Is your existing pole barn showing signs of aging? Are your metal panels starting to chalk, fade, or red rust? Years of exposure to the Midwest's demanding weather conditions will lead to the deterioration of your post-frame building.
Some wear and tear won't impact the pole barn's structural integrity. However, small issues, such as metal roof leaks, can develop into major problems if not addressed promptly. So, when is your post-frame building too far gone to repair or renovate?
This article explains when it makes sense to repair or renovate your pole barn, and when it's time to consider new post-frame construction.
3 Reasons Why You Should Repair or Renovate Your Existing Pole Barn
You purchased property with an existing post-frame building or have an older one in your backyard that requires some pole barn maintenance. Overall, your structure appears to be in good condition, and you're satisfied with the size.
Therefore, why not consider investing in your current post-frame building? Below, we present three reasons to repair or renovate your existing pole barn instead of constructing a new one.
1) Your pole barn is structurally sound.
First, structural integrity refers to a post-frame building's ability to withstand structural loads without breaking. Any pole barn, regardless of the size or location, must resist vertical and lateral loads.
If there are no signs of bowing, sagging, or uplifting in the structural components, your older post-frame building could be salvageable.
For safety, we recommend contacting your pole barn builder to inspect your structure for visible and hidden damage.
2) You want to extend the pole barn's useful life.
Second, you can improve your post-frame building if it remains structurally sound. It may not look the same as it did in the 1980s, but a simple pole barn reskin will make it look like new.
Moreover, you can repurpose your post-frame building by converting it into a barndominium and installing interior finishes. You can also opt for a pole barn addition if you need more storage space.
3) Renovating your pole barn can be more cost-effective than building new.
Unfortunately, the cost of a new post-frame building has increased since the COVID-19 pandemic.
The lack of building materials amid the "Great Supply Chain Disruption" is to blame for the fluctuation in pole barn prices.
Renovating your post-frame building makes sense if you're happy with its size and the structure remains sound.
Depending on the project scope, you can avoid "hidden" costs associated with new post-frame construction (i.e., permitting and site preparation).
You may think a new pole barn is a great way to ensure its use for decades to come. However, simple post-frame building repairs and renovations can have the same lasting effect for less money.
2 Types of Pole Barn Repairs & Renovations That Extend the Lifespan of Your Post-Frame Building
Once you know the bones of your post-frame building are in good shape, it's time to think about the two types of pole barn repairs and renovations that have the greatest impact. A new metal roof and steel siding not only protect your investment from the elements but also transform the look.
In the following sections, we take a closer look at how re-roofing and re-siding your post-frame building can extend its lifespan while providing a modern upgrade.
1) Pole Barn Re-Roof
Arguably, the most frustrating pole barn repair is dealing with metal roof leaks. These drips are often caused by ice damming, heavy or melting snow, precipitation, strong winds, and loose fasteners. Another common culprit is a faulty ridge cap.
The ridge cap is a critical part of your pole barn roof—it sits along the peak to prevent water from entering and supports ventilation.
However, aluminum ridge caps installed on older post-frame buildings can pose a hidden risk. Aluminum ridge caps are prone to expanding and contracting with temperature changes, which can cause seal breakage at overlapping points and fastener holes.
Over time, the solid foam gasket shrinks and deteriorates, creating openings that allow leaks. Neglecting these issues can result in rotted lumber, compromising the structural integrity of your post-frame building.
If your pole barn roof starts to leak, installing new metal roofing panels with a durable steel ridge cap will extend its lifespan by 30 to 50 years. Unlike aluminum, steel ridge caps provide lasting protection with superior weather resistance.
Paired with the right fastener, such as a stainless steel-capped, self-sealing screw that encapsulates the washer, your metal roofing system is better equipped to withstand the harsh elements.
2) Pole Barn Re-Side
Depending on the pole barn paint system, metal siding can fade or chalk when exposed to sunlight.
Polyvinylidene fluoride (also known as Kynar 500®) is the premium resin choice for post-frame construction. This advanced formula combines fluoropolymer resin with ceramic pigments to produce excellent resistance to weathering.
Installing steel siding with a manufacturer's warranty can extend the lifespan of your post-frame building up to 40 years when done correctly.
A pole barn re-side restores durability and boosts curb appeal without the high cost of a complete rebuild.
3 Signs It's Time to Build a New Pole Barn
At some point, repairing or renovating your existing pole barn may become financially infeasible. When structural issues outweigh the benefits of repair, it might be time to consider new post-frame construction.
Below are three tell-tale signs that building a new pole barn is a smarter investment than repairs or renovations.
1) Rotted Pole Barn Columns
Rotted pole barn columns are caused by continuous exposure to moisture and subsequent fungi growth.
Uncovering solid posts at the ground level is the best way to determine if they're rotting. Inspect the "decay zone" by digging 6" to 8" deep around the base of your post-frame building.
If the columns are soft or crumbling, it's a clear sign that your pole barn's structural integrity is compromised.
While wood is a natural element, you can greatly reduce the risk of rot by choosing the right building materials during post-frame construction. We recommend the following options to prevent rotted pole barn columns:
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Laminated Posts: Built with two or more layers of dimensional lumber that are mechanically laminated with nails. These posts are stress-rated, pressure-treated, and permeated with 0.80 lb./cu. ft. of Chromated Copper Arsenate (CCA) wood preservative for durability.
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Perma-Columns®: Designed so no wood goes into the ground. They’re sized to fit any laminated post and include microfibers for shock resistance, microsilica for compressive strength, and a corrosion inhibitor to protect rebar reinforcement and brackets from rust.
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Bracket-to-Concrete Columns: Another option where no wood touches the ground. A black powder-coated bracket is anchored into the concrete foundation with heavy-duty screws, then fastened to a laminated post for lasting support.
Some rotted pole barncolumns can be replaced, but if the damage is too extensive, the structural integrity of your post-frame building may be compromised.
2) Sagging Pole Barn Roof Purlins
In severe cases, metal roof leaks can weaken the pole barn roof purlins, causing them to soften and sag.
A post-frame construction crew can repair the issue by rebuilding the roof system, but it may take just as long, or even less time, to build a new one.
Sagging roof purlins pose a safety risk to the people and stored belongings inside the post-frame building.
3) Bowing Pole Barn Trusses
Lastly, trusses carry the weight of the pole barn roof and transfer those structural loads to the laminated posts.
Bowing trusses compromise the structural integrity of your post-frame building.
Well-designed trusses are crucial because if one fails, the others will follow suit. This domino effect can result in a pole barn collapse.
A miscalculation in the snow load or abnormal snowfall in your region can cause bowing trusses. Failing to address this repair can lead to further structural damage.
High winds can cause the walls of your post-frame building to shift out of square. Resolving this issue is complex, as it requires the metal roofing system to be disassembled and rebuilt.
At that point, it may be more practical to consider new post-frame construction.
Will You Renovate Your Existing Pole Barn or Build a New One?
After reviewing the pros and cons of pole barn repairs and renovations versus new post-frame construction, do you know which path is right for you?
Pole barn repairs and renovations are often the most cost-effective option. However, if your structural integrity is compromised, starting fresh with a new post-frame building may be the only solution.
Either way, our Repair and Renovation Specialists can guide you in the right direction. They have the knowledge, resources, and workforce to extend the life of your pole barn or reconfigure it for a new purpose.
Whatever you decide, remember to build with confidence.
Do you have more questions about pole barn repairs and renovations not covered in this article? If you need help with designing and planning, please contact FBi Buildings at 800.552.2981 or click here to email us. If you’re ready to get a price, click here to request a quote. A Customer Engagement Team member will help you determine the next steps.