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From Shop to Shell: Walk Through the Post and Beam Construction Process at Yankee Barn Homes

Due to our unique panelized shell construction process, much of the building work is done ahead of schedule in our shop, saving the client time and money on their job sites. The Douglas fir timbers, SFI certified (Sustainable Forestry Initiative), are kiln-dried, pre-cut and pre-stained to allow for fast building. Yankee Barn Homes uses True Wall Panels, which are panelized in the Yankee Barn Homes production facility using 2×6 studs and best “green polyiso” insulation available. Windows are pre-installed in the True Wall Panels, allowing for a superior fit and seal to prevent heat loss.

Stud Precut Line and Shoe/Plate Alignment

 

Stud Precut Line and Shoe/Plate Alignment. Here all the shoes and plates are laid out along a 75′ bench (against the back wall) so we can ensure they are all the precisely cut and the proper dimension.

 

True Wall Plate Line

 

 

True Wall Plate Line. All the plates and studs are brought together and placed on the wall table machine. This verifies that each panel is absolutely square. Next the window components, insulation, and exterior sheathing are installed.

Trim Options Line
Trim Options Line. This is our sander and planer, which we use to create a flat and even surface on our components.

 

 

This is the dado saw

 

 

This is the dado saw, where we cut window trim, stool stock, posts and stair components. The material is cut to length and then dado cut. Angle cuts are made on the chop saw.

Timber frame line

 

Timber Frame Line. This is our 5,000 lb. saw originally made for the US Navy, it was adapted by Yankee Barn Homes to cut the notches in our custom post and beam frames.

 

In the timber frame shop

 

In the Timber Frame Shop, timbers come in cut to length, and are then notched. We have two lines of material that goes through this shop and then a crane lifts the finished components out of the shop.

 

 

 

 

 

True Roof Table Line. Here we frame the roof panels and square them up. Each panel receives energy-efficient plastic and strapping. A steel fence is then pulled up around the panels, ensuring that each panel is perfectly square.

 

Here interior v-groove is installed

 

Interior v-groove is installed. The roof panel is flipped over and super energy-efficient insulation is installed. Next the plywood is installed.

 

 

Components  arrive

 

Components arriveby truck to the building site. Since the frame is already cut and notched in the Yankee Barn frame shop, the barn raising can proceed smoothly.

 

Started second floor deck

 

 

Started second floor deck. “A Yankee Barn goes up very easily, fits together well, and is substantially enclosed in a very short period of time, even when it’s built during the worst ice storm of the century,” said builder Ken Desjardins.

 

Roof beams in place

 

Roof beams in place. “Nothing compares to Yankee Barn quality, how fast the product goes up, and the floor plan flexibility. A Yankee Barn can look anyway you want – a barn, a conventional house, even with stone on the exterior. There are no limitations to the design.”

 

Last of the True Wall panels

 

Last of the True Wall panels lifted into place. “Yankee Barn is flexible and helpful. On this project, we made some last minute changes on site. Yankee Barn worked with us to build the components to make it work.”

 

True Roof® panels in place

 

True Roof ® panels in place for a nearly weather-tight shell. “The shell was built easily in two weeks. ”

 

We want you

 

 

At Yankee Barn Homes, we have as much information as you need to review our custom homes. If there is additional material that you’d like, please let us know.

 

 

DESIGNING WITH YANKEE BARN HOMES

YANKEE BARN HOMES PACKAGE COMPONENTS

FINDING AND QUALIFYING A BUILDER FOR YOUR YANKEE BARN HOME 

Post and Beam Living Latest

Upcoming Events

  • Explore Yankee Barn Homes Day

    June 2, 2017

    Grantham, NH

    Please join us this spring for a fact-finding day at our facility in Grantham, NH. You'll learn everything you need to know about the design and building process of a Yankee Barn Home followed by a construction walk-through at one of our local projects. Call 800-258-9786 or email info@yankeebarnhomes.com for more information. We look forward to seeing you!
  • Yankee Barn Homes East Hampton Private Event

    June 16th, 2017

    East Hampton, NY

    fieldview 300x300Please join us for an exclusive private event being held in East Hampton at our Fieldview home on Friday, June 16th. This event is a testament to the growing presence of Yankee Barn Homes in the Hamptons marketplace. Jeffrey Rosen, Yankee Barn Homes Creative Director, as well as Kerri Terwilliger, Lead Design Manager, will be available to discuss any questions you may have about Yankee Barn Homes, our design process or anticipated costs. We hope you can attend as it will be an excellent opportunity to tour a newly constructed Yankee Barn home, as well as discuss your future build project. To RSVP, please email info@yankeebarnhomes.com or give us a call at 800-258-9786. Be sure to register by Friday, June 2nd, as space is limited. We look forward to seeing you!

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