Barn floor question..
 

Ok - rural Pelican OT braintrust - this city slicker has a question.:confused:

We built a barn up in the country years ago - but it has always had a dirt floor. The foundation is poured concrete (below the frost line) and two rows of concrete block. 2 X framing, rough cut board and batton siding and steel roof. Dark and damp in there..

Now that Dad is getting older (and needs a place to hide from Mom), I want to add some lights, build a work-bench and improve the floor.

What are the best floor options? Mostly it is tractors and stuff. I think a concrete floor would be too expensive. How about crushed stone? It is a wet area (up-state NY), is it possible to add a vapor barrier? How thick does in need to be? Will stone pack down or stay loose?

Thanks.

If you go for gravel ( I wouldn't), place a layer of geotextile,then stone. the geotextile will keep the stone from migrating and mixing with the soil underneath. It will never realy compact though.

I'd pony up and place a concrete slab, place a vapor barrier, then concrete. It will be much more comfortable w/ a concrete floor..

This is the way to go!

Use crushed rock for fine grade and use some re-bar 3/8 or 1/2 in 18'' or 24'' grids. Pour 3.75+ inches of concrete makes the perfect shop. I spend as much time as I can in the shop.

I understand your reluctance to pour concrete, but if you can find someone to help, it can save you a bunch of money. The actual material isn't that much and anyone can call a cement truck and have it delivered. After seeing them do this on my addition, patios and the entire driveway, I think I could do it. Dig deep enough to get a good base of stone, compact with a machine, lay some reinforcement mesh, and pour to a depth of 4" generally. Of course you need to know the proper time to float it, give a broom finish, and lay some expansion joints. This is someone with a little experience would help. That said, a decent home concrete job beats a gravel floor anytime. We have a barn that has a dirt floor and is pole built with no foundation. Along with being cold and damp, there has been many an occasion when I have surprise raccoons and ground hogs that dig there way in there.

A gravel floor just doesn't work in a garage because it is by nature not stable. You can't safely raise a car on it, parts and tools get lost in it, it is dusty, etc. Concrete with a vapour barrier is the way to go. It is expensive, but it isn't going to get any cheaper any time soon.

I have a few old tobacco barns on my farm that I use for storage...I'll post some pics later if you want.

I used 3/4in rock to cover the dirt to keep the barns cleaner, but that is it...it is a terrible surface otherwise; great for storage, horrible for anything else.

One option would be to frame in a raised platform. That is very common in Maryland in old tobacco barns. They called them, "stripping rooms" because that is where they stripped the tobacco from the stems in the winter. I have used the stripping room as a workshop for the last 14 years:) Mine has windows...in the summer I put in a window air conditioner and in summer and use propane heat in the winter.

All that said, I plan on building a real workshop this fall...concrete floor, the works.

My parents have a 5k SF horse stable and they have this octagonal plastic mat which helps the horses from slipping. 1/2" and ribbed. If you want the brand name I can give them a call. Extremely durable.

If you are having any horses then do not use gravel or you will be paying vets to fix broken ankles.

Thanks guys. I guess I should price out the concrete. Waiting to hear back from the crushed stone guy..

My Dad did this a few years ago. He poured concrete in his 50 year old barn and it made a HUGE difference in workability. Definitely go for the concrete.