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Barn Conversion to Woodworking Shop

Near New Market, Maryland

This 1860s bank barn featured beautiful joinery and massive timbers. Neglect and unfortnate modifications threatened its continued survival. Fitzgerald's Heavy Timber Contstruction worked with the owner to develop the concept of what a woodworker's dream shop could be. After relaying and repointing the foundation stonework,  we restored the frame with a combination of salvaged material and locally-harvested and milled oak timbers fastened with traditional joinery repairs.  We enclosed the structure in Polyurethane-core Structural Insulated Panels, installed a radiant heating and cooling system featuring geothermal wells, and fitted out the barn with an electrical system capable of powering many industrial level pieces of woodworking equipment, a complete dust-collection system, climate controlled material storage, separate finishing rooms, office space, kitchenette, full bath, and guest quarters. 

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Before Construction

Before Construction
Roof and Siding Removed -- Beginning Frame Repairs

Roof and Siding Removed -- Beginning Frame Repairs
Corner Post Replacement In Progress

Corner Post Replacement In Progress
Partition 4 Supported on Temporary Cribbing -- Forebay Wall Will Be Moved and Reconstructed Under Partition 4

Partition 4 Supported on Temporary Cribbing -- Forebay Wall Will Be Moved and Reconstructed Under Partition 4
Bird's Eye View of Frame Repairs In Progress

Bird's Eye View of Frame Repairs In Progress
New Roof Frame Being Installed On Origianl Timber Frame

New Roof Frame Being Installed On Origianl Timber Frame
This Tie Beam Had Been Cut Out In Earlier Modifications -- We Used Traditional Timber Joinery To Replace It In-Kind

This Tie Beam Had Been Cut Out In Earlier Modifications -- We Used Traditional Timber Joinery To Replace It In-Kind
Frame Repairs and New Interior Partitions and Floors

Frame Repairs and New Interior Partitions and Floors
Forebay Wall Rebuilt -- Stonework Awaits Repointing

Forebay Wall Rebuilt -- Stonework Awaits Repointing
Installing Structural Insulated Panels

Installing Structural Insulated Panels
We Embedded Radiant Tubing in the Floors to Provide Heating and Cooling

We Embedded Radiant Tubing in the Floors to Provide Heating and Cooling
We Combine Our Knowledge Of Historic Joinery With the Expertise of Our Structural Engineering Partners to Design Critical Frame Modifications Like This New Floor Level

We Combine Our Knowledge Of Historic Joinery With the Expertise of Our Structural Engineering Partners to Design Critical Frame Modifications Like This New Floor Level
Interior View of Woodworking Shop

Interior View of Woodworking Shop
Living Space Overlooking Machinery Room

Living Space Overlooking Machinery Room
Barn Conversion Completed in Dec. 2008, New Interior Stair (Photograph Courtesy of Fitzgerald's Heavy Timber Construction, Inc., 2006).

Barn Conversion Completed in Dec. 2008, New Interior Stair (Photograph Courtesy of Fitzgerald's Heavy Timber Construction, Inc., 2006).
Custom Made Arch Door

Custom Made Arch Door
Forebay Wall Louvers and Doors Reused Over New Windows and Doors

Forebay Wall Louvers and Doors Reused Over New Windows and Doors
Replicated Heavy-Framed Barn Bridge Doors Hide a Climate-Controlled Entry

Replicated Heavy-Framed Barn Bridge Doors Hide a Climate-Controlled Entry
Forebay Wall Moved Forward to Better Support Partition 4 -- Complete with New Doors and Windows

Forebay Wall Moved Forward to Better Support Partition 4 -- Complete with New Doors and Windows
Conversion of a ca. 1860 Bank Barn From Agricultural Use to a Woodworker's Dream Studio

Conversion of a ca. 1860 Bank Barn From Agricultural Use to a Woodworker's Dream Studio