A 40×60 pole barn is the most common shop size we build in Eastern Idaho. Here’s exactly what it costs in 2026 and where the money goes.
The three price tiers
Shell only: $67,200–$100,800
Posts, trusses, metal siding and roofing, framed openings, no concrete, no doors, no electrical. $28–$42/sq ft. This is what you build when you’ll finish it yourself over time.
Insulated with slab and basics: $135,000–$168,000
Adds 6″ reinforced slab, R-25 wall insulation, R-49 ceiling, two 16×10 overhead doors, walk door, 200-amp electrical service, basic lighting. $55–$70/sq ft. Ready to work in.
Turnkey shop: $180,000–$240,000
Everything above plus radiant floor heat, finished interior (drywall and paint), upgraded lighting, 100-gallon air compressor wiring, hose reels, workbench plumbing, half-bath. $75–$100/sq ft. This is what working contractors build.
Where the money actually goes
- Steel package and labor: $48,000–$72,000
- Concrete slab (6″, reinforced): $22,000–$28,000
- Site work and pad prep: $8,000–$15,000
- Doors (two 16×10): $6,000–$9,000
- Electrical (200-amp service + interior): $9,000–$14,000
- Insulation: $11,000–$16,000
- Permitting and engineering: $2,500–$5,000
Cost drivers most builders don’t mention
Sidewall height. Bumping from 12′ to 14′ adds $4K–$6K but matters every day you work in the shop.
Slab thickness. Going from 4″ to 6″ reinforced adds $4K but doubles the load capacity and saves you a tear-out down the road.
Roof pitch. 4/12 is cheapest. 6/12 or steeper sheds snow better and looks better but adds $3K–$5K to truss cost.
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