Case Study: Modern Industrial Barndominium in Davidson County
When the Johnson family contacted us about building their dream barndominium on 5 acres in Davidson County, they had a clear vision: a modern industrial aesthetic with luxury amenities that would serve as both their primary residence and a showcase for entertaining.
Project Overview
Location: Davidson County, Tennessee (15 minutes from Nashville)
Size: 3,500 square feet
Timeline: 8 months from permit to completion
Budget: $525,000 (including site work)
Style: Modern Industrial with luxury finishes
Initial Challenges
Site Conditions
The 5-acre lot presented several unique challenges:
**Sloping terrain**: 8-foot elevation change across building footprint**Soil conditions**: Clay with seasonal water table issues**Setback requirements**: Davidson County's 75-foot setback from adjacent properties**Septic location**: Required pump system due to elevation changesDesign Requirements
The Johnsons requested several specific features:
**40-foot clear span** for great room with no support posts**20-foot ceilings** in main living areas**Guest suite** completely separate from main living area**Workshop space** with 14-foot door for equipment access**Energy efficiency** targeting HERS rating below 60Design Solution
Structural Design
Our engineering team developed a steel frame solution featuring:
Primary Structure:
Clear span steel trusses for 40-foot great room14-gauge steel framing throughoutEngineered foundations with French drain systemMetal roofing with 30-year warrantyLayout Optimization:
Split floor plan with master suite isolated from guest areasCentral great room connecting all living spacesWorkshop with separate entrance and utilitiesCovered outdoor living space integrated with indoor flowModern Industrial Aesthetic
The design incorporated signature industrial elements:
Exterior Features:
Black corrugated metal siding with wood accentsExposed steel beam detailsFloor-to-ceiling windows in great roomStanding seam metal roofing in charcoalInterior Design:
Polished concrete floors throughout main areasExposed steel ceiling structureIndustrial lighting fixturesCustom steel and wood staircase to loftConstruction Process
Phase 1: Site Preparation (Weeks 1-3)
Site Work:
Soil stabilization for clay conditionsInstallation of French drain systemDriveway and utilities rough-inSeptic system installation with pumpChallenges: Heavy rains in Week 2 delayed excavation by 4 days. Our team used this time to prefabricate steel components off-site.
Phase 2: Foundation and Structure (Weeks 4-8)
Foundation:
Engineered concrete foundation with integral French drainsRadiant floor heating loops installed in concreteSteel anchor bolts precisely positioned for frameSteel Erection:
Main frame erected in 3 days40-foot clear span trusses required crane assistanceAll connections welded and inspected per engineeringPhase 3: Envelope (Weeks 9-12)
Roofing and Siding:
Standing seam metal roof installationContinuous soffit and fascia systemBlack corrugated siding with cedar accent boardsHigh-performance windows and doorsInsulation:
Spray foam insulation for superior air sealingR-25 walls, R-50 ceiling for energy efficiencyThermal bridging minimized with proper detailingPhase 4: MEP Systems (Weeks 13-20)
Electrical:
400-amp service for future electric vehicle chargingSmart home pre-wiring throughoutIndustrial-style exposed conduit in workshopGenerator hookup for backup powerPlumbing:
PEX throughout with home run manifold systemTankless water heater with recirculation pumpFloor drains in workshop and utility areasRough-in for future outdoor kitchenHVAC:
Variable-speed heat pump systemDedicated workshop ventilationSmart thermostats for zone controlERV for fresh air in tight constructionPhase 5: Interior Finishing (Weeks 21-32)
Flooring:
Polished concrete in main living areasLuxury vinyl plank in bedroomsCeramic tile in bathroomsEpoxy coating in workshopCustom Millwork:
Floating shelves with hidden steel bracketsCustom kitchen island with steel baseBuilt-in storage throughoutIndustrial-style barn doorsUnique Features and Solutions
Great Room Design
The 40-foot clear span great room became the project's centerpiece:
**Exposed steel trusses** painted flat black for industrial look**Floor-to-ceiling windows** on south wall maximize natural light**20-foot ceilings** create dramatic volume**Integrated sound system** with speakers hidden in ceilingWorkshop Integration
The workshop space was designed for serious use while maintaining aesthetic appeal:
**14-foot overhead door** for equipment access**220V service** throughout for welding and machinery**Concrete floors** with integral color and sealer**Separate HVAC** for comfort during extended useEnergy Efficiency Measures
Despite the industrial aesthetic, energy efficiency was prioritized:
**Spray foam insulation** eliminated thermal bridging**High-performance windows** (U-0.30, SHGC 0.25)**LED lighting** throughout with smart controls**Energy recovery ventilator** for fresh airPermit and Inspection Process
Davidson County Requirements
Working in Davidson County required careful attention to local codes:
**Structural engineering** required for steel construction**Energy code compliance** with manual J calculations**Septic permits** coordinated with health department**Electrical permits** for 400-amp service upgradeInspection Timeline
**Foundation inspection**: Passed first inspection**Framing inspection**: Required minor adjustment to beam connections**Electrical rough-in**: Passed with no issues**Final inspection**: Completed with only punch list itemsCost Breakdown
Construction Costs
**Site work and foundation**: $65,000**Steel structure and envelope**: $140,000**MEP systems**: $85,000**Interior finishing**: $180,000**Permits and engineering**: $15,000**Total construction**: $485,000Additional Costs
**Driveway and landscaping**: $25,000**Appliances and fixtures**: $35,000**Custom millwork**: $20,000**Project total**: $565,000Results and Client Satisfaction
Performance Metrics
Six months after completion, the barndominium is performing exceptionally:
**HERS rating**: 55 (exceeds initial target)**Utility costs**: 40% lower than previous home**Structural performance**: No settling or movement issues**Maintenance**: Minimal requirements to dateClient Feedback
*"The process exceeded our expectations. The team's attention to detail and problem-solving throughout construction was impressive. Living in our barndominium has been everything we hoped for - the open spaces are perfect for entertaining, and the workshop lets me pursue my hobbies without leaving home."* - Mark Johnson, Owner
Lessons Learned
What Worked Well
**Early soil analysis** prevented foundation issues**Steel prefabrication** during weather delays kept project on schedule**Detailed planning** minimized change orders**Quality subcontractors** delivered excellent workmanshipAreas for Improvement
**Winter concrete** required longer cure times than anticipated**Custom millwork** took longer than standard options**Coordination** with utility companies needed earlier startKey Takeaways for Similar Projects
Site Selection
Conduct thorough soil analysis earlyConsider utility access and costsPlan for drainage and grading requirementsUnderstand local setback and height restrictionsDesign Considerations
Steel framing enables amazing open spacesIndustrial aesthetics require careful detail planningEnergy efficiency and style can coexistPlan for future needs during initial constructionConstruction Management
Weather contingencies are essentialQuality subcontractors are worth premium pricingRegular communication prevents surprisesPlan for county inspection requirementsConclusion
The Davidson County project demonstrates that luxury barndominiums can successfully combine industrial aesthetics with high-performance construction. The key to success was thorough planning, quality materials, and experienced contractors familiar with local requirements.
For prospective barndominium owners in Middle Tennessee, this project illustrates the possibilities when design ambition meets construction expertise. The result is a unique home that provides modern comfort while embracing the industrial character that makes barndominiums special.
Interested in creating your own modern industrial barndominium? Contact us to discuss how we can bring your vision to life while navigating local requirements and maximizing value.
