We Built a Barndominium in 90 Days (Avoid Our Mistakes)

Ready to jump into the wild world of barndominium building? When my partner and I decided to tackle building our dream barndo in just 90 days, we had no idea what a rollercoaster ride we were in for! The rush of seeing our metal frame go up was incredible, but boy, did we learn some tough lessons along the way.

Our 90-Day Barndominium Journey

When we decided to build our barndominium, we didn’t just want a home—we wanted an adventure! Our journey from blueprints to move-in took exactly 90 days, which felt like both an eternity and a blink of an eye.

Day 1 started with the concrete pour for our foundation, a critical step that set the pace for everything that followed. The concrete team arrived at dawn, and by sunset, we had the beginnings of our dream home taking shape. Those first few days were filled with equal parts excitement and anxiety as we watched the weather forecast like hawks—rain would’ve delayed everything!

By week 2, the metal frame installation began, and wow—talk about a transformation! What had been just a concrete slab suddenly started looking like an actual structure. This phase moved surprisingly quickly, with the crew installing the entire frame in just 4 days. Standing inside those metal bones, we could finally visualize our future living room, kitchen, and bedrooms.

The exterior metal cladding went up during weeks 3 and 4, giving our barndo its distinctive look. We chose a classic dark gray for the roof and walls with white trim—a decision we’ve never regretted. This phase was particularly satisfying because each day brought visible progress that we could photograph and share with friends and family.

Weeks 5 through 8 focused on the interior rough-ins for plumbing, electrical, and HVAC. This less visible work tested our patience, but we knew it was crucial for a functional home. Our daily site visits became a ritual, with each of us taking turns spotting new details and changes.

The final month transformed our shell into a home with drywall, flooring, cabinetry, and fixtures all coming together in a carefully choreographed dance of subcontractors. Some days had up to 15 different workers on site simultaneously, requiring constant communication and decision-making on our part.

Moving day—exactly 90 days after breaking ground—felt surreal. We’d done it! Our barndominium journey had numerous ups and downs, unexpected challenges, and split-second decisions, but the result was exactly what we’d dreamed of: a unique, efficient home that perfectly suited our lifestyle and needs.

Choosing the Right Location and Design

Selecting the perfect spot and crafting the ideal design for your barndominium sets the foundation for your entire build. Our location and design choices significantly impacted our 90-day timeline, creating both opportunities and challenges we hadn’t anticipated.

Site Selection Lessons

Location selection is more than just finding pretty views. Accessibility to utilities saved us thousands of dollars that we hadn’t budgeted for initially. Our property already had water, sewer, and electrical connections nearby, which eliminated weeks of potential delays and extra costs. If we could do it again, we’d have conducted a more thorough soil test before breaking ground. The unexpected rocky terrain in one corner of our site required additional excavation work that pushed our schedule back by three days.

Consider the natural elements when positioning your barndominium. We placed our large windows facing south to capture maximum natural light, reducing our electricity usage by approximately 25%. However, we didn’t account for the prevailing winds in our area. Positioning your main entrance away from direct wind paths protects against weather exposure and improves energy efficiency.

Don’t overlook the importance of property setbacks and local zoning regulations. We had to shift our entire structure 15 feet to the west after discovering our original placement violated county setback requirements. This mistake cost us valuable time and an additional $1,200 in surveying and site prep adjustments.

Floor Plan Considerations

An open-concept design significantly simplified our construction process. Fewer interior walls meant faster framing, less material, and more flexibility during the build. Our 1,800-square-foot layout features a spacious central living area with bedrooms positioned along the perimeter, which made the plumbing and electrical installations more straightforward.

The ceiling height decision was crucial! We opted for 12-foot ceilings in the main living space instead of the standard 9-foot height, creating an airy, expansive feel. Though this added approximately $3,500 to our material costs, the dramatic impact was worth every penny.

Storage planning deserves more attention than we gave it. We underestimated our storage needs by about 30%, especially in the kitchen and utility areas. If redesigning, we’d incorporate more built-in cabinets and dedicated storage spaces. Custom storage solutions are much more expensive to add after construction than when integrated into the original design.

The bathroom layout needed more thought too. We positioned the master bathroom plumbing against an exterior wall, which created insulation challenges during winter months. Placing plumbing along interior walls or adding extra insulation for exterior plumbing walls helps prevent freezing issues and improves energy efficiency.

Flexibility in your design saves time and money during construction. We created a multipurpose room that could serve as an office, guest bedroom, or hobby space. This adaptable approach has proven invaluable as our needs have changed over time, eliminating the need for costly renovations later.

Budget and Timeline Realities

Our barndominium journey taught us that even the most detailed plans can’t predict every financial and scheduling curveball. Despite our careful preparation, reality had other ideas for both our wallet and our calendar.

Unexpected Costs We Encountered

Foundation adjustments added $7,500 to our initial budget when soil testing revealed unstable conditions requiring additional reinforcement. We’d budgeted for a standard foundation, but our property’s clay-heavy soil demanded extra engineering that blindsided our financial plan.

The HVAC system exceeded estimates by $4,200 when we discovered standard residential units weren’t optimal for our open-concept space with high ceilings. Our contractor recommended a commercial-grade system with specialized ductwork to efficiently heat and cool the barndominium’s unique dimensions.

Custom windows for the cathedral ceiling weren’t part of our original budget but added $3,800 to the total cost. These specialty windows required additional framing and waterproofing techniques that standard window installations don’t include.

Our electrical panel upgrade cost an extra $2,100 after determining our initial 150-amp service wouldn’t support our workshop equipment alongside household needs. The 200-amp service we installed provides ample power but required additional permits and inspections that delayed progress by four days.

Weather-related delays cost us approximately $1,200 in additional labor when unexpected rain forced workers to leave mid-installation, then return later to resume work on the exterior metal cladding.

Timeline Management Strategies

Front-loading material deliveries saved us eight crucial days during construction. We arranged for all major materials to arrive before they were needed, preventing the common construction delay of waiting for supplies while crews stood idle.

The weekly contractor meetings every Monday morning became our project lifeline. These 30-minute check-ins helped identify potential bottlenecks before they became problems and allowed us to adjust the schedule proactively rather than reactively.

Creating parallel work streams accelerated our timeline significantly. While the plumbing rough-in happened in one section, electrical work progressed in another, and exterior finishing continued without interruption. This approach shaved approximately two weeks from our overall timeline.

Establishing a three-day buffer between major construction phases proved invaluable when our flooring delivery arrived damaged. The buffer allowed time for replacement materials to arrive without disrupting the entire schedule of subsequent installations.

Maintaining a dedicated decision-making spreadsheet eliminated delays caused by indecision. We logged all pending choices with deadlines, ensuring we provided timely input on everything from light fixtures to door hardware without holding up progress.

Leveraging prefabricated elements whenever possible trimmed our timeline substantially. Prebuilt trusses, pre-hung doors, and factory-finished cabinets arrived ready to install, eliminating time-consuming on-site fabrication and finishing work that would have extended our 90-day goal.

Construction Challenges and Solutions

Our barndominium journey wasn’t all smooth sailing—we encountered several significant hurdles that tested our resolve and problem-solving abilities. These challenges taught us valuable lessons about construction planning and adaptability that we’re sharing to help you avoid similar pitfalls in your build.

Foundation Issues We Faced

The foundation proved to be our first major obstacle when our soil test revealed unexpected clay expansion rates that weren’t initially detected. This discovery forced us to modify our foundation design from a simple slab to a more robust pier-and-beam system, adding $7,500 to our budget. We also encountered issues with concrete curing times during humid days, which delayed our timeline by nearly a week.

If we could do it over, we’d hire a geotechnical engineer before purchasing the land to conduct comprehensive soil analysis—not just the basic tests our contractor recommended. We’d also schedule the concrete pour during the early morning hours to avoid afternoon humidity and heat that affected setting times.

The plumbing rough-in beneath the foundation revealed another challenge: our original drainage plan conflicted with the soil’s natural water flow. This required a last-minute redesign of the slope gradient for wastewater lines, teaching us that consulting with both a plumber and excavation expert simultaneously could have prevented this issue.

Weather-Related Setbacks

Man, let me tell you—Mother Nature doesn’t care about your construction schedule! We lost 12 critical days to unexpected storms that flooded our work site and made it impossible for heavy equipment to access the property. The metal frame installation had to be postponed twice because of high wind advisories that made crane operation dangerous.

Looking back, building a temporary gravel access road would have been worth every penny. It would have allowed crews to reach the site even after heavy rainfall, saving at least 5 of those lost days. We also should have rented large commercial dehumidifiers instead of the small residential units we used, which struggled to dry out the interior after the roof was complete but before windows were installed.

The most frustrating weather challenge came during the exterior finishing phase when temperature fluctuations affected our siding installation. The metal panels expanded and contracted more than anticipated, creating alignment issues. If we’d known, we would have scheduled exterior work during more consistent temperature periods and used specialized fasteners designed for thermal movement.

Interior Design Decisions

The interior design phase transformed our barndominium from a metal shell into a comfortable, functional home. While we made some fantastic choices that we love daily, there were definitely decisions we’d reconsider if we had a do-over.

Space Optimization Successes

Our multipurpose room configurations paid off tremendously in the finished barndominium. We installed a kitchen island with retractable leaves that serves as both dining space and extra countertop area depending on our needs. The built-in storage benches along the eastern wall provide seating and hidden storage for seasonal items, maximizing every square inch. We’re particularly pleased with our decision to include pocket doors throughout the main living area, which saved approximately 30 square feet of swing space compared to traditional doors.

Another win was our strategic electrical outlet placement at 42-inch intervals, including USB-integrated outlets near workspaces and bedside tables. We installed a custom murphy bed system in the office that transforms into a guest room in seconds – hands down one of our smartest space-saving investments at $2,800. The open sight lines we maintained between kitchen, dining, and living areas make our 1,800 square feet feel much larger while still allowing for distinct functional zones.

Finishing Touches We Reconsidered

Looking back, our cabinet selections could’ve been better planned. We chose high-end custom cabinets ($9,200) but didn’t properly account for how much storage we’d actually need. I’d recommend measuring your actual dishware and cookware before finalizing kitchen cabinet layouts – we ended up with beautiful cabinets that don’t quite fit our plates!

The polished concrete floors looked fantastic in showrooms but proved impractical in real life. They’re cold in winter, show every water spot, and have already cracked in two places despite our careful installation. For the same $6,400, we could’ve installed luxury vinyl plank flooring with radiant heat underneath.

Our biggest regret? The minimalist lighting plan that left several areas too dim for practical use. We saved $1,800 upfront but spent nearly $3,200 adding fixtures later. The paint colors we selected online looked dramatically different on our walls with the barndominium’s natural light patterns. Take time to test paint samples at different times of day before committing to whole-room applications.

The bathroom vessel sinks looked spectacular in design magazines but are challenging to keep clean around the raised edges. Our open shelving in the kitchen, while visually appealing, collects dust faster than we can keep up with. If we’d known the maintenance requirements, we might have opted for more practical alternatives like undermount sinks and glass-front cabinets instead.

Working With Contractors

Managing relationships with contractors proved crucial to completing our barndominium in just 90 days. Clear expectations, consistent communication, and strategic decisions about which tasks to handle ourselves made all the difference in keeping our project on schedule and within budget.

Communication Strategies That Worked

Our most effective communication approach was establishing a dedicated project management system that all contractors could access. We used BuilderTrend to share documents, track progress, and manage change orders in real-time. Every Monday morning, we held a 30-minute standing meeting with all lead contractors to discuss the week’s goals and potential conflicts. These meetings prevented scheduling overlaps and helped trades coordinate effectively.

Setting up a 24-hour response policy for all questions and concerns paid dividends throughout the project. When our electrician needed clarification on outlet placement at 4pm, we provided answers by the next afternoon, preventing costly delays. We also created a shared photo folder where contractors documented their progress daily, which helped us spot issues before they became problems.

Our color-coded timeline chart displayed prominently at the site entrance helped everyone visualize deadlines and dependencies. Trades could immediately see how their work affected others, creating natural accountability. For complex installations like our custom steel staircase, we arranged pre-installation meetings between affected contractors, eliminating confusion and rework.

When to DIY vs. Hire Professionals

Painting interior walls was our most successful DIY project, saving approximately $5,800 in labor costs while giving us complete control over the finish quality. We tackled basic trim installation in non-critical areas and handled all the caulking work throughout the home. Simple landscaping tasks like spreading mulch and planting shrubs were satisfying weekend projects that saved money without impacting our timeline.

However, attempting to install our own kitchen backsplash proved to be a costly mistake. What should have been a two-day professional job turned into a week-long struggle resulting in uneven tiles and wasted materials. We quickly learned to recognize specialized skills that required professionals, including all electrical work, plumbing connections, and HVAC installation.

The concrete floor finishing was another area where hiring professionals made financial sense. Our contractor’s team completed the grinding, staining, and sealing in three days with specialized equipment that would have cost us $4,200 to rent. Their expertise in timing the application between other trades prevented damage to the finish that would have been inevitable with our amateur approach.

For fence installation, we struck a perfect balance by hiring professionals to set posts and install gates while we attached the fence panels ourselves, saving about $2,300 while ensuring structural integrity. This hybrid approach worked wonderfully for several aspects of our build, allowing us to contribute sweat equity without compromising quality or timeline.

Permitting and Legal Considerations

Getting permits for our barndominium was like navigating a maze—blindfolded! I’d never imagined the paperwork tornado that would sweep through our build. County-specific regulations vary dramatically, and we learned this lesson the hard way.

Our first hiccup came when we discovered our property was subject to agricultural zoning restrictions that limited residential square footage. We spent two weeks scrambling to modify plans and apply for a variance. In retrospect, we should’ve checked zoning laws before purchasing the land!

The building department required three separate inspections during our foundation work alone. Scheduling these inspections in advance would have saved us nearly two weeks of downtime—a crucial mistake during our tight 90-day timeline.

We also underestimated the importance of hiring a permit expediter. For $1,500, these professionals navigate bureaucratic channels and often cut permit approval times in half. That expense would’ve been worth every penny considering the delays we faced.

Another surprise was the septic system permit, which required its own engineering study and health department approval. This single oversight pushed our schedule back by 11 days. If you’re building on rural land, start your septic approval process early!

We learned the hard way that some contractors won’t pull their own permits. Our plumber assumed we’d handle his paperwork, creating a confusing situation that delayed our rough-in phase. Always clarify permit responsibilities in your contractor agreements!

Our most painful lesson came from not researching easements thoroughly. We discovered a utility easement running through our property that restricted where we could place our barndominium. Had we known earlier, we could’ve adjusted our foundation placement without costly modifications.

Living in Our Barndominium Today

Our barndominium has transformed from a construction project into our dream home that delivers daily joy. After six months of living here, we’ve discovered the true benefits and a few unexpected challenges of barndominium life.

The vaulted ceilings create an incredible sense of spaciousness even in our modest 1,800 square feet. Natural light floods through our strategically placed windows, reducing our electricity usage by approximately 20% compared to our previous home. The metal construction has proven remarkably quiet during rainstorms—contrary to popular belief—and our heating costs dropped 35% this winter thanks to the superior insulation package we selected.

Our open floor plan functions exactly as we’d hoped, making entertaining a breeze with room for 15 guests at our housewarming without feeling cramped. The polished concrete floors in common areas require less maintenance than we anticipated—just a quick microfiber mop every few days keeps them looking spectacular.

However, not everything has been perfect. The acoustics in certain areas create unexpected echo chambers, particularly in our main living space. We’re addressing this by adding textured wall panels and plush area rugs that complement our industrial-modern aesthetic. We’ve also discovered that temperature variations between our upstairs loft and main floor can reach 8-10 degrees during extreme weather, requiring additional ceiling fans to improve air circulation.

Our barndominium’s metal exterior has performed admirably against the elements, but we’ve noticed minor condensation issues around some window frames during severe temperature fluctuations. A simple dehumidifier and strategic weather stripping have largely resolved these concerns.

The multifunctional spaces have proven more valuable than anticipated. Our workshop area converts to additional guest space in minutes, and the covered patio has become our favorite three-season living area. The built-in storage solutions throughout the home have eliminated clutter entirely—a feature we appreciate daily.

Living in our barndominium has confirmed our decision to build rather than buy conventional. The customized layout perfectly matches our lifestyle, and the unique character of our home continues to draw compliments from visitors. Despite the challenges during construction, the results have exceeded our expectations and created a home that truly works for us.

Conclusion

Building our barndominium in 90 days was an adventure filled with triumphs and challenges. The lessons we learned about soil testing foundations preparing for weather delays and managing contractor relationships will stay with us forever.

Would we do it again? Absolutely. Despite the budget overruns and scheduling headaches the satisfaction of creating a space perfectly tailored to our needs has been worth every struggle.

Our advice? Plan meticulously but stay flexible. Test materials before committing. Communicate clearly with your team. And remember that your dream home isn’t built in a day but with thoughtful decisions made step by step.

The barndominium life has exceeded our expectations. We’ve created not just a house but a home that truly works for our lifestyle.