication Number 442-763, December 2002 , http://www.ext.vt.edu/pubs/bse/442-763/442-763.html