In part two of their barndominium conversation, Kathi Miller welcomes back Blair Neihouser of FBi Buildings to dig into the real challenges of building a barndominium . Blair breaks down the most common mistakes — from homeowners underestimating what it takes to act as their own general contractor, to design choices that look great online but don't work in post-frame construction.
The conversation covers insulation options, hidden budget surprises like site development and utilities, and what separates a strong builder from a risky one. Blair also shares FBi Buildings' geographic footprint, current design trends, and a preview of their upcoming barndominium guidebook.
[0:00] Welcome and episode overview — Kathi Miller introduces part two of the barndominium series with Blair Neihouser of FBi Buildings, shifting focus from advantages to challenges and lessons learned.
[1:45] The GC problem — Blair explains why homeowners who take on the general contractor role often underestimate the complexity, coordination, and time commitment involved in building a barndominium.
[5:30] Design mistakes — Why designs found on Pinterest and Instagram often don't translate to post-frame construction, and why bump-outs and small offsets are particularly difficult to execute in this building style.
[10:00] Insulation options — A breakdown of fiberglass batt, spray foam, and the hybrid "flat and batt" approach, including tradeoffs in cost, performance, and compatibility with metal exteriors.
[16:30] Budget surprises — The site development costs that catch people off guard: driveways, septic systems, wells, and utility runs that don't show up in early project budgets.
[20:00] What a good builder brings — Blair outlines two key traits to look for: an engineering mindset specific to post-frame residential structures, and a network of reliable subcontractors.
[24:30] FBi Buildings' approach — How FBi's in-house structural engineering and third-party home layout partners combine to produce designs that are both livable and buildable.
[31:00] Design trends — Matte black continues to lead, while timber frame integration on porches and entryways is emerging as the next major trend, alongside mixed materials and hidden fastener roofing profiles.
[37:15] The costliest mistake — Blair identifies the foundation as the hardest and most expensive error to fix, and explains why choosing the right foundation type and contractor is critical.
[41:00] Myths, advice, and FBi resources — Blair addresses the two biggest barndominium misconceptions (cost and simplicity), previews FBi's upcoming 70-page guidebook, and shares how listeners can connect.
In 30 Seconds: If you're planning a barndominium, here's what this episode comes down to: it's a home, it costs like a home, and it takes as long as a home. The biggest mistakes happen when people underestimate the complexity of managing a construction project, choose designs that don't work in post-frame, or overlook site costs before a single board goes up. The biggest wins come from choosing a builder with real engineering expertise, a reliable subcontractor network, and the willingness to ask the right questions early.
In part one of their conversation, Kathi Miller and Blair Neihouser of FBi Buildings covered why barndominiums have exploded in popularity and what makes them such a compelling choice for the right buyer. In part two, the conversation shifts to what can go wrong — and what it actually takes to get it right.
Blair has seen both sides. FBi Buildings has been in the post-frame business since 1958, covering a large footprint across Indiana, Illinois, Michigan, Ohio, and Iowa. After nearly seventy years and three generations of family ownership, the company has worked through enough projects to know where people tend to get into trouble.
The most common mistake Blair sees is also one of the most understandable. People assume that because a barndominium has the word "barn" in it, the building process will be simpler than traditional home construction. That assumption leads many of them to take on the general contractor role themselves — and that's where things can come apart.
"It's a full-time job," Blair said. "If you think about a homebuilder, that guy meets with the customers, meets with the subs — and at most, two houses going on at one time — and that's his job."
Managing subcontractors, coordinating schedules, communicating expectations, and keeping a complex project moving forward isn't something most people can absorb into an already full life. The structure might go up without a problem, but when it's time for the electrician to show up and nobody communicated that the framing needs to be ready first, the project stalls — and that costs money and momentum.
The second major pitfall is design. With so many inspiring barndominium images available on Pinterest, Instagram, and Google, it's easy to fall in love with a look that was never meant for post-frame construction.
Blair puts some of the responsibility here on builders, including his own team. When someone brings in a photo of a home they love, the right response isn't just to say yes — it's to ask good questions. What do you love about this? Is it the material, the color, the roofline? Because some features, like small bump-outs or slight offsets, don't work well when a post-frame structure is laid out on four-foot, seven-foot, or eight-foot post centers.
The goal is to help a customer into a design that's genuinely buildable — not one that looks beautiful on screen but requires workarounds in the field.
Post-frame construction offers a meaningful advantage when it comes to insulation: the wall cavity is deep. That means you can fit six to eight inches of fiberglass batt insulation in the wall, creating a strong thermal barrier. Adding building wrap or a Tyvek layer underneath the steel exterior also helps reduce air infiltration.
Spray foam is increasingly popular, especially for homeowners who want a tight, energy-efficient building. The tradeoff is cost, and Blair notes that any spray foam applied to the interior surface of a metal panel needs to be coordinated carefully with warranty requirements.
There's also a hybrid approach — a thin layer of spray foam, maybe an inch or two, combined with traditional batt insulation. It reduces spray foam costs while still providing some air sealing. The risk is that a thinner foam layer may not fully close the air barrier, which can allow minor moisture transfer. It's a topic where opinions vary widely in the industry, and Blair acknowledges that there are people with much more detailed views on the subject.
The costs that tend to blindside first-time barndominium builders aren't usually in the structure itself — they're in what it takes to prepare the site. Driveways, septic systems, wells, and electrical service runs all need to be considered before the first post goes in the ground. On a multi-acre property, those costs add up quickly and don't always make it into early budget conversations.
Blair also pointed out something that applies to any construction project: expect some hiccups. Construction is a messy business, and setting that expectation from the start leads to a much better experience when something doesn't go exactly as planned.
When it comes to selecting a post-frame builder for a residential project, Blair points to two things that matter most.
The first is an engineering mindset. There's a meaningful difference between a builder who picks up a standard lumberyard package and one who approaches each project with location-specific structural engineering. A barndominium is a home — people live in it every day, and the trusses, spans, and connections need to be designed for that reality. Wide-open recreation spaces, second floors, porches with complex rooflines — these aren't everyday decisions for every post-frame contractor.
The second is a strong subcontractor network. Most homeowners building their first barndominium don't have a trusted concrete contractor or a plumber in their phone. A good builder does. That network can make an enormous difference in how smoothly a project comes together.
FBi Buildings handles structural engineering in-house, which allows the design and engineering teams to stay tightly connected throughout the process. Customers may not speak directly with an engineer, but the sales professionals working with them are constantly coordinating to make sure the structure is sound and the project is actually buildable.
For interior floor plan layout — where the bedrooms go, how the living areas connect, how the space functions day to day — FBi brings in third-party residential design firms. One they use regularly is Back Forty. The goal is clear: let specialists focus on what they do best, and make sure the structural design and the living design work together from the start.
Matte black continues to be the dominant exterior color choice for barndominiums, and Blair doesn't see it going away. What's emerging alongside it is timber frame integration — big, heavy beams used on porches and entryways to create a Colorado lodge or mountain retreat feel. Six-by-six and eight-by-eight timber frame elements paired with open web trusses on covered porches are showing up more often, adding warmth and texture to what might otherwise be an all-metal exterior.
Mixed materials more broadly are a growing trend. Instead of all-metal panel exteriors, builders and homeowners are integrating stone, board and batten, and other elements to give the building more visual depth. On the roofing side, Blair noted a shift toward hidden fastener profiles — like McElroy Metal's Meridian panel — particularly on porches, mansards, and eyebrow sections, where the cleaner look fits the overall aesthetic.
When Kathi asked Blair to name the single most costly mistake he's seen on barndominium projects, his answer was immediate.
"Your foundation is hard to fix," Blair said. "People have run into a lot of frustrations that have cost them big money."
Post-frame construction offers several foundation options — wood posts in the ground, perma columns, or full concrete walls — and the right choice depends on the specific design and site. But choosing the wrong foundation, or hiring a contractor who doesn't execute it well, creates problems that are expensive and sometimes impossible to fully correct. Concrete is permanent. Getting that decision right from the beginning is not a place to cut corners.
After years of barndominium conversations, Blair has heard the same misconceptions over and over. Two sit at the top of the list.
"The biggest misconception is it's gonna be cheap, or at the very least a lot cheaper than another route," he said. "It's a home. You're gonna invest what you would normally invest in building a home."
The second myth is closely related: that because it's a barn-based structure, the process will be quick and simple. It won't. Site development, utilities, layout decisions, subcontractor coordination — all of it takes time. The word "barn" doesn't change the fact that a barndominium is a home, and building a home is a serious project.
Blair also hears regularly from people asking whether barndominiums are noisy when it rains. The short answer: not if they're properly insulated. The concern usually comes from people who remember standing in an uninsulated shed during a rainstorm. Once a proper roof assembly is in place — the same kind used under a shingle roof — the rain noise is comparable to any other well-built home, or even quieter.
Blair closed with something that doesn't always make it into the early conversation: basements are possible with barndominiums. Not every post-frame builder will tell you that, and some will actively advise against it. But for buyers who want the extra space, it can absolutely be done.
FBi Buildings has nearly seventy years of experience and a wide footprint across the Midwest. They're currently finishing a barndominium guidebook — roughly seventy pages — covering the full process from site evaluation to move-in. It will be available as a digital download or a printed copy for a small fee at fbibuildings.com.
Blair is also reachable directly by phone or text at 309-252-0607, or on LinkedIn. For general inquiries, FBi's corporate office is the best first stop.
For more on metal roofing and siding products mentioned in this episode, visit mcelroymetal.com.