The barn—and barn construction—is one of human civilization’s oldest and most important structures. For thousands of years it has played a critical role in the agriculture and animal husbandry necessary for societies to flourish.

In the most basic of terms, a barn is a large building to house animals and/or store grain. In its earliest iterations, the barn also served as human living quarters, known in the English-speaking world as a housebarn. Over time, it became understood that separating living quarters from the animals was a wiser (more sanitary) situation, and the housebarn split into a farmhouse and a barn, leaving the latter to focus exclusively as a dwelling for animals and/or a storehouse for grains and hay, simplifying the design. For thousands of years the barn has served this purpose well and continues to play an important role even in our modern society.

That said, our modern society affords modern materials and engineering know-how, allowing for improved barns to better serve our ancient but still relevant needs. In this article, we’ll explore how to build a barn with modern materials in order to optimize the structure.

Understanding the General Layout of a Barn

All things considered, a barn is a fairly simple structure. At their most minimal, a barn is a large open space enclosed by walls and a ceiling. At their most functionally elaborate, the large open space will be sectioned into a handful of areas such as stalls and tack rooms for a horse barn or pens, and a milking parlor for a cow barn.

Traditionally, barns were constructed with three aisles, a feature of building with heavy timbers which we will discuss further below. Interestingly, this is where early church building and eventually the mighty gothic cathedrals got their architectural base from!

The three aisles of a barn involve a central aisle in the center (later known in cathedral architecture as the nave) with a shorter aisle on each side. The way the timber posts carrying the roof were laid out down the aisles, it made for “bays” in the outer aisles which were used for storage, horse stalls, etc, while the main aisle was the navigable area from which to enter and exit.

This was the blueprint for barn architecture for thousands of years, and thousands of barns remain all over Europe and North America that can attest to this. With advances in modern construction materials and architectural understanding, the three-aisled barn isn’t a required layout choice. For example, there are many modern barns that are cuboid shaped put together by prefabricated metal panels and that serve the needs of farmers, ranchers, and agricultural business very well.

That said, the three-aisle barn does uniquely cater to many functional aspects of having a barn, especially in mid-sized agricultural settings. It also continues a long architecture tradition that remains aesthetically pleasing. Due to this, the three-aisled barn or a design very similar remains popular and in use during new barn construction to this very day.

How to Build a Modern Barn

Let’s take a look at the general steps of barn construction, then focus on one of the most important aspects: material choice.

Planning and Design

Whether you choose a classic three-aisled barn, one of its derivations, or a modern look, the barn will generally have the same footprint, with size adjustments based on need. In the planning and design phase, the biggest concern is just that: determining how big the barn must be to suit your purposes. Is it a medium-sized barn going to hold 4-6 horses or will it be a large barn with dozens of horses or cattle? Consider your specific needs in order to properly determine the size of the barn.

Small Livestock Barns

The typical square footage for small livestock barns is 24 feet by 24 feet (576 square feet) to 36 feet by 36 feet (1,296 square feet). This size can accommodate a few horses, goats, sheep, or other small animals.

Medium-Sized Livestock Barns

Medium-sized barns for larger livestock such as cattle or horses might range from 36 feet by 48 feet (1,728 square feet) to 48 feet by 72 feet (3,456 square feet). These barns provide more space for animals, equipment storage, and additional features like milking parlors or tack rooms.

Large Livestock Barns

For larger-scale operations or commercial farms, barn sizes can be much larger. A large livestock barn might range from 60 feet by 100 feet (6,000 square feet) to 100 feet by 200 feet (20,000 square feet) or more. These barns can accommodate a significant number of animals and often include multiple sections for different purposes, such as housing, milking, and storage.

Site Preparation and Foundation

As with all construction, the first step is to prepare the site by clearing the ground of rocks, vegetation, and leveling it. It is prudent to opt for a foundation as the vast majority of barns are rather large. For smaller barns, you may be able to rely on concrete footings, but we are going to assume the purpose of your barn is more than just a large shed.

Important note: Before pouring the foundation, you will need to determine whether or not you’d like drainage in the barn. Having proper drainage is an incredible addition to a barn if you’ll be housing and working with livestock considering the cleaning necessary for a sanitary environment. It doesn’t have to be extensive, maybe only one or two drains, but it’s ideal to have this planned in order to work into the foundation beforehand. You can of course do this after the fact, but many find it easy to do so prior to building, so consider drainage before pouring the slab.

Selecting the Right Building Material for Barn Construction

Now that your foundation is ready, it’s time to erect the barn. Historically, this was a social event called barn raising. Community members would gather to help their neighbor erect their new barn by lifting the cut and assembled timbers into place. Before modern materials, this was the go-to barn construction method that utilized wood for barns, called timber framing.

Timber Framing

Timber framing, also known as post-and-beam construction, is the historical method of barn construction where very large timbers are milled and cut to form the main, load-bearing structure of a barn. Mortise and tenon joints are carved into the wood so that they fit together, which eliminates the need for fasteners. You can think of timber framing as a big, thick skeleton from which the roofing and wall sheathing is adhered.

Although it was utilized in barn building and many other types of historical buildings because it was the easiest if not only way to construct a sturdy structure, it just so happens to also be aesthetically pleasing and homey. In fact, timber framing continues to this day and is utilized in many luxury homes to create a rustic, wooden beam aesthetic.

Pros

• Structurally sound and long-lasting

• Offers unique architectural possibilities

• Aesthetically pleasing, exudes the classic barn aesthetic

Cons

• Costly and labor-intensive

• Finishing challenges: the timbers only form the barn’s skeleton

Prefabricated Metal Panels

Prefabricated metal buildings for barn construction are a popular choice for agricultural structures as they offer rapid installation of a highly durable material. Instead of the time-consuming task of sourcing massive timbers, carving them and their joints, then erecting them, prefabricated metal panels go up extremely quickly, including the walls and roofing. The trade-off for the rapid construction is limited aesthetic options, unlike the glory of a timber-framed barn. Additionally, prefab metal buildings are noisy and present condensation issues in humid climates. If you desire insulation, that will also need to be added to the metal building once complete.

Pros

• Rapid construction, including the roof and walls

• Durable

• Low maintenance

Cons

• Limited aesthetic options

• Condensation and moisture issues

• Noisy

• Requires insulation, if desired

• Hard to control indoor environmental temperatures

Insulated Concrete Forms (ICF)

Insulated concrete forms (ICF) are a fantastic modern building material that advances the use of concrete in construction. ICFs are hollow blocks made of expanded polystyrene (EPS) foam that are connected together to form a wall in which reinforced concrete is placed. While concrete and barns don’t seem to go together on the surface, insulated concrete walls and reinforced concrete are the perfect barn construction materials because they offer a huge advantage over timber framing and prefab metal: thermal efficiency and strength.

The combination of EPS foam sandwiching reinforced concrete creates an extremely durable and thermally efficient “composite” material. Any kind of insulation, much less highly-efficient insulation, is a benefit that most barns historically pass on. Timber or stick framing and prefab metal panels do not offer insulative properties on their own, and most building a barn choose not to go through the added trouble of installing insulation in such a large structure where thermal requirements are less than in residences. That said, insulation is highly advantageous as it helps to not only protect and enhance the health of livestock, it also reduces climactic swings that can negatively impact feed and grain storage as well as tools and equipment.

Not only do ICFs inherently protect the inhabitants of your barn from temperature, but the inherent strength of concrete protects the building like no other material. It’s true that heavy timbers are durable, too, but only as far as the timbers go. The material between the timbers that form the walls are not as durable. With ICF, instead of a strong skeleton with a weak skin, the entire structure is the same, insulated concrete that provides complete durability.

ICF structures are specifically chosen for barn construction in regions with intense weather, such as tornadoes and hurricanes, as the ideal building material for protection. Considering these risks, as well as snow and thunderstorms, and even just basic security, a barn constructed with ICF offers the best qualities that a barn most requires for functionality.

Pros

• Energy efficiency

• Sound insulation

• Durability

• Fast construction

• Fire resistance

• Design flexibility

• Controllable indoor environment

• Walls of any height

• Above and below ground construction

Cons

• Initial costs

• Skilled-labor required

• Finishing challenges*

ICF “Finishing Challenges” for a Barn Build

Although it may seem like a con, “finishing challenges'' for ICFs provides the opportunity to pair the best of modern materials with the aesthetic grandeur of a traditional barn. To finish an ICF barn, you will need to complete the wall finish, interior framing, and the roof.

ICF Wall Finishing

Finishing the exterior of an ICF wall is simple. Exterior finishes can be directly applied to an ICF wall assembly with exterior grade screws. Woods siding for a traditional look can be chosen, but all other types of siding materials and cladding may be applied—though vertical board and batten siding would require strapping on the wall. ICFs pair perfectly well with all manner of traditional and modern cladding materials.

ICF Roofing / Interior Framing

The roof of an ICF-built structure is typically constructed with a traditional truss using wood beams and studs. Depending on the width of the barn, it may be as simple as adding trusses and finishing the roof from there, which leaves you with a large open area within. The engineering for an ICF-reinforced concrete wall has the capacity to support long span trusses and point load beams.

That said, the roof is actually an aesthetically important part of a barn and traditionally constructed to create additional height within the interior. The most classic barn roof is the gambrel, a symmetrical roof with two slopes on each side, to maximize the headroom within the barn. Depending on the complexity of your truss design, a gambrel roof can be made to add further headroom while also creating a more dramatic aesthetic. A gable roof is also a great selection for a barn with a lot less necessary design and engineering know-how.

When it comes to interior framing of barn construction, the roof and width of your barn synergize. If you’d like to harness the interior design and functionality benefits of the classic three-aisle barn with your ICF walls, incorporating heavy beams can turn your interior framing into a quasi timber-framed barn for the creation of bays for stalls and storage areas, and to provide the necessary strength to support a large gambrel or gable roof.

In this way, you get the thermal efficiency and extreme durability of ICF for the structure's walls, while staying true on the inside with a rustic, timber-framed look capable of supporting a roof that maximizes headroom and aesthetic appeal. For a final finishing touch, adding cupolas and/or dormers is a great choice to complete the classic barn look.

Partner with Fox Blocks for an Incredible Modern Barn Built with ICF

Barn construction is a modern sensation in architecture considering its simplicity, functional purposes, and deep historical aesthetic.

Modern barns for large animal livestock—and even small animals such as chickens and turkeys—require more sophisticated equipment and control of the indoor environment to keep animals healthy and safe while also protecting expensive farm equipment.

When looking to build a new barn for your specific needs, consider doing so with Fox Blocks insulated concrete forms to maximize durability and thermal efficiency, whether to provide your animals a comfortable, healthy, and safe environment or to fully protect your tools and farm equipment for inclement weather conditions.

Fox Blocks is a premier supplier of ICFs with advanced knowledge of pairing this modern material with traditional and modern architecture.

Reach out to our experts today to see how we can help you craft the perfect modern barn utilizing ICF!