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The
reassembly phase:
Frame enclosure/Structural Insulated Panels
 After
we reassemble the barn frame, the next step is to enclose
it. If the frame is to remain a structure for agricultural
purposes, or perhaps a garage or outbuilding, sheathing
the walls and roof with either old or new boards similar
to the original barn will be sufficient. However, the
majority of our frames are intended for residential
or commercial use and enclosure requires a more finished
appearance to include insulation. Again this enclosure
material with be fastened to the exterior of the frame,
just as barn board originally did, but will now be viewed
as the interior finish directly against the frame. Most
people use a combination of dry wall on some walls and
honey-colored antique sheathing on other walls. The
majority of people use the antique honey-colored boards
on the roof. We then recommend structural Insulated
panels applied directly to the outside of this first
layer with the finish exterior materials such as vertical
siding, clapboard or wood shingles applied to the exterior
of the panel. After this, the roof receives either metal,
asphalt shingles, wood shingles or slate. The frame
is now fully exposed to the interior, with the roof
and walls finished in the materials of your choice,
which hide a superior insulation system
 Although
the traditional techniques of joining and building old
barns are timeless, the methods used to enclose old
barn frames have changed dramatically over the years.
In the past a conventional light frame could be built
around or in between the timbers. The frame would then
be covered with sheathing and siding materials on the
exterior with drywall on the interior and the cavity
in between filled with fiberglass insulation. However,
this process was slow and expensive and resulted in
an enclosure which was not particularly energy-efficient.
In light frame construction, the insulation is interrupted
every 16 or 24 inches by a stud or rafter. This recurring
break in a homes' insulation allows heat to escape and
cold to enter at these points.
 During the energy
crisis of the mid-seventies, structural Insulated panels
were developed for residential use as a take off from
manufacturers of cold storage rooms. Because the post
and beam framed home market has grown considerably during
the past twenty years, structural Insulated panels manufacturers
sprang up all over the country to meet this new demand.
Through experimentation and trial and error, some very
sophisticated methods of manufacturing high performance
panels have developed. These structural Insulated panels
consist of rigid foam insulation sandwiched between
layers of sturdy oriented strand board. The panels are
nailed or screwed to the exterior of the completed frame
leaving the frame exposed to the inside.
Panels can be quickly installed, saving barn frame owners
weeks of construction time and labor costs. Another
advantage is that the panels form solid walls that deaden
outside noise, creating a very quiet home environment.
But energy efficiency is the most important reason we
recommend structural Insulated panels. Because they
wrap the frame in a continuous blanket of super-insulating
foam, structural Insulated panels lower energy costs
considerably.There is no break in the frame's "thermal
envelope" because the seams between the panels
are sealed with expanding foam, making structural Insulated
panels ideal for soaring ceilings and large open spaces
common to old barn frames. Today, the majority of our
old barn frames are enclosed with structural Insulated
panels which showcase the beauty of the frame and allow
the timbers to be exposed inside the home.
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