Replacement of timber barn
Project - Stanion Lodge Farm, Kettering
Case Study: Demolish and replace storm damaged barns
Project Overview
ACT Industrial Buildings was commissioned to upgrade an agricultural site by demolishing old brick and timber barns, making the remaining structures water tight, and designing a bespoke steel barn to fit into an offset, irregularly shaped space. The project also required the new unit to support the eaves of an existing building on one side, ensuring structural continuity and operational efficiency.
Scope of Works & Key Features
Demolition & Site Preparation:
Complete removal of outdated brick and timber barns, followed by roof remedial works to ensure remaining structures are water tight and stable.
Design & Construction of Steel Barn:
A bespoke steel-framed building covering approximately 240m², carefully designed to fit into the irregular, off-square space between two existing units.
The new unit was engineered to support the eaves of the adjacent building, ensuring structural integrity and seamless integration.
Structural Components & Features:
Steel Frame:
A steel framework tailored for irregular site conditions, providing strength and durability.
Drainage & Water Management:
Installation of drainage systems and valley gutters to manage rainwater runoff effectively.
Retaining Walls:
Constructed to support the uneven terrain and hight differences between buildings.
Eaves Support:
The new structure was designed to support the eaves of the existing building, creating a unified and stable structure.
Cladding & Roofing:
Timber cladding applied to the exterior for aesthetic appeal and airflow.
Drip stop roof system to minimise condensation.
Challenges & Solutions
Irregular Site & Space Constraints:
Fitting a new structure into an off-square, awkward space required precise planning and custom design. The support for the existing building's eaves added complexity, which was addressed through bespoke structural engineering.
Waterproofing & Drainage:
Making the remaining structures water tight was critical. ACT implemented targeted drainage solutions, valley gutters, and tailored detailing to prevent water ingress.
Structural Support for Existing Building:
Designing the new unit to support the eaves of the neighboring building required careful load calculation and reinforced steelwork, ensuring stability without compromising existing structures.
Project Outcome
The project successfully delivered a 240m² steel barn that fits precisely into the irregular space, supporting the adjacent building's eaves and providing a durable, weatherproof extension. The bespoke design maximized site usage and integrated seamlessly with existing facilities.
Key Benefits:
Precise fitting in an off-square, constrained space
Support for existing building eaves, ensuring structural continuity
Enhanced site water management and stability
Aesthetic timber cladding combined with durable steel construction
Improved operational capacity with a bespoke, functional unit
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