So You Want to Take Down a Barn?

Jeff Layton and Amanda Gatlin decided to dismantle the Mississippi barn that Amanda played in as a child and use some of the pieces in their new home. They soon discovered the true scale of the emotional and exhausting undertaking.

Photographed by Jeff Layton of MarriedToAdventure.com

When deconstructing a barn, work backward from how it was built. For example, the roof needs to come off before any wall boards. Jeff was surprised to find the roof came off easily.

Photographed by Jeff Layton of MarriedToAdventure.com

With old barns, not all of the wood can be reclaimed. Often, large sections will be rotted out and not suitable for reuse.

Photographed by Jeff Layton of MarriedToAdventure.com

Jeff learned that when you find square nails, the wood is more than 100 years old.

Photographed by Jeff Layton of MarriedToAdventure.com

Barns are icons of farm life, and the weathered structures serve as reminders of simpler times. However, when one must be taken down, the precious barnwood that can be salvaged is in a class of its own.

“We didn’t want to get rid of our beautiful old barn,” says Crystal from the Whole-Fed Homestead blog. The 1800s barn had loads of character and was an enduring presence on her and husband Karl’s homestead. It was an incredibly hard decision for the couple to make, but the structure had become run-down and unsafe. Even though Crystal and Karl knew they couldn’t keep the barn, they didn’t want to see all that barnwood go to waste. So, the two began their search for someone to dismantle the barn and make use of the wood. The process, however, was more complicated than they anticipated, and they learned a lot along the way. (Get all the details about their experience on their blog at www.wholefedhomestead.com.)

Crystal and Karl’s experience is one shared by many who either have an old barn on their property that they want re­moved or are looking for a barn to dismantle themselves to reclaim the wood. One point that should be made clear up front -- this is not a quick or easy process.

So what goes into deconstructing a barn and salvaging the wood? If you’re going to do it yourself, then quite a bit. But even if you hire a contractor, there’s still a lot to consider.

The first decision you’ll have to make is whether you will be demolishing the barn or dismantling it. Since most people reading this would be interested in reusing the old wood, we’ll stick to dismantling. Next, you should roughly determine how much of the barn can be salvaged. Does the wood still look intact, or is it rotted or damaged? Are the beams still solid? Are most of the boards and beams long, or is the barn constructed of fairly short pieces? Determine the type of wood and whether it was hand-hewn. If it’s a hardwood that bears signs of old-fashioned tools, then that’s better for reclaiming. While the weathered outer walls may not provide much useful wood, the beams located within often reveal a trove of solid, nicely patinaed pieces. In addition to the wood, think about the other parts of the barn. Are there any metal hinges or latches, square nails or foundation stones that you could make use of?

Do all your research before you start so there are no surprises during deconstruction. Do you need a permit to take down an old barn? Is the location accessible for trucks, trailers and other equipment? Be aware that even if you can get heavy equipment close to the structure, most of the disassembly will need to be done by hand. You want to be careful with the wood, and it’s very likely you won’t have access to a power source near the barn. The aged wood will be dry and can split, so you have to take your time.

When you’re ready to start, you should dismantle the barn in the reverse order that it was put up. Start by removing the windows and doors; next come the floorboards, and then the roof. Carefully remove the walls, starting with the internal walls and then moving out. Keep the frame of the barn intact. Then, wrap a heavy rope or chain around one of the beams, and using a truck or other machinery, slowly pull the beam structure apart. When the structure collapses, remove the joists and cut the large beams into smaller pieces.

Once the barn is disassembled, you’ll need to begin the tedious task of denailing all the boards and beams. If you (or your contractor) will be sending any of the pieces through a mill or cutting them with saws, a single errant nail can cause costly damage to blades. You’ll also need to clean up the remaining rubble on the barn site. Be sure you’ve determined who will remove the final debris, how it will be transported, and what it will cost.

Of course, this is a simplified version of a complicated process. But if you’re lucky enough to have an old barn that needs to be taken down, you’ll have gorgeous raw materials for furnishings and decor that are built on memories. And even if you don’t want the wood for yourself, it’s comforting to know that those old boards and beams will soon have a new life adding beauty to someone else’s home.

What’s Reclaimed?
According to Reclaimed Barns & Beams in Shelbyville, Indiana (www.reclaimedbarnsandbeams.com), the parts of barns that are most commonly reclaimed are carrier and sleeper beams, upper frame beams, weathered barn siding, interior boards and decking.

What Will It Cost?
Based on national averages, it typically costs between $5,000 and $6,000 to demolish a 30 ft. x 40 ft. post-and-beam barn (source: www.hometowndemolitioncontractors.com). If you are not keeping the wood for yourself, you can negotiate a price that allows for the contractor to keep any salvageable wood.

Tips for Hiring a Contractor
When choosing a contractor for your barn deconstructing project, here are a few tips to keep in mind:
• Write Up a Detailed Contract. Include everything you can think of, including what materials the contractor gets to keep (i.e. just the wood, or metal pieces as well), what will be done with leftover scrap, what is the estimated end date, and what is the cost.
• Ask for Proof of Insurance. Anyone in business of dismantling barns should have general liability insurance. You want to make sure you’re protected if one of the workers should fall off the barn, or if a beam lands on your car.
• Call Several Companies. As this is a growing -- and relative new -- industry, you’ll probably find a wide range of prices and job details. Contact several companies and ask for references.
• Be Aware of Possible Damage to Property. Heavy equipment will be needed to pull the posts down, which could result in broken driveways, rutted dirt or other damage. Don’t be surprised if it happens, or discuss it ahead of time with the contractor.

How to Find Help
Many companies are now getting into dismantling old barns, but it can still be hard to find someone. Search online for “barn dismantling companies” or “reclaimed barn wood” to find any companies near you.