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Yes, barn doors can be too heavy, although the limitation is usually imposed by the mounting hardware you buy and not your home’s framing, unless you’re building an unusually wide door. To keep the weight down, you can opt for 1-by material rather than 2-by material, and choose a softwood like pine rather than a hardwood like maple or oak. Check the weight limits on your mounting hardware, and always attach your door track to studs rather than to drywall anchors.

Rather than using a common two-by-four piece of wood for a rafter, you probably will use two-by-six, two-by-eight, two-by-ten, or even two-by-twelve boards. Wider lumber is typically a better choice in a larger building as it provides more sturdiness. Some installers may use wider lumber for rafters near the edges of the roof, where the greatest stress occurs, and save money with narrower lumber toward the middle.

Average barndominiums last between 50 and 150 years depending on the materials they are made from, how well they are maintained, and the environment they are built in. Barndominiums are very durable and have a much longer lifespan than traditional wood homes. With proper care and maintenance, well-built barndominium homes can last generations. 

This answer varies based on where you are, but most states require that all homes are greater than 320 square feet. Remember that four walls are not the only requirements—windows, closet space, minimal ceiling heights, and indoor air quality are also factors. Each state and municipality differs, though, and as some don’t consider tiny homes permanent shelters, you’ll need to check to ensure you aren’t violating any local or state laws with your build.