Quonset huts have existed since the 1950s and were originally known for their long life and simplicity.
Even though new construction of Quonset huts is less common today, renovations are still possible.
If you're contemplating a Quonset hut makeover, you've landed in the perfect spot. In this blog, we'll discuss the cost of reskinning an existing Quonset hut and detail the process step-by-step.
How Much Does It Cost to Reskin a Quonset Hut?
Like new post-frame construction, pole barn renovation costs are based on the following factors:
- Building type
- Fastener type
- Building size
- Building location
- Construction crew labor
The scope varies depending on the project; it can involve reskinning the entire building, just the endwalls, or adding endwalls to an open-ended structure, including replacing sliding doors and windows. In certain instances, existing roofing may not need removal, with new framing and steel roofing installed directly over it.
A full reskin on an existing Quonset hut can cost $25 to $30 per square foot.
Editor's Note: The prices stated above fluctuate based on the current state of commodity markets. They do not include metal trimming, travel expenses, delivery/freight costs, dumpsters and port-a-john rentals, screws, engineering review of construction drawings, and equipment costs.
5 Critical Steps for a Quonset Hut Reskin
1) Removing Old Metal
One of the first steps in reskinning a Quonset hut is removing any old or worn-down metal so that new materials can be added. 
The metal panels can be cut through or pried off, often done with snips or hacksaws. Doing this safely is important to prevent damage to nearby structural elements or potential injury.
Once the original metal has been removed, inspect the underlying structure for any damage or deterioration that may require repair or reinforcement before installing new endwalls.
Clean the surface to remove any debris, rust, or contaminants that could affect the adhesion of new materials.
We'll note that a thorough project scope assessment is vital before any renovation begins. In some cases, certain sections (like the roof metal) could be left on and wouldn't need to be removed.
2) End Wall Installation
When the old metal is fully removed, new metal can be installed. Measure the end wall area carefully to ensure accuracy. Cut the new metal panels to the appropriate size using metal cutting tools such as shears or a saw.
Before the new metal panels go up, ensure the building's frame is properly aligned and securely anchored to the existing structure. In some cases, additional work may need to be done to maintain the structural integrity. Use levels to help verify the building's alignment.
The metal can be attached directly to the Quonset hut framing. Fasteners such as screws or rivets are used to secure the panels in place. All panels should be pre-cut at this point, and space evenly on the end wall as they're being installed.
After completing these steps, you're well on your way to a full quonset hut reskin.
3) Roofing Replacement
Although a Quonset hut roof differs from a standard sloped roof, the process is similar. Start at one end of the building and work across overlapping metal sheets as required.
McElroy Metal offers curved roof steel and has a division for Quonset huts, so they're a great dealer for Quonset hut reskins. Their metal panels fit perfectly with a roof's curvature.
The panels are flimsy compared to standard metal sheets, allowing for an easier installation. Use care when handling the product.
Again, overlap the metal panels to ensure that no water or air can get in, and using a screw gun, secure each panel one by one.
Once the new roofing material is installed, make any necessary adjustments or additions to ensure proper fit and functionality. Seal any seams or joints to prevent water infiltration.
Editor's Note: The roof should be inspected for damage or rot beforehand. Issues compromising the structure, like additional supports or braces, will need to be repaired to ensure the roof can support the new material.
4) Door & Window Replacement
Replacing the doors and windows of your Quonset hut can improve its functionality. Modernizing these elements can make the structure more accessible, secure, and energy-efficient.
Remember to consider the value of an aesthetic upgrade, too! Updated designs and materials can enhance the visual appeal, giving the structure a fresh and contemporary look.
New materials can also contribute to better insulation and ventilation within the Quonset hut. This can help regulate temperature and humidity levels, creating a more comfortable interior environment.
Overall, investing in high-quality materials can contribute to the longevity of the Quonset hut.
It's important to hire experienced professionals to install new doors and windows. They'll ensure proper fitting and functionality, minimizing the risk of issues in the future.
5) Sealing & Weatherproofing
Go one step further by sealing and weatherproofing your building. Identify vulnerable areas, such as windows, doors, and vents, where water infiltration is most likely to occur. 
Use a high-quality sealant or caulk to seal gaps, seams, and any other openings in the Quonset hut. Apply the sealant generously along the edges and seams, ensuring a tight seal that prevents water from seeping in. Silicone-based sealants are often recommended for their durability and flexibility.
While not directly related to sealing and weatherproofing, adding insulation to the interior of the Quonset hut can provide additional protection against temperature fluctuations and moisture buildup. Insulation helps to regulate indoor temperatures and reduce the risk of condensation, which can lead to mold and mildew growth.
Finally, prioritize regular maintenance to ensure that your sealing and waterproofing efforts remain effective over time.
Overall, a total reskin can range from $25 to $30 per square foot. Sometimes, the end walls wouldn't need to be replaced, which can lower the cost.
Every building is unique, and renovation can differ from one pole barn project to the next!
Are You Ready to Reskin Your Quonset Hut?
After learning more about pole barn repairs and renovations, will you reskin your Quonset hut?
As long as the structural integrity is intact, you can't go wrong with giving your pole barn a total makeover.
At FBi Buildings, our Repair and renovation Specialists will help you navigate the building process and get the most bang for your buck.
We'll also tell you a secret: it doesn't matter who built the original pole barn. We'll repair or renovate ANY post-frame building!
Are you ready to start reskining your quonset hut? Call our office at (800) 552-2981, and we'll gladly give you a FREE renovation quote.
Do you have more questions about reskinning Quonset huts that are not covered in this article? If you need help 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, and a member of our Customer Engagement Team will help you determine the next steps of your project.