Construction Guide

This chapter discusses planning, including time and labor estimates and pre-delivery checklist, to help you and your contractor prepare for the delivery and raising of your Yankee Barn.

2.1.1 Yankee Barn Supervisors
To speed the shell assembly process, a Yankee Barn Homes Shell Specialist is included with every kit to work along with the builder’s crew.
Although individual arrangements vary, advisors are usually scheduled to arrive in time for the unloading of the trucks. Generally they remain on-site until the frame, wall panels, and roof panels on the main house are installed.

2.1.2 Time and Labor Estimate
Time and Labor Estimates for Yankee Barn shell assembly assumes:
Use of a Yankee Barn Shell Specialist or an experienced Yankee Barn builder.
The time and labor estimated on the following chart is for our most popular frames, the Prairie Barn and Mark I, which are 48' long and two stories tall. Use this chart as a rough guide for a structure of this size, and adjust according to actual design and other factors.
The crew should consist of at least two skilled framing carpenters and two rugged assistants. At various stages, additional help will make the work go much more efficiently, for example when the crane is being used. The crew members below include the Yankee Barn Shell Specialist.
A more accurate time estimate for your shell assembly is included in Yankee Barn’s “Cost Projection.” This is an estimate of the costs your builder would typically incur on site to raise and finish your Yankee Barn. Many items are estimated based on R.S. Means, a nationally published estimating system, but unique Yankee Barn operations like the “barn raising” are based on our experience.

Time and Labor Estimates - based on 48' Prairie Barn Frame This chart should only be used as a rough guide for a 48' Prarie Barn or Mark I. Actual design and specifications will change these estimates. For example, complex roofs will take longer to install. A “Cost Projection” for your design is available from Yankee Barn Homes.
		Days	Workers	Crane/ fork lift
1.	Unloading Four Trucks	1.25	2*	.5
2.	Structural Frame	3.5	5*	3
3.	Second Floor Conventional Joists and Plywood
		1.25	5*	1
4.	Wall Panels	3	5*	2
5.	Roof Panels	1.5	6*	1.5 with crane
6.	Greenhouse
	Shell	2	2*
	Glass and Trim	1.5	2
7.	Exterior Trim	6	4
8.	Exterior Doors	1	2
9.	Attic Planking	1	2
10.	16' Roof Beam Dormer	1.5	4*	1/2
11.	Yankee Barn Stairset	1.5	2
12.	Yankee Barn Rails and Balusters	1.5	2
13.	Skylights (per)	.5	2
14.	Site Installed Window(s)	.25	2
*Including YBH Shell Specialist

 

2.1.3 Additional Labor Requirements
Yankee Barn offers a variety of options, ranging from country porches and raised ceilings to custom order windows. Occasionally some work cannot be done in the Yankee Barn shop. You and your builder should anticipate this in your estimates, or build in allowances for additional labor. For example, it is sometimes necessary to install one or more windows on-site, because windows may fall on a panel joint or arrive too late to be installed in the Yankee Barn shop.

Planning and Delivery for Yankee Barn Homes

Pre-delivery Checklist

1. Preparation
   1. Power to Site: Protected by circuit breakers and a ground fault interrupt. 3 (min.) 100' grounded extension cords.
   2. Backfill Foundation.
   3. Clear and safe access to the unloading area for 65' Over-the-road tractor trailers with space to turn around and exit.
   4. First deck complete to plans by YBH.
   5. 30' cleared space around the foundation to allow access by equipment and workers.
2. Equipment
   1. Forklift for Unloading: All-Terrain forklift with 10,000 lb. capacity and 50' reach; 8' forks (Shipped by YBH on first truck) and telescoping boom. Forklift should remain on site for the shell assembly. If site is accessible, much of the crane work can be done with the forklift.
   2. Crane for installation of wall and roof panels (normally needed on the last two days of the project). Must have 70' reach and 1,000 lb. capacity.
   3. Steel Scaffolding: 6 sections, 6 ft. Ladder type or equivalent (optional but recommended).
   4. 28' (min.) Extension Ladder, Shorter Extension Ladders
   5. Two Saw Horses (min.)
   6. 20' to 24' Aluminum Staging Plank (optional but recommended)
3. Special Tools
   • 1 Qt. Caulking Guns (in addition to the one provided by Yankee Barn)
   • 1/2" electric drills (2 min.); cordless drills (2 min.)
   • Drill bits; two each: 1/4"x 5 " standard high speed
   • Drill bits; one each: (3/4" x 4")
   • 7 1/4" or larger Skill Saw with carbide blade
   • Sawzall ­ with NEW long wood-cutting and metal-cutting blades
   • Handsaws (sharp)
   • 16" Makita Circular Saw (optional)
   • Selection of 1-1/2" or larger wood chisels
   • Flat bar, goose neck bars
   • One each: 4-8 lb. long handled sledge hammer
   • Two each: 27' ­ 30' 3" ratchet straps
   • 30' rope for tag line
   • Impact wrench or ratchet (helpful installing granary ledgers and any other application requiring lag screw installation)

4. Materials (Supplied by you or your builder) List will vary dependant on the size of the home.
   • Lumber – 50 each: 2x4-8' for bracing and betters
   • 30 each: 2 x 4’s, 16" minimum
   • 24 each: 2 x 4’s, 12' minimum

2.1.4 Additional Information
If you have any questions concerning equipment, materials, labor estimates, or the Yankee Barn itself, please call the customer service office at 1-800-258-9786. Our staff is ready to assist you.

Your Yankee Barn packages arrive on 48 foot long trailers hauled by “over-the-road” type 25 foot long tractors. A typical home requires four fully-loaded trucks.
Actual unloading of the trucks is your contractor's responsibility. You will need either a rough terrain forklift with a 10,000 pound capacity to remove the bundles.

2.2.1 What You Will Find
Your Yankee Barn packages are bundled in logical groupings:

• Wall, roof, and floor system are wrapped with water-resistant paper. The contents of each bundle are clearly labeled on the wrapping paper.
• Timber is bundled with metal banding in several groups.
• Sliding glass doors and any large windows which cannot be installed in the panels are packed in a seperate door box.
• The “grocery box” is a large plywood container where you will find final construction plans along with all the nails, screws, glues, sealants, and other bits and pieces required to assemble your Yankee Barn.

2.2.2 Unloading
Two hours are allowed for actual unloading of each trailer, which should be adequate if you are properly prepared for their arrival. Your equipment operator must be careful in removing the bundles from the truck. Forklift operators in particular must be attentive to avoid making gouges on the exposed surfaces of the panels and timbers. The panels and timbers should be kept off the ground to prevent staining.

Unloading Your Yankee Barn-Quick Guide

What You Need

• 10,000# All Terrain forklift and operator
• 1 to 2 helpers to guide the driver and place betters.
• Lumber to use as betters under the packages (2x4's are OK- 6x6 are better). Wall packages will be 8' wide and up to 16' long. Remaining packages are 4' wide and as long as 24'.
• 8' Fork Extensions (supplied on first truck-yours to keep).
• YBH Shell Specialist or someone with a clear understanding of what packages will be needed and when.
• Space to allow access for 65' Tractor Trailer trucks to enter the unload and then turn around to leave.
• Space to unload and store packages on the job site.
  

Unloading

• First truck usually arrives at 7:30 A.M. and subsequent trucks are scheduled for two hour intervals thereafter. You are allowed two hours to unload each truck, after which there may be an extra hourly charge.
• Packages should be placed on level, dry land to avoid damage to the contents.
• Place timber frame, grocery box, and dimensional lumber closer to foundation for initial assembly.
• Walls will be installed second in the sequence and should have unobstructed access.
• Roof is last to be installed as part of the shell and roof panels, can be double stacked if necessary.
• Exterior trim and siding will be used next.
• Stairs, windows (interior tri, screens, grills, etc.) and skylights will be used last.
  

Note:
The packages, especially the wall packages, need to be lifted and moved with care. Make sure the tips of the forks extend to the far side of the package before lifting and lower the packages close to the ground when driving about the site. Some wall packages can be very heavy and tipsy.

2.2.3 Extended Storage
We do not recommend long-term storage of your packages on-site. Heat, humidity, and condensation can cause warping, mildew, and other structural and cosmetic damage. If you plan to assemble the shell more than four weeks after delivery, or if you anticipate extremes in weather, the Yankee Barn packages should be stored under cover.
Finish items such as laminated planking and Southern Yellow Pine flooring are susceptible to water damage. Do not depend upon the paper wrapping to protect these materials from rain. Store well off the ground, or better, remove from the site and store under cover.