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Pole Barn Mistakes: 8 Common Errors to Avoid

Barn Kit Pros Team
December 16, 2024

Tags: barn kit, barn kit pros, construction mistakes, pole barn construction, pole barn construction mistakes

Pole barn mistakes can lead to costly setbacks, delays, and frustration during your construction project. Whether you’re building it yourself or working with a contractor, knowing what to avoid is crucial for a smooth and successful process. In this post, we’ll cover eight common mistakes people make when constructing a pole barn and share tips to help you steer clear of them.

Mistake	What Goes Wrong	How to Fix It
Bad Site Choice	Water damage, unstable ground	Pick high ground, test soil
Foundation Issues	Posts rot, building tilts	Use concrete plugs, proper depth
Cheap Materials	Early failure, constant repairs	Buy treated lumber, quality steel
Wrong Design	Collapse risk, structural problems	Get engineer-approved plans
Poor Weather Protection	Leaks, moisture damage	Install proper ventilation
Missing Permits	Fines, forced rebuilds	Get all permits before starting
Bad Utilities	Unsafe wiring, frozen pipes	Plan electric/water upfront
Wrong Size	Too small, can’t expand	Build bigger than you think

Quick Facts:

Foundation problems cost 10.8% extra
Snow loads hit 60 lbs per square inch
Most areas need permits for builds over 200 sq ft
Quality materials last 40-60 years vs 3-5 for cheap ones

Here’s the deal: Skip any of these steps and you’ll pay way more fixing problems later. This guide shows exactly what to do instead.

Let’s break down each mistake and how to avoid it.

1. Wrong Site Choice and Ground Work

Pick the wrong spot for your pole barn, and you’ll have problems before hammering the first nail. Here’s what matters:

Site Preparation Requirements	Specifications
Ground Leveling Tolerance	Within 3 inches across area
Clearing Beyond Footprint	Minimum 4 feet on all sides
Soil Compaction Target	95% of maximum density
Standard Pole Length Limit	Within 8 inches of level (Hansen Pole Buildings)

Before breaking ground, you NEED to:

Check local zoning and setbacks
Study how water moves across your land
Test if the soil can handle the weight
Know where utilities run
Make sure trucks can get in and out

Here’s what NOT to do with your site:

1. Skip the Right Materials

Your fill material makes or breaks your foundation. No large rocks, loose shale, or random debris. They’ll cause settling issues later.

2. Ignore Water Flow

Water is your #1 enemy. Stay away from low spots, watch how rain flows, and grade your site so water runs AWAY from your building.

3. Rush Through Prep

Strip EVERYTHING down to good soil. That means all plants, topsoil, roots, and checking for hidden utility lines.

Step	Action	Purpose
1. Mark Site	Use fluorescent paint for corners	Define work area
2. Level Ground	Remove hills and fill low spots	Create flat surface
3. Check Level	Use string level between posts	Ensure even surface
4. Grade Surface	Slope away from building edges	Direct water drainage

Quick Tips:

Meet your excavator on-site
Make room for big trucks to turn around
Think about future add-ons
Build up the middle for better drainage

Bottom line: Cut corners on site prep, and you’ll pay for it later with crooked floors and water problems.

2. Foundation Problems

Your pole barn’s success starts with the foundation. Here’s what matters most:

Foundation Type	Depth Required	Best For	Key Requirements
Post in Ground	3-4 feet deep	Basic storage	Concrete plug (10" thick)
Monolithic Pad	12" thick edges	Finished interiors	Full concrete slab
Concrete Pier	48" below ground	High rain areas	Crushed stone backfill

Here are the top 5 mistakes that can wreck your foundation:

1. Skipping the Concrete Plug

A 6×6 post won’t cut it alone. You NEED that concrete plug. Here’s the math:

6×6 post = 30 square inches touching soil
12″ concrete plug = 113 square inches touching soil
Soil typically handles 2000-3000 lbs per square foot

2. Poor Drainage

Put pea gravel in the first foot around posts. Simple fix, big impact: stops water from sitting there and eating away at your posts.

3. Bad Post Protection

Protection Type	Job	Where to Use
Waterproof Sleeves	Stops moisture	Ground contact spots
Ground Treatment	Fights rot	Buried posts
Crushed Stone	Moves water away	Post base

4. Missing the Frost Line

"The post MUST sit on a 10-inch thick concrete plug. And that plug? It needs to be at least 42 inches deep – below the frost line. Our township won’t budge on this."

Mike the Pole Barn Guru

5. Wrong Foundation Pick

Soil Type	What You Need	Watch For
Clay	Extra drainage	Ground movement
Sandy	Good compaction	Settling
Well-drained	Standard depth	Water table

Don’t Fall For These Quick Fixes:

Adding concrete later
Surface patches
Shallow footings
Skipping soil tests

Bottom line: Your posts need proper ground treatment. Want an alternative? Try steel brackets in concrete with wood laminate above ground.

3. Using Low-Quality Materials

Cutting corners on materials? Here’s what you’re getting into:

Material Type	Low Quality Issues	High Quality Standards
Posts	Rot, insect damage	CCA .60 treated SYP
Lumber	Warping, early failure	#1 grade SYP for beams
Metal Panels	Quick corrosion	40-year warranty steel
Fasteners	Rust, loose connections	Galvanized/stainless steel

Let’s break down what you NEED for each main component:

Component	Required Grade	Why It Matters
Support Beams	#1 SYP	Carries roof load
Wall Framing	#2 SPF or better	Structural stability
Roof Purlins	High-grade SPF	Load distribution
Ground Posts	Treated SYP	Rot prevention

"With today’s steel roofing and siding paint systems, you’re looking at up to 100 years of service life. But expect some color fade and possible rust spots along the way."

Mike the Pole Barn Guru

Here’s how long your building will last based on material choices:

Material Quality	Expected Lifespan	Maintenance Needs
Basic Untreated	3-5 years	Heavy yearly upkeep
Standard Treated	5-8 years	Regular maintenance
Premium Materials	40-60 years	Minimal upkeep
Top-Grade + Maintenance	100+ years	Scheduled inspections

What you MUST do:

Use pressure-treated lumber where it touches ground
Pick the right metal panel thickness
Go for hot-dipped galvanized fasteners
Choose factory pre-painted steel over galvalume
Don’t skip moisture barriers

The IBC has specific rules about treated wood in pole barns. Follow them, and your building could last 100+ years. Ignore them? Get ready for problems.

Here’s what cheap materials REALLY cost:

Cost Type	Impact	Timeline
Repairs	$1000s per issue	Years 1-5
Replacements	Full component cost	Years 3-8
Structure Failure	Total rebuild needed	Years 5-10
Safety Issues	Legal liability risk	Immediate

Bottom line: Those “savings” on cheap materials? They’ll cost you WAY more in fixes later. Build it right the first time with materials that meet code.

4. Wrong Building Design

Here’s what can go wrong with your pole barn design – and how to fix it:

Design Element	Common Error	What To Do Instead
Truss System	4′ spacing (outdated)	8′ spacing (eliminates headers)
Post Size	Too small	4×4 to 8×8 based on size
Snow Load	Basic 45 psf	Up to 180 psf for heavy snow
Wind Rating	100 mph standard	Higher for storm areas
Load Path	Incomplete	Full ground-to-roof path

Let’s talk money and risk:

Design Approach	Initial Cost	Risk Level	Long-term Cost
No Engineering	$0	High	$10,000+ repairs
Basic Engineering	$1,580	Medium	Minor fixes
Full Engineering	$2,765	Low	Just maintenance

Your building needs these main parts:

Component	Purpose	Key Specs
Posts	Main support	Pressure-treated, ground-contact
Girts	Wall strength	Horizontal, across posts
Trusses	Roof support	2×6 1650msr lumber minimum
Purlins	Roof integrity	Across trusses

"Every Hansen Pole Building is structurally designed by a registered professional engineer."

Hansen Pole Buildings Team

Here’s what you NEED to do:

Get an engineer’s sealed plans
Don’t rely on “that’s how we’ve always done it”
Build for your local weather
Double-check ALL connections
Make sure loads flow from roof to ground

Weather matters MORE than you think:

Weather Factor	Basic Design	Better Design
Snow Load	45 psf	Up to 180 psf
Wind Speed	100 mph	25-50% higher
Post Depth	4 feet	6+ feet
Truss Grade	Basic	High-grade lumber

"Prescriptive requirements based on ‘we have always done it this way’ ignore sound structural design fundamentals."

Mike the Pole Barn Guru

Bottom line: Every part of your pole barn needs to work together. One weak spot? The whole thing’s at risk. Get professional engineering from day one.

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Explore our premium pole barn kits and barndominiums. Get everything you need for your shell delivered directly to your site. Start your custom design process now!

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5. Poor Weather Protection

Here’s what you need to know about protecting your pole barn from weather damage:

Weather Issue	Impact	Prevention
Ice Dams	Structural damage, leaks	Cold roof + proper ventilation
Snow Load	Roof collapse risk	Snow bars, roof rake use
Wind Damage	Tilting, uplift	Deep posts (4’+ depth), proper anchoring
Condensation	Wood rot, mold	DripStop membrane, balanced airflow

Your building needs specific ventilation components:

Vent Type	Location	Purpose
Ridge Vents	Roof peak	Hot air escape
Gable Vents	End walls	Cross-ventilation
Cupola Vents	Roof top	Moisture control
Bird Block Vents	Eaves	Air intake

Wind ratings by location:

Region Type	Required Wind Speed	Anchor Type
Standard US	105 mph	Basic uplift
Storm Areas	130+ mph	Heavy-duty
Coastal	150+ mph	Hurricane-rated

Snow load requirements:

Component	Standard Load	Heavy Snow Areas
Purlins	45 psf	Up to 180 psf
Trusses	Basic grade	High-grade lumber
Posts	4′ depth	6’+ depth
Footers	Standard	Reinforced

Regular maintenance schedule:

Season	Task	Why It Matters
Fall	Clear gutters	Prevents ice dams
Winter	Remove excess snow	Reduces load stress
Spring	Check seals	Stops leaks
Summer	Inspect ventilation	Controls moisture

Wind forces that affect pole barns:

Force Type	What It Does	Protection Needed
Shear Load	Horizontal pressure	Deep post embedding
Uplift Load	Pulls roof up	Heavy-duty anchors
Lateral Load	Side pressure	Cross-bracing

Here’s what you MUST know: Close all doors and windows during storms. Open entries create pressure that can destroy your building. Use high-gauge screws instead of nails – they hold better.

Moisture control basics:

Problem	Solution	Result
Warm air + cold roof	Insulation	Less condensation
Poor airflow	Multiple vent types	Balanced ventilation
Ground moisture	Vapor barrier	Dry foundation
Wall condensation	Air gaps	Moisture escape

6. Missing Permits and Code Issues

Let’s talk about building permits and codes for pole barns. Skip these, and you’ll face fines and might need to rebuild from scratch.

Here’s what different permits cost and how long they take:

Building Type	Permit Cost Range	Processing Time
Agricultural	$0 – $2,000	2-4 months
Residential	$50 – $1,000	3-6 months
Commercial	$1,000 – $100,000	6-12 months

You’ll need these documents at each stage:

Stage	Required Documents	Purpose
Pre-Construction	Site plan, engineered drawings	Initial approval
During Build	Permit display, inspection records	Code compliance
Post-Build	Final inspection report	Occupancy approval

Some states have specific rules:

State	Specific Requirements
Michigan	Concrete must be 50% of post hole diameter
Ohio	All non-barn uses must be reported
Colorado	Follows 2012-2015 International Codes

Here’s why inspections fail:

Issue	Percentage	Solution
Missing documentation	45%	Keep all papers on site
Structural issues	30%	Follow engineer specs
Fire blocking	15%	Install per code
Other violations	10%	Regular inspections

"The first thing I look for is the documentation… If I show up and they don’t have the plans I need for that inspection, then there’s no hope of passing."

Glenn Mathewson, Building Official

Before you start building, do this:

Step	Action	Why It Matters
Zoning Check	Contact local board	Verify allowed use
HOA Review	Check covenants	Avoid restrictions
Permit Application	Submit complete package	Prevent delays
Code Research	Study local requirements	Meet standards

Quick tip: If your structure is over 200 square feet, you probably need a permit. Check with your local Authority Having Jurisdiction (AHJ).

What inspectors look for:

Area	What’s Checked	Common Issues
Foundation	Post depth, concrete	Shallow holes
Frame	Truss bracing, anchors	Missing supports
Utilities	Electric, plumbing	Wrong materials
Final	All systems, safety	Documentation gaps

7. Poor Planning for Electric and Water

Here’s what you’ll pay for pole barn utilities – and what you NEED to know before starting:

Utility Type	Cost Range	Must-Have Items
Electrical	$2,000 – $40,000	GFCI outlets, outdoor fixtures
Heating/Cooling	$7,000 – $25,000	Insulation, air flow
Water/Plumbing	Depends on distance	Deep pipe installation

Your electrical setup needs these basics:

What	How	Why
Panel Spot	Far from feed	Stops dust damage
Wiring	No Romex near animals	Keeps things safe
Lights	Weather-proof	Won’t break down
Cables	Deep enough	Meets code

"The first thing I look for is the documentation… If I show up and they don’t have the plans I need for that inspection, then there’s no hope of passing."

Glenn Mathewson, Building Official

Here’s how deep your water pipes should go:

Where You Live	Pipe Depth	Extra Steps
Cold areas	6" below frost	Add pipe wrap
Medium temps	24" down	Basic wrap
Hot spots	12" down	Sun protection

Before you start digging:

Do This	Talk To	Check For
Ground Check	Utility companies	Hidden lines
Rules Check	Inspector	Local codes
Water Check	Plumber	Hook-up spots
Power Check	Electrician	Power needs

Farm buildings need special attention:

Space	Rule	Why
Feed Areas	Cover all wires	Stop fires
Animal Spots	Sealed lights	Beat moisture
Work Zones	Lots of outlets	Run tools
Wet Areas	GFCI plugs	Stay safe

Bottom line: Draw your utility map NOW. Moving stuff later will empty your wallet.

8. Wrong Building Size Planning

Let’s look at the exact sizes you need for a pole barn that works:

Use	Minimum Size (ft)	Space Buffer
Single Car	12 x 20	+3′ sides
Double Car	20 x 20	+3′ sides
Triple Car	30 x 20	+3′ sides
Horse Stall	12 x 12	+aisles
Indoor Arena	80 x 200	+viewing

Most builders go with these proven sizes:

Size (ft)	Main Use	What You Get
24 x 30	Small garage	1-2 cars
30 x 40	Medium shop	2-3 cars + tools
30 x 48	Large garage	3 cars + workshop
40 x 60	Farm shop	Tractors + equipment

Your doors need these heights:

Vehicle	Door Height	Notes
Cars/SUVs	8′	Basic option
RVs	12′	Check your model
Semi-trucks	16-20′	Needs extra support

Here’s what makes sense for your build:

Don’t go past 80′ wide – it spikes your costs
Keep it under 16′ tall unless you need more
Space posts 8′ apart (10′ for ends)
Think about what you’ll need later

Check these size rules:

Rule Type	Who to Ask
Building codes	Local office
HOA limits	Your association
Setbacks	Property survey
Height rules	Zoning office

Start at 20′ x 30′ – anything smaller costs more than it’s worth. For garages and shops, stick between 24′ and 48′ deep. This gives you space for work and storage without breaking the bank.

Here’s the deal: Build for tomorrow, not just today. Adding space later costs WAY more than getting it right the first time.

Conclusion

Here’s what you need to know to build your pole barn right:

Key Area	Common Mistakes	How to Get It Right
Planning	Rushing, missing permits	Get detailed plans (20-100 pages), secure all permits
Site Work	Poor location, bad drainage	Do site survey, prep ground properly
Size & Design	Too small, wrong door heights	Think future use, follow size rules
Materials	Cheap critical parts	Buy quality structural materials
Professional Help	DIY when not qualified	Use pros for builds over 10′ tall, 45′ wide

"Many pole barn jobs can get extremely complicated, and if you’re not careful, can lead to some significant mistakes."

Gordon Sebranek, Engineering Department Manager at Wick Buildings

To build it right:

Work with a 3-4 person crew
Bring in pros for concrete, electrical, and plumbing
Follow local building codes
Pick quality over cheap materials

"The most critical part of building a pole barn, or any structure, is to guarantee that it’s built safely."

DIY Pole Barns

Size guidelines that work:

Start with 20′ x 30′ minimum
Stay under 80′ wide to keep costs down
Match door heights to your vehicles
Add extra space to your measurements

FAQs

What are the negatives to a pole barn house?

Let’s talk about the biggest issue with pole barn houses: they’re tougher to heat and cool than regular homes.

Here’s what happens with pole barn houses:

Problem	Effect	Fix
Poor Insulation	Your wallet takes a hit on energy bills	Pack in extra insulation during the build
Hard to Control Temperature	Rooms get too hot or cold	Get a top-notch HVAC system
High Energy Bills	You’ll pay more in extreme weather	Seal up every crack and gap

Think of a pole barn like a coffee thermos without the vacuum seal – it just doesn’t hold temperature well. Here’s why:

The walls are thinner than regular houses, so heat moves in and out too easily. This means:

Your heater works overtime in winter
Your AC struggles in summer
Your energy bills? They go UP

Here’s the fix: Don’t skimp on insulation during construction. Yes, it costs more at first. But you’ll thank yourself every month when you see those lower energy bills.

You Have Questions?

We Have Answers

Why is it important to keep pole barn posts from rotting?

Rot can significantly weaken the structure of a pole barn, compromising its stability and lifespan. Since the posts serve as the foundation, any rot or decay can lead to uneven settling, leaning, or even collapse over time. Preventing rot from the outset ensures your pole barn remains safe, durable, and cost-effective in the long term.

How does pressure-treated wood help prevent rot in pole barn posts?

Pressure-treated wood undergoes a treatment process that infuses chemicals into the wood fibers, making it resistant to rot, moisture, and insect damage. This treatment prolongs the wood’s life even in wet environments, helping to reduce maintenance needs and repair costs. Using high-grade pressure-treated wood, like that in Barn Kit Pros kits, ensures better durability for your pole barn posts.

What are concrete footings, and how do they protect pole barn posts from rotting?

Concrete footings are solid concrete bases placed under the posts to lift them off the ground, creating a barrier between the wood and soil. This keeps the posts dry and prevents moisture from seeping into the wood, which is a primary cause of rot. Concrete footings, especially precast options like "perma-columns," are one of the best ways to extend the life of your pole barn’s foundation.

Are post protector sleeves necessary, or can you rely on pressure-treated wood alone?

While pressure-treated wood offers strong resistance to rot, adding post protector sleeves provides an additional layer of protection. These plastic sleeves cover the portion of the post in contact with soil, creating a waterproof seal that helps keep moisture out. Combining sleeves with pressure-treated wood is especially effective in areas with high soil moisture, maximizing protection against rot.

What kind of maintenance is required to keep pole barn posts from rotting over time?

Regular inspection and maintenance are essential to spot early signs of decay or moisture issues. Check around the posts periodically for any soft spots, discoloration, or insect activity. Applying water-resistant sealants or wood preservatives can also help protect the wood over time. Addressing any issues early prevents costly repairs and keeps your pole barn posts in optimal condition for years.