Did anyone consider a large Pole Barn (50x100) with an 800 square foot apartment inside ? It would be used as a temporary housing/hot rod shop/storage facility until we can get the main house built.
We would like to build one on our property in N.C. using as many green concepts as possible: geo-thermal, solar panels on a metal roof , insulated concrete floor, etc?
Has anyone done this before?
Any ideas ?

Actually, I have considered your idea several times in the past. The combination of 'pole barn' framing with SIPS is a very economical way to build an insulated shell for residential or any other use. We have incorporated this idea in several home plans recently. And while the metal siding typically used on barns is not the cheapest siding available, and is not normally used on homes, it is exceptionally strong and durable, with usable life span well over 50 years. PM me if you have specific questions.

I plan on doing the same, 50 x 100 and 40 x 40 apartment attached, ICF only, of course. No geothermal, but solar hydronic and a wood stove. SIPs for the roof would be good though, and maybe furring strips to allow space for the solar tubes and then sheet metal roofs.

Once in a non-climate controlled large garbage transfer station steel building with 40'ceiling we put a 20 x 20 ICF office in a corner, they want us to add a second story on it too, they even have the ceiling height for a 3rd. We used a 4" ICF and it is warm, quite and dust free. This would be a good option for you if you do not climate control the whole thing.

Posted By Polycore on 15 Dec 2008 10:37 AM

There is a company called Versa Frame and they sell pre-engineered building structures that are a series of metal tubes (walls & truss) that create the building framework. Once covered with SIP's or other rigid insulation, you have a sealed energy efficient shell that is easily finished on the inside. These buildings can be assembled quickly and easily. We provided R45 wall and roof sections for a versa frame building this month and the entire shell was erected, insulated and sheeted in less than a week. I have attached a few photos of the latest project.

These Versa Frame buildings would be easy to incorporate solar panels and other forms of alternate energy.

I got sidetracked but visited the Polycore website and am blown away by this product!

So far, I've not seen anything comparable this side of the border. I can certainly see an application for this incorporated into the design of our 'pole barn/apartment" project. However..........some initial concerns:
1. The cost. With the recent cost of steel, is this really a viable option? I almost shudder to think what a building of our size would cost.
2. The span (50x100) x 16 ft high- is possible as well? The "shop area" will have to be designed with a car hoist/lift or two in mind.
3. I assume the strength will support the dual purpose, living area ceiling/above storage ceiling/floor?
4. Local contractor/installer in the Charlotte,NC area - is there such a person? (our 4 heavily-wooded acres is just north of Charlotte; in Concord,NC)
    
As I said, I was in awe examining the Polycore website - a fasinating concept in engineered building.

Posted By Faldo on 09 Dec 2008 06:50 PM
Did anyone consider a large Pole Barn (50x100) with an 800 square foot apartment inside ? It would be used as a temporary housing/hot rod shop/storage facility until we can get the main house built.
We would like to build one on our property in N.C. using as many green concepts as possible: geo-thermal, solar panels on a metal roof , insulated concrete floor, etc?
Has anyone done this before?
Any ideas ?

old post ..............but pole buildings have been used since the 70's for residential, commercial and agricultural buildings,

However many building department would not allow the shop/apartment before the house for zoning reasons in fear that the main house never gets built

Faldo,

Thank you for taking the time to review the Polycore Website. I would like to take this opportunity to answer some of your questions:

1) The Polycore building systems do rely on structural steel and EPS as the main components of our system. Although steel prices have increased, our supplier has held our purchasing price due to the large volume of our demand. We control our cost and supply of EPS through our sister company EPS molders Inc. The Polycore systems are marketed to be a cost-effective green building material. Our price is on par with traditional materials, but is far more energy efficient, and is priced far less than ICF and SIP's.

2) Each of our projects are custom engineered and the gauge and positioning of the structural steel is determined by our engineering firms. This allows us to accomplish virtually any span and create any load bearing column just by specking the right steel for each project. Obviously larger spans will push up the cost of our product, but we often use the experience of our field engineers to determine the best cost effective way to use our product in a project. We manufacture foundations and foundation floors for residential use, but also manufacture structural, curtain and In-fill walls for commercial applications.

4) Although you may not have an experienced installer in your area, the product is easily installed by any contractor with a construction background. We have developed extensive installation manuals with graphical representation of each step, to ensure that the Polycore systems are being installed consistently and accurately by all contractors. The Polycore panels are light weight and easily installed in a very timely manor. A crew of 3 experienced installers can errect a fully insulated (R36) 1200 sq ft foundation in 7 hours with simple hand tools. I would be supprised to find a concrete or ICF crew that could claim to have the same turnaround time.

I urge you to send in some plans and receive an estimate on your project. You will find that our system is cost effective, reduces your construction time line and offers superior insulation compared to traditional materials. If you have any additional questions please feel free to PM me.

Have a great day,

Posted By cmkavala on 17 Feb 2010 05:21 AM

Posted By Faldo on 09 Dec 2008 06:50 PM
Did anyone consider a large Pole Barn (50x100) with an 800 square foot apartment inside ? It would be used as a temporary housing/hot rod shop/storage facility until we can get the main house built.
We would like to build one on our property in N.C. using as many green concepts as possible: geo-thermal, solar panels on a metal roof , insulated concrete floor, etc?
Has anyone done this before?
Any ideas ?

old post ..............but pole buildings have been used since the 70's for residential, commercial and agricultural buildings,

However many building department would not allow the shop/apartment before the house for zoning reasons in fear that the main house never gets built

Thanks for the info.
We've already made inquiries at the local zoning office. They limit the size of the apartment for the reason you stated. After the main house is built, they consider it to be a "mother-in-law"  apartment.

Their only concern seemed to be that there be only one outbuilding per house per 2 acres.

Yes, pole barns have been around a long time, but we're looking to add technology where we can and make it cost effective too. We have been on "garagejournal.com" asking for the pros and cons on a variety of garage/apartment builds; using different materials.  I'm sorry I'm using the term "pole barn" in a generic fashion.