The restoration and repair phase

It is a rare barn indeed that requires no structural or surface repairs. We, at The Barn People, feel that the restoration phase is really what separates the amateur from the professional. In many ways it can be likened to the restoration and refinishing of a fine antique. A barn bought as an "as is" commodity can be likened to purchasing a used car. It may run fine for awhile, but then things start to go wrong and it becomes a never-ending saga of agony and unforeseen expenses. Our product is the vintage Vermont barn fully restored and reassembled to look as it did the day it was built almost two centuries ago.

When the barn frame arrives at our shop, all the labeled parts are carefully sorted according to their placement within the barn's framework and again according to their condition and overall appearance. The beams are then stacked under cover to protect them from the sun's damaging ultra-violet rays, which tend to gray the honey-colored timbers rapidly.

Again, because our product is the vintage Vermont barn frame restored and reassembled to look as it did the day it was built almost two centuries ago, meticulous attention is given to the original beams that require repairs due to blemishes or deterioration. Whenever possible the original beam is kept intact and sections of wood that match in color and character are spliced in to replace deteriorated or unsightly areas. Repairs are done utilizing salvaged beams from other barns that could not be saved. We have quite an inventory of salvaged beams for just this purpose. Utilizing space-age epoxies and hidden steel, the majority of our repairs go unnoticed. If the timber will not be as strong as it was intended, it will be replaced. We have been told that we "set the standard" in this industry. It is this attention to detail and structural repairs that has earned us this reputation.

When all structural elements meet our standards, they are laid out on the ground and preassembled into large wall sections. Each large section is then "squared up". Measurements are again taken to make sure all the posts are the same length and so forth. Any corrections to these measurements are now made to a new set of blueprints.

At this point any missing beams are replaced, again using beams that match in color and character joined to the original frame utilizing authentic and matching joinery techniques. The preassembled large frame sections are now ready for the often utilized "adaptation phase".

Once a contract has been signed, clients are then given the option of customizing the barn frame to meet their particular needs. It is at this time that all changes or additions to the original frame are made. These changes may include new lofts in certain areas, which will require additional joist beams spaced at regular intervals or perhaps the removal or relocation of a specific beam to facilitate a doorway, window or addition. Many times we've added a network of additional timbers to frame a shed or "saltbox" addition which will later serve as a bedroom, office, or perhaps a dining nook. These additions also permit a smaller barn to grow on the ground floor plan without adding volumes of space above.

Because the frame is laid out and all "squared up" these changes or additions can be performed again, utilizing beams that match in color, character and authentic joinery and will then appear as an integral part of the original barn frame and never look like an "awkward afterthought".

Hand Washing

The entire frame is now hand washed. Each member is first placed on a set of saw horses and sprayed with a hose. A nylon bush is used by hand to scrub off all the barn dirt that has accumulated over the years. It would probably be faster to pressure-wash the beams, as people often do, but we have found that it tends to fuzz up the wood fibers and also removes some of the honey-colored patina which is so important to the frame's appearance. We use environmentally friendly TSP-PF which is a phosphate-free detergent mixed with water for the hand scrubbing. The beams are sprayed again with the hose and the barn dirt just floats away. In less than half an hour the beam is dry and the appearance is the difference between night and day. Besides removing barn dirt, this process also insures that the barn will not smell like the barn it once was, once the new furnace is turned on. Hand washing is essential!

Insect Treatment

No one wants to think about bugs in the beams. Beams that appear to have been damaged by insects or dry rot are replaced with beams that match the color and character of the original. However, just to be on the safe side the entire frame is then sprayed twice with Bora-care, a state of the art treatment, which kills anything living in the wood including mildew, but remains non-toxic to humans and animals. Although one coat is recommended, we go the extra mile and apply two. This insures that there will never be an insect or mildew problem. In addition to killing anything that may be living in the wood, it also has residuals meaning that it will remain in the wood for many years to follow. Insect treatment is also essential!

The "Finished" Look

Our barn frame's timbers require no further attention of any sort. They have been fully restored, hand washed and treated for insects and mildew. The splendid honey-colored patina is as good as it gets!

Click here for a photo gallery of the restoration phase.