2016 Judges’ Award
Jim Rollins, Jack Walters & Sons Corp. DBA Walters BuildingsThe Jeptha Creed Distillery in Shelby County, Kentucky, is the county’s first distillery in more than a hundred years and will become part of the Craft Bourbon Trail. The building is a combination of post frame and timber frame with a steep 9/12 roof pitch, a 60’ load-bearing steel beam that allows open access in the distilling area without the use of columns, and T1-11 exterior siding. The exterior features mountain stone wainscoting; decorative cedar trusses; and trim, functional dormers to hide the HVAC intakes and exhaust.
Cladding: T-1-11 Siding by BlueLinx, cedar trim by Liese Lumber; Roofing: Walters Buildings 28 gauge roof panel; Windows: Kolbe; Doors: Plyco commercial, Clopay overhead; Fasteners: Maze Nails, Sealtite Woodbinder screws, Fastenmaster Timberlok screws, Simpson Titen Anchor screws; Insulation: roof, closed-cell spray foam R-20; walls, closed-cell spray foam R-13; Foundation or Structural Components: Concrete frost wall; Unique Features: store area has timber-frame trusses by Northeastern Log Homes, seamless gutters by Jimmy Baxter Gutter, cupolas and decorative exterior trusses by Walters Buildings.
Experts Division ($0–6 Million in Annual Gross Volume)
Matt Greiner, Greiner Buildings Inc.
Mike Birkinbine’s agricultural storage building in Blue Grass, Iowa, is a good example of a post-frame building that is both functional and good-looking. The locations of the four large garage doors and two end-wall doors make it convenient for customers to park their vehicles and for workers to access equipment. The location of the awning and main door will allow the owner to finish the space as an office or “man cave” without disturbing the traffic pattern and integrity of the storage space. Post frame was chosen for this building because of its easy maintenance and speed of construction and because the building can easily be finished differently in the future as the owner’s needs change.
Cladding/Roofing: Central States 29 gauge Panel-Loc Plus with Fluropon paint; Windows: AJ 900 Series EZ-Fit with painted exterior trim to match; Doors: AJ 7100 Series with one light, painted to match the trims; Fasteners: Atlas hex-head screws: Foundation: Foundation: 4” slab; Unique Features: CHI 3216 garage doors with custom Americoats color to match side steel color; MWI cupulas, one 4’ x 4’ and one 3’ x 3’ with weathervanes.
Commercial Buildings (under 5,000 sq. ft.)
Steve Eversole, Eversole Builders Inc.
The Fairfield Area Humane Society in Lancaster, Ohio, is designed as a quarantine facility that enables the not-for-profit organization to separate the ill animals from the healthy ones. Post-frame construction was chosen because it is cost effective and creates a “tight” building that lowers the risk of infection and makes disinfection of the space easier. Low-maintenance materials were also used to meet the needs of the organization.
Cladding/Roofing: H&H Metals 29-gauge painted steel; Windows: Jeldweld; Doors: Plyco; Fasteners: Direct Fasteners; Insulation: R-19 fiberglass; Foundation or Structural Components: embedded; Unique Features: The building is lined inside with white steel. The floor is epoxy-coated, and all edges are caulked and scaled for easier disinfection. A separate HVAC system provides fresh air and separates the air in the quarantine section from that in the rest of the building to minimize the risk of contamination.
Commercial Buildings (5,000–10,000 sq. ft.)
Matt Greiner, Greiner Buildings Inc
Red Acre Barn, a wedding venue in Prole, Iowa, is impeccably designed using reclaimed barn boards and corrugated steel. The project’s aesthetics required the use of post frame; a tall second story and large clear spans provided flexibility in the layout. A wrap-around second-story balcony allows guests to observe the party below. The Red Acre Barn features everything an event venue needs: separate areas for the bride and groom, a bar, bathrooms, storage, an office and a kitchen. The beautiful interior and exterior are a perfect backdrop for photos of the just-married couples.
Cladding/Roofing: Central States 29-gauge Panel-Loc Plus with Fluropon paint; Windows: Plyco CTBE Thermal Break Step Saver with grids; Doors: Plyco 92 Series steel with Belleville Fiberglass; Fasteners: Atlas hex-head screws; Insulation: R-19 Anco Textrafine (walls), R-21 3’ closed-cell spray foam (ceiling); Unique Features: The exterior post-frame design is matched with a practical interior. This was accomplished by using high-end materials and design inside and out.
Commercial Buildings (over 10,000 sq. ft.)
Dan J. Miller, K & M Builders, Ltd.
The staff at the Soehnlen Veterinary Clinic in Navarre, Ohio, cares for both small- and large-breed animals. The clinic has a full laboratory with digital X-ray and ultrasound capabilities and the capacity for surgical procedures, including C-sections and spaying or neutering, to be performed on dogs, cats, rabbits, ferrets, prairie dogs and potbelly pigs. This facility also boards and serves as a daycare facility for up to 40 dogs. Post frame was an advantage for this project because of the lower expense and lower estimated time to build.
Roofing: North Star Metals 29- gauge painted steel, a recyclable product with White aluminum fascia and soffit; Windows: 32 Jeld-Wen white vinyl double-hung with contour grills and screens; Doors: Agri Steel Doors, 8300 white raised-panel solid doors, narrow aluminum doors with 10” bottom rails; Insulation: R-19 fiberglass insulation (walls and ceiling), single bubble plyfoil insulation under entire roof that increases reflectivity for considerably less heat loss; Foundation or Structural Components: embedded; Unique Features: Quality Lumber was provided by Gerber Lumber. The exterior includes Azek material, which is cellular PVC for lifetime protection from the elements, eliminating the need for painting and making the exterior maintenance free. Treated .60 posts were used for higher moisture resistance to reach the industry standard of .40. Twenty-nine-gauge paned steel siding with 605 sq. ft. of limestone wainscoting and 20” x 20” pillar caps were used along with Steinway equipment gates. The interior was finished with 1” x 8” x 12” barn siding for the ceiling. The building is equipped with two bathrooms as well as exam rooms. An Elkay 2-level drinking fountain was also included.
Matt Greiner, Greiner Buildings Inc.
The Walkers’ hobby shop in Washington, Iowa, was built to store prized possessions and host social gatherings. The hobby shop includes a craft room for refurbishing antiques and a surround-sound movie theater for watching football games with friends. Post frame was an advantage for this building because of the ease and quickness of incorporating both a hobby shop and man cave into one building. The speed of the building process enabled subcontractors to be on location much faster than in stud-frame construction, and the materials will last longer.
Cladding/Roofing: Central States 29-gauge Panel-Loc Plus with Fluropon paint; Windows: Quaker Manchester series vinyl double-hung; Doors: Therma Tru Classic-Craft Canvas fiberglass; Fasteners: Atlas hex-head screws; Insulation: blow-in R-38 12’ thick (attic), 2’ closed-cell spray foam R-14 (walls); Foundation or Structural Components: embedded; Unique Features: The owners incorporated refurbished antiques, such as double church doors from their family church and pocket doors, throughout. An antique hutch was built into the kitchen, and antique columns were incorporated into the stone fireplace. Different types of wood were installed on the ceilings, walls and floors. Stained and heated concrete floors are featured on the main level, and solar panels were installed on the roof.
Horse Barns/Facilities (under 5,000 sq. ft.)
Tim Noble, Kentuckiana Building & Development, LLC–Wick Buildings
Post frame was an advantage for the Zaxes’ horse-stall barn in Prospect, Kentucky, because of its speed of construction, lower cost per square foot and ease of modifications and additions in the future.
Cladding: Wick Steel; Roofing: GAF Camelot II royal slate shingles; Windows: Plyco; Doors: Plyco and glass sliders; Foundation or Structural Components: embedded; Unique Features: Full custom wood tack room; slate shingle roof; stone wainscot; wood plank and stone-stamped concrete floors; stable comfort stall mats; teak-stained stalls; tack room with acid-stained floors.
Horse Barns/Facilities (5,000 sq. ft. and over)
James P. Hochmuth, Fuog InterBuild Inc.
The Marlboro Ridge Equestrian Facility Horse Barn in Upper Marlboro, Maryland, was built for use by the Marlboro Ridge planned community. The barn, arena and other equestrian facilities were part of the initial concept for this Toll Brothers community. From the initial concept to the dedication, the project took more than 10 years to complete. Ninety-five percent of the building was completed as post frame.
Cladding: HardiePlank lap siding/MaxRib 29-gauge Kynar Metal siding by McElroy; Roofing: MaxRib 29-gauge Kynar Metal Roofing by McElroy; Windows: Andersen Silverline; Doors: Plyco (double doors), Lemieux (exterior entrance door), Fuog/InterBuild Inc. (custom wood sliding doors); Fasteners: McElroy; Insulation: foam R-19; Foundation or Structural Components: embedded; Unique Features: 22 stalls with an apartment for a full-time groundskeeper, ADA-compliant throughout, 1-hour fire-rated corridors and living spaces.
Steve Eversole, Eversole Builders Inc.
The Bloom Township Fire Department Substation in Carroll, Ohio, was strategically built in the center of the township, resulting in a reduction in response time by half and greatly improving the safety of the community. Post-frame construction made this building economically feasible for the small budget-conscious township. Many features that add to the building’s longevity, ease of maintenance and comfort could be incorporated within the budget.
Cladding: Central States 26-gauge steel; Roofing: Owens Corning Duration; Windows/Doors: Plyco; Fasteners: Direct Fasteners; Unique Features: 5½ /12 roof pitch allows scissor trusses to give 19-foot clearance in the center so truck cabs can tilt up; 2-hour fire wall between the truck bay and bunk rooms; full-service kitchen in the crew’s living quarters; 10” concrete floor supports heavy equipment, #4 rebar 12” on center either way; large fans in the bay area.
Matt Greiner, Greiner Buildings Inc.
John and Amy Marshall’s home in Lewis, Iowa, showcases the versatility of post-frame construction from its custom silo entry with open-span ceilings and a one-of-a-kind catwalk to a theater room. Built in Iowa farmland, the rustic custom design is intended to look like a barn and boasts an impressive two-story fireplace, an extravagant open staircase, and a loft of oak and metal spindles, with oak flooring and tile throughout. The low construction cost, unique design, quick construction time, heating and cooling efficiency, and ease of maintenance made post-frame construction the best choice for this project.
Cladding/Roofing: Central States 29-gauge Panel-Loc Plus Fluropon paint; Windows: Hayfield 751 casement; Doors: fiberglass doors supplied by the customer; Fasteners: Atlas hex-head screws; Insulation: 6” R-19 Anco Textrafine; Foundation or Structural Components: 4” slab; Unique Features: The silo has radius walls to match the house to the garage. The roof was framed to have eight sides to a point.
Jeff Nicholson, Tailored Building Systems
Originally a freight train depot built in the early 1900s, the GTW Depot in Kalamazoo, Michigan, was remodeled to be a mixed-use commercial building, featuring a microbrewery, sushi restaurant, and financial office. The original building was constructed with heavy timber posts and exposed rafters, and post frame, with its flexibility to match the wide spacing (15′ on center) for the new columns and rafters, seemed the only option for matching the existing structure. Post-frame construction allowed for a very well-insulated building with low utility costs.
Cladding: McElroy Metal 26-gauge, Kynar 500, R Panel and trims; Roofing: Western States Metal Roofing 16” on center, Corten standing-seam panels; Windows/Doors: Tubelite; Insulation: R-19 blankets with 2” styrofoam; Foundation or Structural Components: concrete pier with thickened slab; Unique Features: The owners wanted to maintain the authenticity of the existing building, so as many original building components as possible were reused during the construction; the existing wood doors, door track and hardware were refurbished. Much of the existing wood floor was salvaged. The exterior needed to look old, so Corten steel was chosen as an accent.
Dustin Stoll, Graber Post Buildings
The Unruh recreation barn in Floyds Knobs, Indiana, was designed to be a user-friendly, versatile space for entertaining guests. The owners needed a space that could be used for a variety of gatherings, such as a child’s roller-skating party or a fundraising event for the Multiple Sclerosis Society. Post-frame construction provided the flexibility needed and met the tight construction schedule.
Cladding: James Hardie ; Roofing: Graber Post 29-gauge G-Ribt, AkzoNobel Paint; Windows: Pella; Doors: Therma-Tru Walk Doors, CHI overhead doors; Fasteners: Paslode, Sealtite; Insulation: spray foam R-19 (walls), R-38 (roof); Foundation or Structural Components: cast-in-place concrete walls; Unique Features: a large 7’x7’ custom cupola in the center of the roof; custom faux sliding barn doors, exposed trusses on the interior. The view from the all-glass CHI overhead doors on the rear of the building, which overlooks a 250’ cliff, allows guests to see many miles into the distance.