Prefab barn stall walls RUSTING!

[Sparky007]

Hi all,
I'v recently acquired ownership of a property that has a 24 stall prefab barn built in 80's (manufacturer unknown) and the lower part of the metal sheeting on the stall walls has rusted to varying degrees. In many of the stalls there are one or more wall panels where the metal has rusted through so the interior wood is exposed an inch or more at the bottom and the metals has a sharp edge because it no longer goes into the frame at the bottom.

Soooo, my question is: Has anyone else had this problem and figured out how to fix it without spending a fortune?

Thanks!

[MistyBlue]

Yeesh...that sounds sucky. Repairing/replacing on 24 stalls is a lot of work and not cheap!

I can't picture what type of stalls these are. Do you have any photos you can post/link to? That might help a whole lot with suggestions.

[Sparky007]

Yup, totally sucky! And replacing them is so NOT an option!

I will have to get to my other computer to post a photo of the actual walls complete with the rust, but its the same type of barn as Barnmaster/MD barns/FCP/Choice etc.

[Bluey]

That may have been Port-A-Stall barns and they had a guarantee of 20 or 25 years, so you are there now.

If someone had seen the rust start and cared for it right, they would be like new now.

Just as any kind of stall, wood or metal, you have to keep looking at it and be repairing whatever wears out.

Stall acids and some horses are hard on barn materials.

How do you fix those?
Ask the newer barns that use those type stalls what they do for it, maybe add light metal plates to the botton foot or two in the stalls you have a problem?

[Sparky007]

Hi Bluey,
Yes, I agree that taking care of the stalls would been preferable, but I didn't own the property then :-)

I thought about adding a sheet of galvanized metal around the bottom, but the problem is that it would leave a sharp edge where it ended (the seam can't be welded because there is wood underneath the sheet metal)

[clanter]

overlay a plywood panel ; use AC or BC grade as it sanded on one side...bevel the top edge using a router...end-to-end joints 45 degree cut rather than butt joints

Should be able to screw the plywood directly to the panels...either used treated plywood or paint all sides prior to installing

[Bluey]

Hi Bluey,
Yes, I agree that taking care of the stalls would been preferable, but I didn't own the property then :-)

I thought about adding a sheet of galvanized metal around the bottom, but the problem is that it would leave a sharp edge where it ended (the seam can't be welded because there is wood underneath the sheet metal)

They may have some glues that could bind the two pieces without welding.
You could also fit them so there is no piece sticking out, measure and cut exactly to fit against where you cut on what is still good and then screw and caulk both pieces to match, not overlap and leave an edge.

Or you could replace the whole panel where the bottoms are rusted out.
If I remember, those were made of three 4' by parts, so you only have to replace 1/3 at the time.

[Sparky007]

Sorry to everyone for not replying sooner - I wasn't near a computer. But I finally got to one and here's a link to a photo of an example of the rust too!https://picasaweb.google.com/lh/photo/EXzecL2L1R3OwKXWtLzLr53HiIrPbF0s4lUAC7wvF04?feat=d irectlink

A barn contractor recommended the plywood idea but I'm worried that the plywood will delaminate due to the moisture (the stalls have concrete floors and even though they're slightly sloped to the outside I think the pee gets trapped under the mats and that might make the plywood not last).
Also, he quoted over $7,000 to put the plywood up! If I'm going to spend that amount of money I want to make sure it looks good and lasts (though I would rather spend less as the property is for sale and its unlikely I will get my money back!)

I saw these HDPE panels in a catolog (they say you can use them for stall walls: http://www.farmtek.com/farm/supplies/ProductDisplay?catalogId=10052&storeId=10001&langId=-1&division=FarmTek&productId=278471[/URL]
The tops wouldn't have to be routered and it would solve the delaminating problem and they claim its really tough stuff but it would also cost alot for the material and it would still need to be cut into strips about a foot high.

A barn contractor in TX that I spoke with said on new barns they sometimes do a treatment along the bottom of spray-on truck bed liner stuff. That might work but I think the cost might be huge given how much it costs to do a truck bed!

I also thought of cutting back the badly rusted part where its sticking out and putting something like Bondo over the edge, and then spray painting over the parts that are just discolored by rust with galvanized paint.

Any comments on these ideas or any new ideas?

[Bluey]

For a temporary, cheap fix, looking at that picture, you could screw in a couple or three where the metal is rusted higher, of 1" tongue and grove boards, painted to protect the wood, along the bottoms and that may do to cover any exposed metal edges, for now.

Those white plastic planks from Farmtek may also work, if they are not too expensive, since you only need some for some rusted out bottoms.