In the world of supply chain and logistics, there is a distinct line between “Expense” and “Capital Expenditure” (CapEx). Buying a garden shed is an operational expense; you swipe your credit card, install it on a Saturday, and it’s done. Building a 6台用ガレージ is a CapEx project.
A structure of this magnitude—typically ranging from 1,200 to 2,400 square feet—is not just a “big garage.” It is essentially a commercial warehouse sitting on your residential property. It requires industrial logistics, heavy equipment for assembly, and a foundation that rivals that of a small house.
As a Supply Chain Director, I see many customers approach a 6-car project with a “2-car mindset.” They take the price of a standard 20×20 garage and simply multiply it by three. This math is dangerously wrong. It ignores the exponential costs of clear-span trusses, the massive volume of concrete required, and the specialized labor needed to erect steel at heights of 14 feet or more.
In this comprehensive budgeting guide, we are going to treat your 6-car garage project like a procurement audit. We will break down the Bill of Materials (BOM), analyze the labor variances, and expose the “hidden” supply chain costs that often blow budgets by 30% or more.
Chapter 1: Defining the Scope (The SKU Configuration)
Before we talk dollars, we must define the unit. “6-Car Garage” is a vague term. Are you parking six Miatas, or are you storing a collection of extended-cab trucks and a boat? Do you need a lift? The dimensions dictate the steel engineering.
The Dimensions Matrix
To comfortably park six vehicles with room to open doors, or to mix parking with workshop space, you are looking at specific “Clear Span” dimensions.
| Configuration | Typical Dimensions | Total Sq. Ft. | Supply Chain Note |
|---|---|---|---|
| The “Tight Fit” | 30′ W x 40′ L | 1,200 | Minimum for 6 compact cars. Very tight door clearance. Hard to maneuver. |
| The “Standard” | 40′ W x 40′ L | 1,600 | Good depth. Allows for 2 rows of 3 cars deep. Common truss size. |
| The “Commercial” | 40′ W x 60′ L | 2,400 | The Gold Standard. Fits 6 cars + lifts + shop space. Highest resale value. |
| The “Wide Span” | 60′ W x 40′ L | 2,400 | Allows for side-by-side parking (3 double doors wide). Requires massive, expensive trusses. |
My Recommendation: For this guide, we will budget based on the 40′ x 60′ (2,400 sq. ft.) model. This is the most efficient use of steel per square foot.
Zoning and Height Restrictions
Before you budget for steel, you must budget for “Air Rights.” A 6-car garage usually requires 12-foot to 14-foot legs to accommodate lifts or RVs.
| Feature | Standard Garage | 6-Car Commercial Garage | Zoning Risk |
|---|---|---|---|
| Eave Height | 9 Feet | 12 – 16 Feet | Many HOAs limit accessory structures to 12ft height. |
| ピークの高さ | 12 Feet | 18 – 22 Feet | May exceed the height of your primary residence (often forbidden). |
| Lot Coverage | ~400 Sq. Ft. | ~2,400 Sq. Ft. | May push you over the “Impervious Surface” limit for your lot. |
Chapter 2: The Steel Package (Material Costs)
The steel kit is the easiest cost to calculate because it is a fixed commodity price. However, on a building this size, “Upgrades” are actually “Requirements.”
1. Truss Engineering
A 40-foot wide building requires a massive webbed truss system. You cannot use the simple bent-bow tubing found in small carports. This is commercial-grade engineering designed to handle snow loads over a wide span without sagging.
2. Siding and Roofing
For a building this large, Vertical Roofing is mandatory. You cannot run horizontal panels 60 feet without leaks.
Steel Kit Cost Breakdown (Estimated*)
| Component | Specification | Estimated Material Cost | Why It’s Necessary |
|---|---|---|---|
| Primary Framing | 12-Gauge Webbed Trusses | $18,000 – $22,000 | 20-year structural warranty; high wind load rating. |
| Roofing Panels | 26-Gauge Vertical Roof | $6,000 – $8,000 | Thicker commercial steel to prevent hail damage. |
| Siding Panels | 26-Gauge Vertical Walls | $5,000 – $7,000 | stronger shear strength for tall walls. |
| Doors (Openings) | 3x (10×10) Frame-outs | $1,500 | Structural headers to support the door weight. |
| Trim/Fasteners | Color-matched screws/J-Trim | $1,000 | Leak prevention. |
| Insulation Pkg | Double Bubble (Vapor) | $1,500 – $2,000 | Critical to prevent “steel rain” (condensation). |
| KIT TOTAL | Materials Only | $33,000 – $41,500 |
Note: Steel prices fluctuate weekly based on global commodities markets.
Chapter 3: The Foundation (The Concrete Variable)
This is where budgets die. Concrete is expensive, and a 40×60 slab is enormous. You aren’t just pouring a 4-inch patio slab; you are pouring a “Monolithic Slab” with heavy footers to support the steel columns.
The Volume Calculation
- Slab Area: 40′ W x 60′ L = 2,400 sq. ft.
- Thickness: Minimum 6 inches (recommended for lifts/trucks).
- Footers: 12″ x 12″ perimeter beam (thickened edge).
The Math: You will need approximately 55 to 60 Cubic Yards of concrete.
Concrete Specs & Pricing Matrix
| Item | Specification | Unit Cost (Est.) | Total for 40×60 |
|---|---|---|---|
| Site Prep | Grading / Leveling | $1,500 / Day | $1,500 – $3,000 |
| Gravel Base | 4″ Compacted #57 Stone | $30 / Ton | $1,200 |
| Vapor Barrier | 6-mil or 10-mil Poly | $0.10 / Sq. Ft. | $300 |
| Rebar/Mesh | Fiber mesh + Rebar grid | $0.75 / Sq. Ft. | $1,800 |
| Concrete | 4000 PSI Mix | $150 / Yard | $9,000 |
| Finishing Labor | Screed, Float, Power Trowel | $1.50 / Sq. Ft. | $3,600 |
| Pump Truck | If truck can’t reach back | $1,000 / Day | $1,000 (Optional) |
| TOTAL | Foundation Turnkey | $18,400 – $26,000 |
Supply Chain Warning: Do not try to save money by pouring a 4-inch slab for a 6-car garage. If you put a heavy diesel truck or a 2-post car lift on a 4-inch slab, it will crack under the point load.
Chapter 4: Labor and Equipment (Installation Logistics)
For a standard carport, a crew of two guys with ladders can knock it out in a day. For a 40×60 Commercial Metal Building, you need a mechanized crew.
1. The Installation Crew
While many of our kits include “Free Installation,” that usually applies to standard residential sizes. For commercial sizes, there may be a “High Lift” fee or a requirement to house the crew if the job takes 3-4 days.
2. Heavy Equipment Rental (The Hidden Cost)
You cannot lift a 40-foot steel truss by hand. It weighs hundreds of pounds. You need a Telehandler (Lull) or a Scissor Lift.
| 設備 | Daily Rate (Est.) | Weekly Rate (Est.) | Why You Need It |
|---|---|---|---|
| Telehandler (Forklift) | $600 | $1,800 | Lifting trusses to the roofline safely. |
| Scissor Lift | $300 | $900 | Allowing crew to drive screws at the peak (15ft+ up). |
| Delivery/Fuel | $500 | $500 | Transporting the lift to your site. |
| Waste Dumpster | $400 | $400 | Disposal of steel banding, pallets, and trash. |
| TOTAL EQUIPMENT | $3,600 (Est.) |
Budget Impact: Always add a buffer for “Weather Days.” If it rains and the crew can’t work, you still pay for the equipment rental.
Chapter 5: The Upfit (Doors, Lights, and Power)
A steel shell is not a garage. To make it functional, you need access and visibility. This “Upfit” phase is where you can spend $5,000 or $50,000.
1. Garage Doors
For a 6-car garage, you typically want three large bay doors (e.g., 10′ wide x 10′ tall or 12′ x 12′).
| ドアタイプ | Cost Per Door | Total (3 Doors) | Pros/Cons |
|---|---|---|---|
| Manual Roll-Up | $800 | $2,400 | Cheap, reliable, but low insulation (R-0). |
| Chain Hoist Roll-Up | $1,200 | $3,600 | Easier to open large doors; still industrial look. |
| Insulated Sectional | $2,000 | $6,000 | Residential look, high R-value, quiet operation. |
| Auto Openers | $500 | $1,500 | Essential for daily drivers. |
2. Electrical & Lighting
A 2,400 sq. ft. building is a cavern. You need serious lumens.
Lighting Layout Strategy:
- 要件 ~50 Lumens per sq. ft. for a workshop.
- Total Lumens: 120,000 Lumens total.
- Fixture: High Bay UFO LED Lights (20,000 Lumens each).
- Quantity: 6 to 8 Fixtures.
| Electrical Component | Estimated Cost | Notes |
|---|---|---|
| Panel Upgrade | $1,500 | Sub-panel (100A or 200A) fed from house. |
| Trenching | $15 / ft | Digging conduit from house to shop. |
| Wiring & Outlets | $2,500 | EMT Conduit (Required for exposed metal walls). |
| Lighting Fixtures | $1,000 | 8x High Bay LEDs + Exterior Security Lights. |
| TOTAL ELECTRICAL | $5,000 – $7,000 | Varies heavily by distance from main house. |
Chapter 6: The “Soft Costs” (Permits and Plans)
In supply chain, “Soft Costs” are non-tangible expenses. You can’t touch them, but you have to pay them.
Permit Timeline and Cost Matrix
| Permit / Fee | Estimated Cost | Timeline | Notes |
|---|---|---|---|
| Engineered Drawings | $500 – $1,500 | 2 Weeks | “Wet Stamped” plans required for >1000 sq ft. |
| Building Permit | $1,000 (Avg) | 4-6 Weeks | Based on project value (~1-2%). |
| Impact Fees | $0 – $5,000 | Instant | Charged by county for adding “impervious surface.” |
| Variance Fee | $500 | 2-3 Months | If you are building closer to the property line than allowed. |
プロのアドバイス Check the Impact Fees first. Some municipalities charge massive fees for adding 2,400 sq. ft. of concrete because it increases rainwater runoff load on the city sewers.
Chapter 7: The Grand Total (Low, Mid, High)
Let’s aggregate the data. What does a turnkey 40×60 6-Car Garage actually cost?
The “All-In” Budget Matrix
| Cost Category | Economy Build (DIY/Basic) | Standard Build (Pro/Turnkey) | Premium Build (The Dream Shop) |
|---|---|---|---|
| Steel Kit | $33,000 | $38,000 | $48,000 (Custom Colors/Gauge) |
| Concrete Fdn | $18,000 | $24,000 | $30,000 (Epoxy Floors) |
| Labor/Equip | $4,000 (Rental Only) | $6,000 | $9,000 |
| Doors/Windows | $3,000 (Manual) | $7,500 | $12,000 (Glass/Alum) |
| 断熱 | $2,000 (DIY Bubble) | $4,000 | $12,000 (Spray Foam) |
| Electrical | $2,000 (Basic) | $6,000 | $10,000 (HVAC/220V) |
| Permits/Plans | $1,000 | $1,500 | $2,500 |
| GRAND TOTAL | ~$63,000 | ~$87,000 | ~$123,500 |
| Price Per Sq. Ft. | ~$26 | ~$36 | ~$51 |
The Supply Chain Reality Check: Most websites will advertise the Kit Price ($38,000) and consumers assume that is the final price. In reality, the Turnkey Price 通常 2.2x to 2.5x the Kit Price. If you budget $40k for a 6-car garage, you will run out of money before the concrete is cured.
Chapter 8: Financing and Value (ROI)
Spending $87,000 on a garage sounds like a lot. Is it worth it?
1. Resale Value
A 2,400 sq. ft. workshop is a massive differentiator in real estate. For the right buyer (car enthusiast, business owner), it can add nearly dollar-for-dollar value to the appraisal, unlike a swimming pool which adds very little.
2. Storage Fees Savings
If you are currently renting a self-storage unit or a commercial warehouse bay for your cars/boats/business inventory, you might be paying $800 – $1,200 a month.
| Scenario | Monthly Cost | 10-Year Cost | Asset Ownership? |
|---|---|---|---|
| Renting Warehouse | $1,000 | $120,000 | No |
| Building Garage | $87,000 (Total) | $87,000 | Yes (Asset Appreciates) |
A $87,000 garage pays for itself in 7.25 years in saved rent alone, while you own the asset the entire time.
Conclusion: Plan for the Finished Product
A 6-Car Garage is a legacy project. It is a structure that will likely outlast your time in the home.
As a Supply Chain Director, my advice is this: Do not value engineer the Core Infrastructure.
- You can add insulation later.
- You can upgrade to electric door openers later.
- You can add the epoxy floor later.
- You cannot make the slab thicker later.
- You cannot make the building taller later.
Secure your budget for the Concrete + Steel Frame. Get the permit for the size you really want (40×60). Build the shell correctly. If you run out of money, treat the interior upfit as Phase 2.
Ready to spec out your commercial-grade garage? Contact our project managers. We can help you navigate the truss engineering and load calculations to ensure your budget aligns with your dreams.
Frequently Asked Questions (FAQ)
Q: Can I build a 6-car garage on a residential lot? A: Usually, yes, but you must check “Lot Coverage” ratios. Cities often limit the total square footage of structures to a percentage of your land (e.g., 30%). A 2,400 sq. ft. building covers a lot of land, so you may need an acre or more to comply.
Q: Do I need 3-Phase power for my shop? A: Probably not. Standard residential 240V single-phase power can run almost all welders, lifts, and compressors used by hobbyists. 3-Phase is only needed for heavy industrial machinery. If you need it, utility connection costs can exceed $10,000.
Q: How tall should the eaves be for a car lift? A: If you want a standard 2-post lift, you need a minimum ceiling height of 12 feet. Therefore, order a building with 12フィート脚. If you want an RV lift, go for 14-foot to 16-foot legs.
Q: Can I finance a metal building project? A: Yes. Because these are permanent structures on concrete, they often qualify for Home Equity Lines of Credit (HELOC) or construction loans. Some manufacturers also offer direct financing for the materials portion.
Q: Is it cheaper to build wood or steel for this size? A: At 40 feet wide, Steel is significantly cheaper. Wood trusses at that span become incredibly heavy and expensive to ship and install. Steel’s strength-to-weight ratio makes it the undisputed winner for clear-span buildings over 30 feet wide.
