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    Project Showcase: Purcellville Farmhouse Brewery Taproom

    Hearthstone TeamMay 10, 20256 min read
    Project Showcase: Purcellville Farmhouse Brewery Taproom

    Key Takeaways

    • 12-week project delivered 2 weeks ahead of schedule
    • Fire marshal engaged at design phase prevented inspection surprises
    • Critical materials (tap system) ordered during design with 12-week lead time
    • ABC license activated before peak summer season due to early CO

    When a local craft brewer purchased a century-old dairy barn in Purcellville, they saw potential for a destination taproom that would celebrate the building's agricultural heritage while meeting the demands of a modern brewing operation.

    The Challenge

    The existing structure had good bones—heavy timber framing and fieldstone foundation—but decades of deferred maintenance and outdated utilities made it unsuitable for commercial use. Our task was to bring the building up to code for food service while preserving the character that made it special.

    Schedule Controls & Milestone Management

    **Critical Path**: ABC (Alcohol Beverage Control) license approval required completed CO (Certificate of Occupancy). Any construction delay meant lost revenue.

    PhaseDurationKey Dependencies
    Structural Remediation4 weeksEngineering approval before proceeding
    MEP Rough-In3 weeksFire marshal pre-inspection required
    Health Dept. Inspection2 weeksCommercial kitchen complete
    Final Inspections2 weeksAll trades complete, punch list resolved
    ABC Walkthrough1 weekCO in hand, all signage installed

    Schedule Controls Applied

  1. Weekly owner-contractor-architect coordination calls
  2. 3-week look-ahead scheduling updated every Monday
  3. Critical material orders placed during design phase (tap system: 12-week lead)
  4. Weather contingency built into outdoor work phases
  5. Fire marshal engaged at design phase to avoid surprises
  6. **Result**: Opened 2 weeks ahead of original schedule, allowing ABC license activation before peak summer season.

    Preservation First

    We worked with a structural engineer to assess the existing timber frame and develop a repair strategy that kept as much original material as possible.

    Structural Work

  7. Sistered compromised beams with matching reclaimed timber
  8. Reinforced foundation with new footings where needed
  9. Added concealed steel connections at critical joints
  10. Historic Character

  11. Cleaned and preserved original stone walls
  12. Refinished exposed timber beams
  13. Sourced reclaimed barn wood for new interior elements
  14. Modern Brewery Requirements

    Behind the rustic aesthetics, this is a fully modern commercial facility.

    Infrastructure

  15. Three-phase electrical service for brewing equipment
  16. Commercial grease trap and floor drains
  17. HVAC system designed for large occupancy loads
  18. Fire suppression throughout
  19. Brewery-Specific

  20. Dedicated brewing area with epoxy floors and washdown capability
  21. Walk-in cooler for keg storage
  22. CO2 monitoring and ventilation systems
  23. Taproom Design

    The taproom balances the building's agricultural history with contemporary hospitality design.

  24. Original stone walls exposed and cleaned
  25. Reclaimed wood bar top from local tobacco barn
  26. Custom steel tap tower fabricated locally
  27. Garage doors opening to outdoor beer garden
  28. Health Department Compliance

    Food service in a historic building required careful coordination with Loudoun County Health Department. We installed:

  29. Commercial three-compartment sink
  30. Handwashing stations
  31. Food prep areas with proper surfaces
  32. Accessible restrooms
  33. The Result

    Today, this brewery is a destination for locals and visitors alike—proof that adaptive reuse can honor the past while creating something new. The building that once housed dairy cows now hosts thousands of guests annually, contributing to Purcellville's growing reputation as a craft beverage destination.

    Share:
    Commercial Design-BuildBreweryHistoric PreservationPurcellville

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