Building a Dome | AiDomes

This Aidome owner hired a Florida Builder by the name of Gary Cook who hired the independent Kit Assembly Consultant, Randy Dixon, to supervise the builder’s workers during the assembly of his 27’ Aidome linked to a 22’ garage dome.  Here is direct quote from the Dome Owner: “Randy Dixon and a crew of five and sometimes six people, brought the project from a basic slab with a few standing riser panels to this state in 9 1/2, eight hour working days.”

The state the dome owner is referring to is that all the panels for the two domes and link are installed, with some seams having a first layer of concrete.  At this phase of assembly, the builder’s concrete workers can complete the exterior concrete work without the consultant being on site and can call him when any questions arise.   The exterior work left to be done involves concreting the seams, link, framing in locally purchased doors and windows, concreting the entryway and dormer panels, priming, sealing and painting the exterior concrete.  Then the dome is considered weather tight and interior finishing can occur without weather concerns. Finishing includes such items as framing, plumbing, electrical, kitchen and bathroom fixture and cabinet installation, HVAC, drywall finishing, etc.

This dome owner is installing mini-split ductless AC/heating units.  Because five foot tall risers will fit on the truck for a 27′ and a 22′ kit, the dome owner chose to order custom five foot tall risers (versus our standard four foot tall risers); thus causing his first floor height where a second floor is installed above to be 8’6″ tall.  In the three frequency domes, 30′ – 48′ five foot tall risers will not fit on the truck.  However Ai can custom manufacture an additional two foot tall riser which is installed above the four foot tall riser, resulting in first floor ceiling height where a second floor is installed above of ten feet in these larger domes.

To identify panels for one kit from another kit and to protect the expanded polystyrene insulation from UV light, the white EPS is painted a certain color for each kit.  In this case, the pink signifies the 27’ panels

 

Jamaica 45ft & 34ft Aidomes in Runaway Bay.

Robert Stephens purchased the two Aidomes after the building kits were assembled.  He and his crew beautifully finished the exterior and interior.  The domes will be presented for short term vacation rental and small functions such as intimate weddings with max 80 guests.  To view their website explaining how to rent the dome, click on Runaway Bay Aidomes.

The floor plan layouts below were the original design; however the plans have been modified.   A 45′ dome can be designed with three to four bedrooms and 2 1/2 baths.  A 34′ dome can be a garage dome or a two bedroom two bath home.

The Dome building kits are shipped in containers from American Ingenuity’s factory in Rockledge Florida.  One 34′ dome can fit in one 40′ high cube container. One 45′ kit can fit in one 45′ high cube container and one 20′ container.  To obtain shipping quotes, email the receiving port name and Ai will contact a freight forwarder and obtain a shipping quote.  Email address is GlendaB.aidomes@gmail.com

At no cost to you, if you give your property address and building department name,  Ai will call the building department, email them a sample set of plans and find out what is required for them to issue a building permit on the dome.

PDF for Downloading & Printing

Online Viewing – Opens in Browser


Approx.Finished Costs: http://aidomes.com/approximate-finish…
Owner Builder: http://aidomes.com/diy-prefab-dome-ho…
Local Builder: http://aidomes.com/choosing-a-contrac…
Independent Consultant: http://aidomes.com/kit-assembly-consu…
Ten Steps to Building AiDome: http://aidomes.com/10-steps-to-your-n…

The finished price per sq. ft. a home can be built for is dependent upon house square footage size, finishings, state (location within the state) and whether the dome is built by a local Contractor/Builder or is Owner Built.  Every area varies on what the finished cost per sq.ft. is because labor costs, site development costs and building code requirements vary by area.

You will find on smaller structures the cost per sq. ft. runs higher than larger homes. This is because all homes regardless of size will require a bathroom(s) and a kitchen – which are two of the most expensive rooms to build. On a larger home the cost to install the bathrooms and kitchens is spread out over a larger square footage area. On a small home with less square footage to divide the bathroom & kitchen into, will result in a higher cost per sq. ft. to build.

The Finished Cost below is an estimate based on the home being built by a Contractor/Builder and having a moderately finished home on a monolithic slab.  Total estimated finished cost on the dome includes onsite installation of the slab, dome kit, plumbing, electrical, doors, windows, HVAC, kitchen (cabinets and midline appliances) and baths, etc.

One 27′ dome kit or larger kit requires one semi-truck for delivery.  The kit includes the insulated prefab panels for the outer shell only, no windows, doors, interior finishes or utilities are supplied. We believe the Buyer should not pay shipping costs for an additional truck to receive these items because the interior items & doors & windows can be competitively sourced locally and purchased locally.

To view three actual dome kits pricing which Ai shipped recently, click on Actual.  To view an article which has four charts – one of which lists items which can be purchased from Ai and other charts estimating finished costs when the dome is Owner Built or by a Contractor, click on Approx. Finished Costs.

To look up an estimate for home finishing costs
for your state/area go to Building-cost.net
Click on start calculator and enter the following parameters for an estimate.

building-cost10-25-16

The following is a Construction Cost Estimate Report
Utilizing building-cost.net and the above criteria

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American Ingenuity (Ai) – 8777 Holiday Springs Rd – Rockledge, Florida 32955

321-639-8777 –  Mon-Fri 9-5 Eastern Time – GlendaB.Aidomes@gmail.com 

The above Aidome in the British Virgin Islands

withstood 2017 Hurricane Irma’s 200 mph winds with no damage. 

To view an Aidome in St Croix US Virgin Islands which in 12 days went through two category 5 hurricanes (Irma & Maria) with no damage, click on St Croix.

 

WHY BUILD A GEODESIC DOME FOR YOUR NEW HOME OR BUSINESS?

Q: Why did the founder of American Ingenuity (Ai) in 1975 decide on the dome shape for his commercial dome to be built in Melbourne Florida and why did he choose to use fiber concrete instead of wood?  

A: The dome, or partial sphere, is a geometric form that encloses the greatest amount of volume with the least amount of surface area. Historically, massive domes constructed of stones, brick or concrete were common in ancient Greece and Rome. In modern times, Buckminster Fuller was the first to formulate geodesic principles for constructing a spherical surface by triangular subdivision. However nearly all of Fuller’s domes were built from wood framing with shingled roofs.

Ai’s founder, Michael Busick, did not want to build his Florida commercial dome out of wood and shingles because termites eat wood, hurricane force winds rip off shingles and a wood dome has an increased shingled roof area causing expensive reroofing costs every 11 or 12 years.  Instead Mr. Busick hired a University of Miami architectural professor, engineering students and director of the Florida Solar Energy Center to come up with building materials specifically to build the geodesic dome without wood or a shingled roof. The materials were concrete, mesh and expanded polystyrene (EPS) insulation. Back in 1976 the first Ai dome was built by propping up precut EPS panels, hand tying road mesh on the exterior of the EPS and guniting concrete on to the exterior.  Mr. Busick soon learned that guniting concrete over the entire exterior surface was a waste of concrete and labor.  This is why he invented Ai’s prefab panel.  Building an Ai dome from prefab concrete panels makes construction easier than stick built construction or pumping concrete on to an airform and results in the dome triangle and riser panels having a 225 mph wind and F4 tornado warranty and being super-energy efficient.

The panel concrete is a special formulation containing synthetic fibers and two liquid admixtures. The following is why Ai ships these same ingredients with the Building Kit  so that the concrete mixed on site which is hand troweled in the seams between the panels and on the entryway and dormer panels has the same properties as the prefinished concrete Ai applies at its Florida factory on the prefabricated panels.  Fibers in concrete work to reduce the formation of shrinkage cracks in concrete’s plastic state while helping to improve shatter resistance and reduce water migration. The result: tougher concrete. These ingredients improve the concrete’s characteristics, create super toughness, extend durability, make concrete impervious to water, give higher tensile and compressive strength, provide elasticity for expansion, and improve freeze protection. The concrete in your dome out performs other exteriors because of its specially developed formula. Because of its exceptional composition, it actually gains strength over the years. The exterior concrete adheres directly to the galvanized steel mesh and E.P.S insulation without the need of a bonding agent. The panel concrete is 3/4″ thick. The seam areas between the panels average two inch thick fiber concrete.

Why build a concrete geodesic Aidome from a building kit consisting of prefabricated concrete component panels versus a box shaped conventional house?  The dome, or partial sphere, is a geometric form that encloses the greatest amount of volume with the least amount of surface area.   During the past decade the home buying public has experienced increased Acts of Nature (tornadoes, hurricanes, fires), a substantial increase in the cost of construction, the cost of energy and the cost of borrowing.  As a result, there has been increased interest in the use of concrete kit home technology to help address these concerns. Many home buyers have discovered that the Aidome design offers a viable solution; as a result Ai has shipped dome kits into 47 USA states and 15 foreign areas.

As a building concept, geodesic dome construction translates into a highly comfortable and livable building that has a maximum of floor area enclosed by a minimum of materials. These features combine superior strength, superior energy efficiency and cost-effectiveness in a single structure.  In short, the building concept of a dome expands the range of simple and economic building options. The process of stacking the panels, overlapping/locking the galvanized steel mesh of adjacent panels and filling the panel seams with special fiber concrete, produces  1) the structural components of the home;  2) the finished concrete exterior surface;  3) installs all the R28 insulation; and  4) installs all the special shell ½” Georgia Pacific DensArmor Drywall that is moisture resistant and mold resistant (similar to green board).   Ai’s component panel building system is one of the most simplified ways to build a commercial or residential building on the market today.  

Why build a geodesic dome – Super-strength, super-energy efficiency, low exterior maintenance and fire resistant concrete exterior.  The geodesic geometry intersects to form triangular elements, which have local, triangular rigidity, and so distribute the structural stress throughout the geodesic sphere.  The triangle shape is the strongest shape known to man – it will not collapse whereas all other shapes can.  Manufactured domes are constructed using a triangular network to form a spherical shape. This method provides for a free span, self-supporting structure requiring no internal supports such as roof load bearing partition walls. This allows for maximum flexibility of floor plan design and utilization of interior space.  One of the most exciting architectural environments ever designed, a dome brings its best attributes to commercial or residential needs.  It delivers a rewarding living experience filled with warmth, light and open space to those who choose to build a dome. 

As an architectural form, the dome is one of the strongest structural forms devised and built by man.  Domes that were built centuries ago enclose many of the great cathedrals of Europe. Domes are structurally superior to rectilinear enclosures. The partial sphere is an aerodynamic shape that is very stable in high winds and can withstand heavy snow loads.   For these reasons, Ai’s concrete domes greatly exceed the structural requirements of the major building codes in the United States and internationally.  One of Aidomes in the British Virgin Islands withstood Hurricane Irma’s 200 winds with no damage.  An Aidome in St Croix in 12 days went through two category five hurricanes with no damage to the dome.  An Aidome in South Carolina withstood the impact of a 30” in diameter hickory tree with no damage because the continuous galvanized steel mesh in the panels transferred the impact throughout the dome versus when a tree impacts a box shaped house the impact is localized in one area resulting in the tree slicing through the roof.  Ai gives a 225-mph wind and EF4 Tornado warranty on the dome exterior prefab triangle and riser panels.   This article explains more about dome strength.

Ai has stock plans for each of its ten different size kits which when assembled and finished with local materials, result in a tiny home of 172 sq.ft. to 3,000 sq.ft in one dome. Up to four domes can be linked to one dome to produce larger homes.  If a Buyer does not find a stock plan to fit their lifestyle our plans designers can modify or customize a plan from descriptions and sketches for a reasonable fee.   Building kits with Building plans cost from $20,000 to $67,000.  This pricing does not include the engineer seal on the plans (if required to obtain a building permit) or shipping or custom foundation plans.

Ai has made improvements in its entryway panels to result in the 30 ‘ – 48’ entryways having scratch coat of concrete on the underside and preformed lip edge for front of a beam that is poured on site.  Engineers with our Computer Aided Drafting Department have designed revisions in the building plans to comply with code as code has changed over the years.  The Assembly Manual is new and improved and is shipped with each dome kit purchase.

The Ai dome is more energy efficient than a conventional house: Why did an Aidome beat a passive solar house designed by Florida Power & Light (Florida’s nuclear-powered utility company) to win the Grand Aurora Award for Most Energy Efficient Residence in the southeastern United States?

  1. Because the dome’s 7” thick insulation is comparable to 10” of fiberglass batting (A conventional house would need minimum 2×12 walls filled with 10” of fiberglass batting and still not meet the energy efficiency of the Ai dome because the 2×12 would interrupt the insulation)
  2. the reduced exterior surface area of the dome is 30% less than a conventional house so there are less exterior walls for the air conditioning and heating to try to pass through.
  3. and because the exterior triangle and riser panels of an Ai dome contain no wood to interrupt the insulation.

The thick insulation allows cooling and heating bills to be reduced 50% to 60% over conventional houses utility costs.  (this link lists electric bills for Ai’s offices 45’ linked to 34’ dome – 3700 sq.ft. which can be cooled for less than $85 a month in the hot Florida Summer Months.)  The low utility bills can be achieved because the 7” EPS is not interrupted by wood and the dome has 30% less exterior surface area than a conventional house. To view utility bills for 1,075 sq. ft. Aidome home’s electric bills, please view 34’ Dome Home Energy Recap.   For northern climates, the insulation can be upgraded from 7” to 9” or R36.   (Because of the reduced surface area and all the shell panels having either R28 or R36 insulation, the Aidome will pass an Energy Report with double pane Low E glass.  FYI, it is even easier to heat an Aidome than to cool.  To cool a building –  heat generated from sunlight, refrigerator motor, dish washers, clothes dryers, computers, etc. has to be overcome; when heating the heat generated from these items is used.

Other advantages of the Aidome & its panel materials are:

Fire Resistant Exterior Concrete:  Why did two California home buyers, recently purchase Aidome building kits and pay shipping cost from Florida to California?  Their wood houses burned down in fires.  Ai’s panelized system does not contain wood framing (ribs) to interrupt the R28 insulation.  The prefab panels contain no wood to burn or rot or for termites to eat.  All prefab materials are noncombustible with the exterior of the panel being fire resistant concrete reinforced with galvanized steel mesh. 

Under the entryways and dormers, pressure treated wood is used to frame in standard windows and doors with lathe and exterior stucco covering the framed area.  Resulting in the dome and any exterior framed walls being covered with concrete.  The standard, high profile and garage entryway panels for the 30′-48′ kit sizes have been improved and now have a scratch coat of concrete on the underside and a preformed lip edge which folds up to make the front of a beam which is poured on site.  

FYI during kit assembly a temporary wooden rib system is assembled to support the panels.  The prefab panels compress against each other and are locked together with the steel reinforced concrete so after the kit is assembled, the dome is self-supporting and the temporary wood rib system is removed.  In a conventional house supports are needed to support the roof trusses and the roof; but not in the Aidome! The dome’s exterior walls are self-supporting.   

Environmentally Responsible:  Less than half the construction lumber & less than half the energy to operate than average houses.  Insulating foam is ozone protecting, nontoxic, expanded polystyrene (EPS). The EPS contains NO Chlorofluorocarbon (CFCs), no HBCD (hexabromocyclododecane), no TCPP (1-chloro-2-propyl) phosphate and is formaldehyde free.

Special Water Resistant & Mold Resistant Georgia Pacific DensArmor Plus gypsum drywall is installed on each prefab triangle & riser panel.  By the time the component panels are assembled it could rain. If Ai used conventional drywall, the paper matting when wet is a food source for mold growth and the gypsum crumbles.   The DensArmor gypsum drywall is moisture resistant and mold resistant.  DensArmor Plus High-Performance Interior Panels are noncombustible (as defined and tested in accordance with ASTM E136 or CAN/ULC S114) interior panels that consist of a moisture-resistant gypsum core with coated fiberglass mats. The fiberglass mats provide superior protection from incidental moisture.  The treated core and the coated facings made with fiberglass offer greater moisture resistance and improved dimensional stability than regular gypsum board. The product resists warping, rippling and buckling.  The DensArmor has zero flame spread and zero smoke development and complies with the 15 minute thermal barrier test as described in 2010 Florida State IRC Section R316.4.   Georgia Pacific’s Dens-Deck roof board is a patented nonstructural glass mat-faced, noncombustible, water-resistant, gypsum core panel.  Georgia Pacific does not add any flame retardant to its gypsum products.  The DensArmor contains no HBCD and no TCPP.    DensArmor Plus Panels are highly resistant to the growth of mold, and have scored a 10, the highest level of performance for mold resistance under ASTM D3273 test method. DensArmor Plus Interior Panels are the first drywall panels to be GREENGUARD indoor Air Quality Certified and GREENGUARD Children & Schools Certified for low emissions of volatile organic compounds (VOCs) by a leading third-party organization, GREENGUARD Environmental Institute.  In addition, DensArmor Plus interior Panels are the first drywall panels listed as GREENGUARD microbial resistant.  This listing means Dens-Armor Plus Panels, which feature fiberglass mats instead of paper facings used on the surface of traditional gypsum board products, resist mold growth.  The microbial resistant test is based on ASTM D6329, a testing standard set by ASTM International, which develops testing guidelines and procedures for building materials, products, systems, and services.

To install electrical wiring in the prefab panels, take a router or circular saw and cut a groove.  Either install conduit with wiring or install wiring in the groove.  Use expanding foam to fill the groove.  Cut the foam back flush and finish with fiberglass tape and joint compound.  To blend the taped areas to the smooth DensArmor drywall texture, skip trowel or knock down joint compound over the DensArmor.  Interior framed walls are finished like conventional housing.

Flexibility on floor plan layout design:  Since there are no load bearing walls or rectangular compartments, soaring spaces fill a dome.  The dome may be customized to suit the home buyer’s tastes and lifestyle from casual to formal.  Ai has stock plan layouts for each of its ten size kits.  If a stock plan does not fit the lifestyle, then we can modify or customize layouts from descriptions and sketches at a reasonable fee.   Ai Designs professional sets of blueprints, which contain from 13-20 sheets.  The Nomenclature Blueprint in the Building Plans shows the dome geometry with all the panels marked with letters and numbers which match the numbering on the prefab panels.   The number of sheets depends on the size of dome, foundation type and the type of entryways and dormers in the kit.  The blueprints contain dimensions to install the foundation and instructions for panel, dormer and entryway installation, etc.  Plans can be converted to metric for a small fee.    Under the entryway panels multiple windows or French doors can be installed. For example a 40’ dome with finished with local materials is a three bedroom/two bath size home.  Its entryways can have double French Doors and window on each side.  During plans design, we email elevation views of each type entryway, standard, high profile or garage, showing the rough opening size and recommended door and window sizes. Each elevation view has a to-scale ruler which allows for dimension measurement. Ai can design flue pipes, solar tubes, skylights, conduit to hold wiring for solar panels, etc. in the dome shell.  On site, a hole can be cut in the prefab panel – just do not cut within eight inches of the center of a seam.

The building plans have been improved to show symbols for the different length foundation rebar and revisions in how the framed wall under the entryway and dormer panels is installed.

Ai does not burden the price of the building kit with the price of the building plans, engineer seal, energy report.  If we did we would need to increase the price of the building kit 30%.  Instead Ai’s philosophy is that each buyer pays for the engineer seal and Rescheck Energy Report if those items are required by your building department to obtain a building permit.  Ai utilizes independent P.E. Engineers to seal the building plans for all states in USA.  The seal fee for one dome on a slab is $600.  The seal fee for one dome on a basement is $900.  Ai can complete a ResCheck Energy Report for $190 for one dome on a slab, $270 for one dome on a basement; after Buyer provides specific window and door specs..

Flexibility on types of foundations which can be designed:  The Aidome can be built on any type soil or terrain and be elevated to withstand flooding and water surge.  Ai’s standard foundation is a monolithic slab; however Ai can design custom foundations from basements, stem wall, elevated platform on concrete columns or pilings, etc.  To design custom foundations, the buyer of the building plans pays for Ai to hire a local engineer to review their soil report, what type custom foundation is to be designed, calculate load of the dome and interior floors, complete design details which Ai incorporates with their custom foundation blueprints.  Elevated Aidomes in the Florida Keys with stood Hurricane Irma winds and water surge with no damage.

Once Ai knows what type foundation is to be designed, we will ask the engineer for his fee to assist in the design of the custom foundation and his fee to seal the custom foundation plans. Ai completes a Plans Quote listing the engineer fees and Ai’s fee to design the custom foundation plans along with the dome building plans. Once the buyer agrees with the Plans Quote and pays in full for the plans, engineer fees, etc. Ai schedules the plans for design and emails proofs per the Plans Quote.

Low Exterior Maintenance:  The Aidome exterior is a shell of continuous concrete with nothing to rot, burn, rust, shrink, warp, replace or be eaten by termites.  There is no roof to blow off in high winds or to replace every 11-12 years. The exterior concrete is painted every 4-5-6 years with breathable elastomeric paint.

Building Permits on Concrete Dome:  Supply the property tax ID number and building department name and at no cost,  i will call the building department and email a sample set of plans to find out what is required to issue a building permit.  If required an engineer seal can be purchased through Ai for the building plans.  The seal fee for one dome on a slab is $600.   In Florida the highest required wind speed a building is to meet is 180 mph; as a result, the Florida licensed engineer has performed structural calculations on Ai’s largest size dome at 180 mph winds, exposure D which can also be emailed to the building official along with an Equivalency Report or an Engineering Statement which states: “The panel composition of the geodesic dome buildings are certified by me as being designed in accordance with and conform to the intent of 2015 International Building Code, 2014 Florida Building Code 5th Edition, 2016 California Building Code, Residential construction per section R104.11 that allows for alternative materials and methods of construction.  The American Ingenuity dome meets the intent of the minimum steel provisions of ACI 318-11 section 10.5 and provides a comparable or higher level of quality, strength, effectiveness, fire resistance, durability and safety. The inherent strength of the geodesic dome configuration creates a minimalistic combination of materials that is less than the more common building materials and configurations considered by the building codes. This concrete style of dome has been successfully installed in Florida, California and many states throughout the United States. Georgia Pacific’s DensArmor Plus High Performance Interior ½” Gypsum drywall/wallboard is used as the interior face of the panels which meets the thermal barrier requirements of R316.4 as shown by third party testing.”

American Ingenuity (Ai) has been in business for over 40 years and has shipped dome building kits to 47 U.S. states and 15 foreign countries (Caribbean, Thailand, Australia, etc.) from its Rockledge Florida factory.  Ai designs geodesic dome building plans for ten size kits with an AutoCAD program for residential homes or businesses.  After the kit is assembled and finished with local materials (doors, windows, bathroom fixtures, kitchen cabinets, etc.) results in homes of 172 sq.ft. to almost 3,000 sq.ft.  Up to four domes can be linked together to make larger complexes.  The exterior shell building kits with building plans range in price from $20,000 to $67,000. This pricing does not include shipping or engineer seal on the building plans or pricing for custom foundation plans..

The prefabricated panels  for the dome kit includes exterior 3/4″ concrete reinforced with galvanized steel mesh/fibers, center core of nontoxic, rigid, 7″ Expanded Polystyrene (EPS) R-28 insulation (not Styrofoam) with half-inch Georgia Pacific DensArmor Plus drywall adhered to the underside of the EPS with drywall adhesive. Onsite, the kit is assembled by lifting the panels into place with some type of hoisting mechanism, overlapping and locking the galvanized steel mesh in the seam areas.  The seams, entryways and dormers are then concreted onsite with fiber concrete (seam concrete averages 2″ thick). The concrete/steel/eps/ and drywall contain no food source for mold growth and are noncombustible.  Since our panels come pre-concreted, only the seam areas between the panels, along with and the entryways and dormers are concreted on site; resulting in reduced on site labor costs versus building a conventional house with separate materials to build the vertical walls and install roof trusses, plywood, tarpaper, shingles, insulation and drywall.

Ai designs the building plans and manufactures the dome building kit. Ai is not a construction company.   A new and improved Assembly Manual is shipped with each kit.   Ai’s clients hire a contractor to build their dome home, with the remaining clients being self-build or an Owner Builder.  If not owner building the dome, research and find a green contractor and pay him cost plus.  The contractor can hire the Independent Assembly Consultant  to supervise the concrete workers & laborers getting the dome shell assembled up to the first layer of concrete in the seams and on the entryways and dormers.  By doing this, the home owner does not need to be concerned about hiring a contractor to assemble the dome shell that has never completed a kit assembly and the contractor does not have to be worried about learning to assemble the shell….the Consultant takes care of that concern. Once the shell is assembled (with the first layer of concrete in the seams and on the entryways and dormers), the Consultant leaves and home owner or the contractor hires a finish stucco crew to apply the second layer of concrete to the seams/entryways/dormers.  The home owner or their contractor hires the subs (plumbers, electricians, framers, cabinet men, painters, etc.) to prime and paint the exterior, finish the interior and install the locally purchased doors and windows, etc.  Please review the Kit Assembly for assembly steps.

To support the panels during kit assembly, a temporary wooden rib system is installed.  The buyer can purchase precut, drilled, painted 2×4’s from Ai.  The 2×4’s are bolted to steel hubs to make a wooden geodesic skeleton. Once all the seams are concreted and the entryways and dormers are concreted, the dome is self-supporting and the wooden rib system is removed with the steel hubs being returned to Ai for a refund on the hub deposit. Most of the wood can be recycled as interior framing.

The cost to build one of Ai dome kits runs about the same to build per square foot as a traditional home (not built within a housing development)  but has insulation comparable to 10” of fiberglass and has super-strength and all the advantages described above.  A traditional home would require 2×10 frame construction with 10” of fiberglass batting to come close to our dome….but it would have wood interrupting the insulation.

 Ai’s manufacturing costs here in Florida are well below the national average, which offsets any long-distance shipping expenses. We can actually manufacture a kit here in Florida and ship it to the western states and northern states or internationally cheaper than we could manufacture there.  Having our manufacturing plant located in Florida is advantageous for shipping since more is shipped in than out of the state, leaving many trucks headed out empty.  Ai utilizes independent trucking agencies. We contract to have a truck carry the building kit outside Florida for approximately $2.70 to $2.90 per mile per semi-truck from our plant in Rockledge, Florida.   These trucking costs are less than we could do with our own trucks because if we used our own trucks, they would deliver the kit and return to Ai’s factory empty.  One each 27’ thru 48’ kits with standard 4’ riser and standard R28 insulation fit on one semi-truck. Multiple smaller size kits can fit on one truck. Internationally the kits are shipped in containers.  One 34’ kit (when finished with local materials) results in two bedroom/two bath size home fits in one 40’ high cube container.

 

 

The following article covers American Ingenuity’s two page Dome Kit Order Form & Parts List Description. 

Each floor plan varies as to the number and type of entryways, window dormers and door dormers. Once Ai knows which floor plan you prefer, we can complete a preliminary Building Kit Order Form that lists the kit with entryway and dormer pricing. Once your plans are finished, the preliminary Order Form is updated to show pricing for the Parts List Items.

 Generally additional entryways or dormers can add $300 to $4,000 on to the kit with one entryway sale pricing.

  • The 2×4’s cut/drilled/painted for the temporary wooden rib system to support the panels during kit assembly can be purchased from Ai or we email the specifications for them to be cut on your site.  The 2×4’s can number 75 (for 2 freq domes 15’ – 27’) or 135 (3 freq domes 30’-48’) or 210 (4 freq. 60’). 2×4’s can add approx. $605 or $1,088 or $1,999 to your Order Form.
    • (Due to fluctuating 2×4 prices we do not know exact price right now. Pricing will be based on current 2×4 costs at the time of shipment.)  Ai does not add overhead costs to the labor to cut the 2×4’s. Only the labor costs to cut the 2×4’s plus 2×4’ cost itself determines the pricing.
  • Parts List Items can add $300 to $1,500 to the Order Form: The second floor of the dome can be partially suspended from the dome shell. Depending on your floor plan & size of dome there can be 8 to 20 rods.  This means suspension rods are installed in the shell during the kit assembly.  A rod and top and bottom plate is around $50. The rods and other items are listed on the Parts List.

 The following description is to give you a heads up as to what is included within the two pages of the American Ingenuity  Dome Kit Order Form.  

The first page of the Order Form lists:

  • The dome kit size and its regular pricing and discount (any discount is on the kit with one entryway pricing and is not on the building options)
  • All the individual building options (entryways, window dormers, door dormers, cupola, link, etc), each are listed separately with quantities and pricing
  • Pricing for the items from the Parts List.  See below for a description of the Parts List.
  • Shipping Estimate or states Shipping To Be Determined Later.  Minimum shipping cost is $800.
  • Sales tax and applicable Florida surtax if kit is shipped to Florida property address
  • Date sale pricing is good through
  • Date Signed Order Forms and Deposit are due by to receive sale pricing
  • A Shipping Date range for kit shipment
  • Estimated Shipping Costs
  • $120 purchase for the four lifting spikes (items are not returned to Ai).  If purchasing more than one dome, you need one set of spikes for each dome as they wear out with use.
  • Hub Deposit & purchase bolts, nuts, washers:
    • If you are in the USA a deposit is placed on the steel hubs for 5 months rental time with $20 monthly rental cost over five months.  The deposit is returned when all hubs are returned within the five month rental period. 
      • 3 freq domes: 30’- 48’ dome kit –  the hub deposit is $1,610  for 46 steel hubs.
      • 2 freq domes: 22’ & 27’ dome kit – the hub deposit is $910 for 26 steel hubs.
      • 4 freq dome: 60′ dome kit – the hub deposit is $2,485 for  71 steel hubs.
      • The steel hubs are bolted to your locally purchased 2×4’s that you cut, drill holes and paint the ends…the hubs and 2×4’s make up the geodesic wooden support skeleton to hold the panels in place while the seams between the panels are concreted and the entryways and dormers are concreted.   You borrow the hubs from us and UPS or mail them back to us when you are finished with them.  Ai issues you a refund check, less any missing hubs, etc.  Once the mesh in the seams is overlapped, locked with C rings and concreted and the entryways and dormers are concreted the dome is self-supporting and the rib system is removed. There is no wood in or on the shell to interrupt the insulation.
    • Purchase price for bolts, nuts & washers that are used to connect the steel hubs to 2×4 wooden ribs. 2 & 3 freq. $128.  4 freq. $160. These items are not returned to Ai.  The items get worn with use and cannot be used again.
  • International Orders – hubs are purchased because they weight around 150 lbs and cannot be returned.
    • For 2 freq domes 26 hubs are purchased with bolts, nuts, washers for approx. $1,170 and not returned to Ai.
    • For 3 freq domes 46 Hubs are Purchased with bolts, nuts, washers for approx. $2,070 because they are not returned.
    • Ai has to rent a telescoping forklift to load the container. Our forklift cannot be used.  The rental cost is $800 for one day rental.  If your order includes two or more containers, the telescoping forklift may need to be rented for two days or more. You will need a telescoping forklift to unload the container.
    • Add $200 for Ai to complete international paperwork and coordinate your shipping with your freight forwarder.
  • Purchase cut, drilled, painted 2×4’s for temporary wooden rib system from Ai or Ai can email specs for the 2×4’s to be cut, drilled, painted on site.  To determine pricing, Ai only charges the cost of the 2×4 and actual labor costs to cut, drill and paint the 2×4’s.  Ai does not add our business overhead costs to the 2×4 pricing. 
    • For two freq: 15’, 18’, 22’ or 27’ dome there are 75 – 2×4’s – approx. price $605
    • For three freq: 30’ – 48’ domes there are 135 – 2×4’s approx. price $1,088

The temporary support system needs 2×4’s cut to a precise length, holes drilled in both ends of the 2×4’s that make the triangles and one hole drilled in the 2×4 leg for the riser panels and ends painted red, white or blue to match the hub leg colors.  Ai realizes this cutting, drilling and painting is difficult and time consuming for our buyers; therefore, the cut, drilled and painted 2×4’s can be purchased from Ai and shipped on the truck with the dome kit.

Please let us know if there are any items you do not want to purchase, and we will remove them from the Parts List or change any quantities.

The second page of the Order Form is the Parts List which consists of two parts.

 The first part of the Parts List is a listing of items that come with the kit;

  • 4-8 cans of expanding foam, one metal expanding foam dispensing gun and one can of cleaner
  • 2 galvanized steel cables that go around the dome
  • admixture A – for concrete
  • admixture B – for concrete
  • synthetic fibers – for first layer of concrete
  • bonding agent – applied between two layers of concrete
  • C-rings and two pairs of C-ring pliers
  • Cupola kit if you have a cupola

 The second part of the Parts Lists is a listing of items not included in the kit which you can choose to purchase from Ai:

  • Items to suspend the second floor perimeter joists and to suspend other areas of the second floor where there are no first floor load bearding walls
    • 6 ft Suspension rod with nut coated to prevent rust & two nuts & washer -$19 set
    • Top plates, bottom plates or flat plates for horizontal seams….Ai purchases the steel, cuts the steel and drills it and bends it to specs. Each plate $14.90.
    • Garage door header modified Z plate – $14.90
  • Concrete Accelerator (if you are going to be mixing concrete in late fall when temperatures could be freezing at night)
  • ¼” cable for lip edge of first floor door dormer – $2.50/ft.
  • Simpson hangers (connect the second floor edge beams to the joists) – $1.95 to $4.20 each
  • 1/2″ in diameter 6″ long stainless steel forged eyebolts for the top of the dome – $17 each.  During kit assembly a 4″ Vent Pipe is installed where the five top P panels meet.  An eyebolt is installed in each of the five top seams five inches from the vent pipe.  To paint the dome a rope is tied thru an eyebolt and secured to the worker’s harness.  The eyebolt keeps the rope away from the Vent Pipe so the pipe is not damaged.  The rope attached to the eyebolt needs to be part of an engineered system with a maximum arresting force of 900 lbs.  If a cupola is purchased six other eyebolts are purchased for a total of 11 eyebolts.
  • 1”x1” galvanized steel mesh for link – $1.05/sq.ft. – can be ordered in 300 sq.ft.; 500 sq.ft. or 600 sq.ft. amounts…we are shipping complete rolls. This way we do not need to unroll the rolls and measure lengths out and then reroll the rolls and strap them, etc. If you want less than 300 sq.ft. then the price per sq.ft.is $2.10.
  • Ai originally designed 22’ and 27’ domes as two frequency domes for garages because the entryway would remove three riser panels instead of two risers for the 30’ thru 48’ dome entryways. This causes the 22’ and 27’ dome entryway panels to be longer.  Because they are longer they consist of 3 ½” EPS not wrapped in steel mesh and there is no concrete applied on the underside or lip edge.  However if the dome kit buyer purchases 1”x1” galvanized steel mesh for 15’ or 18’ or 22’ or 27’ G  type entryway panels at  $1.05/sq.ft. – minimum 300 sq.ft. or $315. Ai will wrap the 15’ or 18’ or 22’ or 27’ entryway panels at no labor cost for our buyer.
  • 1/2″x 1/2″ galvanized steel mesh for the entryway and dormer framing – $1.05 per sq.ft.
  • Additional “C” Rings (small and large) are purchased because they tend to get dropped. Small (2 – 3 lbs) – $5.85 per pound.  Large (2-3 lbs) – $4.75 per pound.
  • Two additional “C” Ring pliers are purchased – $18 each.
  • Additional Bonding Agent is purchased. The Bonding Agent that American Ingenuity ships with your kit is new and improved and is better than what you can purchase locally.  Locally Home Depot, etc. sells a cheaper bonding agent which is a blend of vinyl & acrylic resins. The bonding agent we include with your kit is manufactured by Richard’s Paint and is number RP295.  It is a 100% pure acrylic resin. Ai sells a five gallon bucket for $107 because Ai wants you to have the very best bonding agent.  Ai recommends that you purchase an extra five gallon bucket for each dome kit instead of purchasing a less quality bonding agent locally when you run out.
  • Additional metal expanding foam dispensing gun $40 – gun wears out from use.
  • Additional synthetic fibers for the second layer of concrete – $7.00 a bag – good for four bags of Portland cement.
  • Additional cans of cleaner for the metal foam dispensing gun – $10.85 ea – small dome 1 can.  Large dome 2 – 3 cans.
  • Additional admixture A and admixture B as liquids get spilled or evaporate in the hot sun.  Depends on size dome.  Small dome 1 gal A and 2 gals B.  Large dome 2 gals A and 4 gallons B.   A is $30.40 a gallon. B is $34.40 a gallon.
  • Additional 24 oz cans of expanding foam – $11.10 ea. Small kits need 12 extra cans; larger kits 40’, 45’ 48’ – 24 cans.
    • Ai ships 4 – 8 cans of expanding foam with your kit at no cost to you. You can purchase more cans from us.  Our cans are 24 ozs. We send a metal dispensing gun and a can of cleaner at no cost. Expanding foam is applied under each riser panel.  Grooves are cut in the dome shell wall board & EPS to insert the electrical wiring.  After the electrical wiring is installed, the grooves are filled with expanding foam, the expanding foam is cut flush and then the wall is finished with tape and joint compound just as drywall is finished or with mixture of cement/perlite – recipe in Assembly Manual.   Of course, you can decrease or increase this number.  The dispensing gun allows your workers to start and stop the foam without having to use the whole can at one time…like you do with the small cans that you purchase from the hardware store that have the plastic nozzle which cannot be restarted the following day.

 Items on the Parts List can be shipped with your dome kit at no extra shipping cost.  American Ingenuity only orders Parts Items based on each customer’s order.  Ai does not stock any of these items; therefore if you need additional items after the kit is shipped we can give you the phone number of the company where you can order parts (bonding agent, Enerfoam, etc) directly from them, pay their shipping cost, handling fee and have the items drop shipped to you.

The Parts List items and the 2×4 pricing for the temporary rib system can change because their costs can fluctuate.  Two months prior to the delivery of your kit, Ai will call the shipping broker and obtain your shipping cost and will review the 2×4’ pricing and Parts List items.  If costs have changed, Ai will complete a revised Order Form showing latest pricing and shipping cost.  The balance due on your Order Form is due three weeks prior to the shipping of your dome kit in the form of a cashier’s check or bank check.

 

This article allows you to review the approximate finished costs on eight size Aidome kits for you to determine which size dome fits your budget.  If a 40′ finished dome is beyond your means, consider purchasing & finishing a smaller size dome kit with link and add on another dome later. This way you are living on your property in a strong, energy efficient, fire resistant dome saving money monthly on your utility bills.  Please note the 15′ and 18′ domes are not included.  To view pricing for the 15′ & 18′, click on Small Kits. 

The finished price per sq. ft. a home can be built for is dependent upon house square footage size, finishings, state (location within the state) and whether the dome is built by a local Contractor/Builder or is Owner Built.  Every area varies on what the finished cost per sq.ft. is because labor costs, site development costs and building code requirements vary by area.

The dome kit includes all the prefabricated panels to assemble the dome shell and panels for one entryway.^^^ To learn about panel composition, click on Composition. Your floor plan selection determines the type & number of additional entryways and dormers.  To learn about entryways and dormers, click on Building Options.   To view stock plans for each size dome kit, click on Stock Plans. To view the Plans Sale Price and the Dome Kit Sale Price for each stock plan click on  Stock Plans & Kit Sale Prices   Once your building plan design is finished Ai  will know the exact type and number of entryways and dormers and Parts List items needed for your dome kit. At that time a Dome Building Kit Order Form will be completed listing the items and their pricing.  To view charts of three dome kits (kit homes) recently shipped by Ai, click on Actual Kits.  Meantime to view estimated pricing for the eight dome kit sizes & items which can be purchased from Ai and charts listing estimated finished costs, please view the charts below.  To view a description of  what Parts List Items are included in the kit and which Parts List Items can be purchased from Ai, click on Order Form Description.   

Below are three charts: 

  1. Chart listing items which can be purchased from American Ingenuity (Ai).
  2. Chart listing approx. finished cost if the dome kit is assembled & finished by an Owner Builder.
  3. Chart listing approx. finished cost if the dome kit is assembled & finished by your local Contractor. If wanted an independent Kit Assembly Consultant can be hired to supervise the contractor’s crew.  At the bottom of this chart is approx. cash down payment amounts for financing. 

Estimated Pricing For Items Which Can Be Purchased From Ai

 

Approx. Finished Cost When Dome Built By Owner Builder 

DIY

Approx. Finished Cost When Dome Built By Contractor

Free Web Site To Calculate Home Finished Costs For Your Area

To view information on a free web site where you can look up finishing costs for a conventional home in your state and area, click on Calculating Square Footage Costs. This article also includes  a Construction Cost Estimate Report from building-cost  for a 1200 sq.ft. home in Melbourne, Florida.

FREE FINANCING BOOKLET 

To view American Ingenuity’s free Financing Booklet which gives name of a Lender and creative ways to finance the dome, please click on Booklet.

 

American Ingenuity (Ai) – 8777 Holiday Springs Rd – Rockledge, Florida 32955

321-639-8777 –  Mon-Fri 9-5 Eastern Time – GlendaB.Aidomes@gmail.com 

The American Ingenuity Dome Kits
are DIY Prefab Dome Homes for Owner Builders or for a Contractor

The prefab dome kit can be a Do It Yourself Project with the owner builder utilizing family and friends or hiring his own workers for kit assembly.  Or the home owner can hire a builder who hires the independent Kit Assembly Specialist who travels world-wide to supervise your kit assembly and the application of the first layer of fiber concrete into the panel seams and onto the entryways and dormers. Then either your workers or your builder’s workers complete the second layer of concrete in the seams & on the entryways and dormers. For interior finishing complete yourself or hire local subcontractors to complete the plumbing, electrical, framing, window/door installation, wall board finishing, kitchen cabinetry, bathroom fixtures, etc.  To view pictures of prefab concrete panel assembly, click on Dome Kit Assembly.

American Ingenuity’s (Ai’s)dome kit is affordable, strong and can be assembled by Do It Yourself individuals because the kit is engineered as a system of pre-finished prefabricated component panels. Each panel is cut at a computer-generated angle so that it fits flush with the adjacent panel. The edges are precisely beveled at the seams where steel and concrete will unite to complete the structure. All panel materials are noncombustible and contain no food source for mold growth.

Building an Ai dome from prefab concrete panels makes home construction easier than stick built construction and results in the dome exterior having a 225 mph wind and F4 tornado guarantee. The process of stacking the panels, overlapping/locking the steel mesh of adjacent panels and filling the seams with special fiber concrete, produces the structural components of the home, the finished concrete surface, installs the insulation and all the dome shell 1/2″ drywall.

This advanced building system makes it easier for an owner builder to construct an American Ingenuity dome than a conventional house or a wooden dome. No exterior walls, no roof trusses, no sheathing, tar paper, or shingles, no soffit, exterior trim, insulation or siding to install and no interior shell drywall to install.  During the dome kit assembly, owner builders or builders can email pictures of the kit assembly. At no cost to you, Ai will review the pictures and give feedback about rebar and cable installation, etc.  Due to large size of panels in 45′ and 48′ domes, considering hiring the consultant to assist in your assembly.

 

Nomenclature-top

Nomenclature Diagram for Downloading & Printing
Nomenclature Diagram
Nomenclature Diagram for Viewing in Browser
Nomenclature Diagram

The building plans contain blueprints for the installation of the foundation and installation and location for each panel. Within the plans is a nomenclature blueprint that shows lettering and numbering for each panel. An example of a nomenclature blueprint is above.

An Expanded Assembly Manual is now available with each dome kit order that explains step by step the panel assembly. (Once a deposit with signed order is received, the manual can be shipped). In the blueprints and Manual is the recipe for the concrete. Ai wants the concrete mixed on site to have the same properties as the concrete that is applied at our factory; as a result the same two liquid admixtures and fibers are shipped with each kit. In the manual is a list of tools and materials to have on site. To view a list, click on Materials and scroll down the page to view the list.

American Ingenuity’s prefabricated component panel consists of:

1.   7″ thick, rigid, nontoxic E.P.S. Insulation (not Styrofoam): The E.P.S. Ai utilizes is a closed cell with a 1 lb. per cubic foot density.  Seven inches of sturdy, rigid R-28 expanded polystyrene foam insulation forms the core of each component panel and is:

  •  Permanent
  • Chemically/thermally stable
  • Resistant to mildew and mold
  • Provides no nutritive value to animals/plants/microorganisms
  • Non-irritating to the skin
  • The insulation will not rot, shrink, absorb moisture, compact, or deteriorate due to age or the weather.
  • No CFC, no HBCD (hexabromocyclododecane), no TCPP (1-chloro-2-propyl) phosphate, no Chlorofluorocarbon (CFC) and no Formaldehyde

2.     Concrete: the concrete in your dome out performs other exteriors due to our specially developed formula. Because of this exceptional composition, it actually gains strength over the years. The special concrete formulation of fibers and admixtures improve concrete characteristics.

3.     Galvanized Steel: Galvanized steel wire mesh is encased in the concrete of each panel. As your dome is assembled the mesh of each panel overlaps and is locked to the mesh of  adjacent panels with C rings commonly called hog rings – resulting in your home being completely wrapped by steel mesh.

4.   Half inch (½” ) Georgia Pacific DensArmor Drywall: The DensArmor is not conventional sheet rock. Conventional sheet rock consists of conventional gypsum and paper backing. The paper backing can be a food source for mold growth. Sheet rock when it gets wet crumbles and molds. The DensArmor gypsum when it gets wet does not crumble due to fiberglass reinforced core. It has fiberglass backing on both sides. After the DensArmor dries out it goes back to its original firmness and consistency per the manufacturer.

Concrete Home
Dome Exterior Has No Wood To Burn or To Rot or For Termites To Eat
No Shingles or Roof to blow off in high winds

To support the panels during dome kit assembly, a temporary wooden rib system is installed. Once all the seams are concreted and the entryways and dormers are concreted, the dome is self supporting and the wooden rib system is removed. Most of the wood can be recycled as interior framing.

 

45' dome - assembly of third row of panels

45′ dome – assembly of third row of panels

In this view of dome kit being assembled a side view of a component panel can be seen. The panel exterior is 3/4″ concrete reinforced with galvanized steel mesh. After the mesh is overlapped and locked between panels, special fiber concrete mixed on site is hand troweled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas are about 3″ deep by 5″ wide with average of 2″ thick concrete.  In this picture you see the first scratch coat applied to the exterior of the entryway panels and first layer of concrete in some of the seams between the panels.

Steps for American Ingenuity Concrete Building Kit Assembly:

  • Foundation installed. Standard foundation is monolithic slab; however Ai can design basement plans, pilings or columns, stem wall, etc.
  • Depending on size dome two to five workers are needed. Some with concrete experience.
  • Installing the first row of panels which are the 4’ vertical riser panels, base panels of the entryways and any first floor door dormer base panels
  • Erecting a temporary wooden rib system to support the triangle and riser panels during assembly using your locally cut, drilled and painted 2×4’s bolted to steel hubs borrowed from Ai.
  • Placing the panel’s one row at time using a hoisting mechanism (man lift) on to the rib system.
  • overlapping steel mesh from adjacent panels, locking mesh with C rings and pliers and depressing the steel mesh in the seam
  • mixing concrete with mortar mixer following concrete recipe in the manual (Portland Cement Type III, masonry or stucco sand, fibers, liquid admixtures)
  • installing cables per blueprints
  • installing rebar around back of entryway panels, back of first floor door dormer panels, top of entryway panels & around first floor window dormer panels per building plans
  • form up and install beams or troughs around lip edge of entryway panels, first & second floor door dormer panels, channels in top of the entryways
  • Concreting the seams between the panels (5″ wide and 3″ deep) with two separate layers of concrete using a bonding agent between the layers; and watering down all cured concrete before applying bonding agent or new concrete. Seam areas average 2” thick concrete.
  • Concreting the entryways, window dormers, door dormers, cupola and link with two layers of concrete. Sponge float finish the final layer of concrete to blend seam concrete to the panel concrete.
  • Framing in the entryways and dormers and installing your locally purchased exterior doors and windows.
  • Removing the temporary wooden rib system. Return the steel hubs to receive a full deposit refund if returned during five month rental period and if all hubs are intact.
  • Wash efflorescence off concrete, prime, paint the exterior concrete per waterproofing instructions in Assembly Manual.

Onsite concrete is only applied in the seam areas between the panels and on the entryways, dormers (or possible link or cupola). Concrete is not applied over the pre-concreted component panels. The interior shell drywall can be finished similar to conventional sheet rock with adhesive fiberlass and joint compound. To blend the seams joint compound can be skip troweled over the drywall before priming and painting.

To learn more about Hoisting Mechanisms click on Hoisting. To learn more about entryways, dormers, etc. click on Building Options.

If I am not ready to assemble my dome immediately, can the kit be stored outside? Yes, however if you expect to have your kit outside for more than two to three months, request that the E.P.S. edges be painted. On site if you need longer than 2-3 months prior to assembly, then on site the EPS edges can be painted again. (some boxed items & wooden 2×4 ribs if ordered should be stored inside.) The dome kit should not sit outside in the winter as freezing can harm the drywall.   Please call us for details at 321-639-8777 – Monday – Friday 9-5 eastern time.

American Ingenuity – 8777 Holiday Springs Rd. – Rockledge, Florida 32955   email: GlendaB.Aidmes@gmail.com

Opportunity To Save Big On Our Last 22′ Dome Kit
Made with ¼” DensDeck (interior drywall)

In keeping up with building codes over the years, AiDomes has phased out the use of quarter inch (¼”) DensDeck drywall in favor of half inch (1/2”) DensArmor Plus drywall. (Interior drywall on each triangle & riser panel).  Both DensDeck and DensArmor are special Georgia Pacific drywall that is moisture resistant and mold resistant. This drywall is not conventional sheet rock, which when gets wet the paper matting is a food source for mold growth and the gypsum crumbles.  The prefab panels contain American Ingenuity’s (Ai’s) standard 7″ Expanded Polystyrene (EPS) R28 insulation and exterior pre-finished 3/4″ fiber concrete reinforced with galvanized steel mesh.

What this means to you: If you’re in a position where you want a 22’ dome for an out building or garage (which local codes may allow ¼” DensDeck) you can save over $6,000.

Ai has a 22’ dome kit with 1/4″ drywall in stock that we are selling AS  IS at reduced pricing of $9,870* versus Ai manufacturing a new 22’ kit with half inch (1/2″) drywall whose sale price is $17,040 with regular price of $21,300.  (Kit includes all prefab panels for dome shell, 4′ tall riser panels & six 3 1/2″ EPS panels for one entryway)

22-woods-demo

Photo of 22′ dome kit assembled.

Once kit is assembled, the first floor square footage is 370 with optional loft built on site having 81 sq.ft. to five feet of headroom.  Approx. area in optional loft from 5’6″ to 6’10” is 48 sq.ft.

22' AS IS Panels 0389

Photo of some of the 22′ AS IS kit panels.
Prefab Panels w’ standard 3/4″ fiber concrete reinforced w’ galvanized steel mesh,
R28 7″ EPS Insulation, 1/4″ DensDeck Drywall

If your building department requires ½” drywall then Ai has two options for you.

  • First Option: purchase the kit for $9,870 with the quarter inch ( ¼” ) drywall & on your site remove the quarter inch (¼”) drywall and adhere free half inch ( ½” ) drywall to the EPS with free adhesive using free ½” DensArmor drywall cut to shapes to fit the 22’ panels. And receive $210 of galvanized steel mesh for free.
  • Second Option: pay $10,989 for the kit and Ai will remove the quarter inch (¼” )DensDeck & apply the half inch (½”) DensArmor. And receive $210 of galvanized steel mesh for free.

If you give Ai your properties tax ID number or site address, at no cost to you Ai will call your building department, show them our web site, email set of building plans if needed and find out what is required to obtain a building permit.  Do they require an engineer licensed for your state to seal the plans?  Do they require an Energy Report?  If so both items can be purchased from Ai.

*The $9,870 sale price does not include shipping, building plans, engineer seal on the plans or energy report. The $9,870 sale price includes the following:

  1. New ½” Georgia Pacific DensArmor Plus wallboard cut into shapes ready to be adhered to the triangle panel’s EPS insulation. Also will be included additional smaller pieces of DensArmor for the riser panels The free ½” DensArmor Wallboard’s value is $949.20 in material cost. (see below why Ai utilizes DensArmor instead of DensDeck)
  2. 17 cans of Enerfoam (drywall adhesive) whose value is $170.70. One can affixes DensArmor to three panels.
  3. 200 sq.ft. of mesh whose value is $210. (A couple of panels had rusted steel mesh which was removed. On site add mesh in the seam before the concrete is applied in the seam.)

See below for description on how to remove 1/4″  DensDeck & adhere the free precut ½” DensArmor drywall to the EPS using free Enerfoam.

The following describes what panels are included in the 22’ kit:  The kit includes all the panels to assemble the dome shell and the 3 ½” EPS panels for one entryway. The triangle and four foot tall rectangle riser panels consist of center core of 7” Expanded polystyrene insulation (EPS) (R28), with ¾” fiber concrete exterior reinforced with galvanized steel mesh & ¼” DensDeck interior drywall. (the edges of the EPS insulation on the triangle & riser panels have been painted which allows the kit to be stored outside for 2-3 months prior to assembly). (some boxed items and other items need to be stored inside.)

Depending on your floor plan selection, additional entryway or dormers can be purchased at current pricing: 22’ G type entryway is $390; first floor Window dormer is $345. First floor Door dormer is $365.

The entryway panels do not have galvanized steel mesh wrapped on them.  If the Buyer purchases the mesh from Ai,  we will not charge any labor costs for the plant to wrap the entryway panels with the mesh.

All panels are premarked with numbers and letters to match the building plans and the Assembly Manual.  The assembly process consists of stacking the panels on the temporary wooden rib system overlapping and locking the steel mesh of adjacent panels, filling the seams with special formulated concrete and concreting of the entryways and dormers.  Finish the interior wall board seams with fiberglass tape and joint compound.  This process produces the structural components, completes the finished exterior surface, installs the insulation and all the interior shell wallboard. Seam areas between panels concreted on site and average two inch thick concrete.  To view kit assembly, click on Assembly.  Independent consultant can be hired to supervise kit assembly.

On site, under the entryways and dormers a 2×4 or 2×6 wall is framed in to install your locally purchased doors and windows.

The concrete applied in the seams and on the entryways and dormers is sponge finished to match the pre-finished texture of the concrete panels. The dome is primed with concrete primer and then painted with two coats of exterior concrete paint to achieve the color you desire.  To blend the DensArmor interior drywall seam finish to the drywall, skip trowel joint compound over all the dome shell drywall.

The following describes why American Ingenuity switched to DensArmor versus DensDeck. (Both DensArmor & DensDeck are Georgia Pacific moisture resistant/mold resistant gypsum drywall). To obtain building permits, more and more building departments require the insulation be protected by 15 minute thermal barrier material. The noncombustible ¼” DensDeck does not have the 15 minute thermal barrier test. The ½” DensArmor Plus High Performance gypsum drywall has the tests to prove it is a 15 minute thermal barrier. All Ai dome kits are now shipped with 1/2″ DensArmor adhered to the EPS using the Enerfoam (drywall adhesive). The Enerfoam adhesive is being shipped at no cost with this AS IS kit if you are adding ½” drywall on site. The Plant utilizes the hinge method that is described below to affix the wallboard to the Eps using the Enerfoam. If you choose to remove the ¼” drywall and apply the free ½” drywall, you will use this same method to affix the ½” DensArmor to the panels on your site.

The following describes how to remove the ¼” DensDeck and adhere the ½” DensArmor.

    • Flip the panel over and pry the ¼” DensDeck off the panel with good metal snow shovel or use large putty knife. Some cement perlite which was used to adhere the DensDeck may come off when the DensDeck is pried off.
    • Select the appropriate pieces of precut ½” DensArmor and lay on the panel.
    • Lift up DensArmor one piece at a time and spray Enerfoam in S pattern on EPS around edges & middle where DensArmor piece will lay.
    • Lay DensArmor piece down. Slide back and forth a few times to make the foam tacky and not swell up.
    • Then when you are sure the piece is in correct location, leave in that position.
    • Install next piece until all pieces are installed for that panel.
    • Place another flipped panel on top of this panel and complete same process.

The following information covers Tiny Home Kit reg & sale pricing w’ specs.  Ai has added two new tiny home sizes to its Tiny Home assortment – 15′ and 18′!   These Tiny Dome Home Kits are constructed using Ai’s superior prefabricated insulated concrete panel system.  Consider them for Special Hideaway, vacation cabin, mother’s home, guest house, hunting cabin, glambing, tiny home, micro home, cottages for resort, rental units for veterans or a starter home.  The Ai dome is much stronger, has noncombustible materials in its wall panels, fire resistant concrete exterior & more insulated than a framed house, concrete block house, log cabin, tent or yurt.  Also all the panel materials contain no food source for mold growth.

Additional dome kits can be added later and linked to the first dome built on your site.  If you believe you want to add on later, discuss with our design team and a link can be installed on the first dome where a second dome can be connected later.

Tiny Dome Home Kits when assembled and finished can result in 172 sq.ft. to 1,278 sq.ft.  The domes can be one story. Dome sizes are measured by feet in diameter with the 15′, 18′, and 22′ kits having a first floor with optional attic/loft.  The 27′, 30′ & 34′ can have a second floor installed if you so desire. The 27′  dome second floor panels are large enough for a window dormer to accept fire egress size window.  The 34′ second floor window dormer is too small to accept a fire egress window so door dormer panels are installed above a first floor standard entryway to accept a fire egress size casement window.  With a 2nd floor egress window installed this allows the 27′ & 34′ domes second floor to contain a bedroom; resulting in the 27’ & 34’ domes being two bedroom/two bath size homes. The 30′ dome second floor panels are not large enough for a window dormer so no bedroom can be designed – use the 30′ second floor for storage, office, craft area, additional bathroom, rec room.  To view stock plans for the 15′ and 18′ along with plans for the other Tiny Domes, click on Tiny Home Plans.

22-woods-demo

22′ Tiny Dome Home After Building Kit Assembled & Finished with locally purchased materials.

As far as Tiny Homes meeting minimum size house requirements – in some areas,  groups are petitioning their county or their city elected government officials to allow them to have Tiny Home Communities (called pocket neighborhoods) where the minimum house size can be below state code. The City of Rockledge, Florida agreed that a group whose face book page is called Rockledge Tiny House Community can purchase property and build Tiny Homes from 172 sq. ft up to 1000 sq ft. in their city.   Normally in Florida the minimum new house size requirement is 500 sq.ft. or 800 sq.ft. or 1,000 sq.ft.  So congratulations to the City of Rockledge Tiny House Group for its victory in changing minimum size house requirements in their city to as small as 172 sq.ft..

Please check local codes to see how Tiny Homes can be built for cottages in a resort or for rental units to rent out to migrant workers, veterans and individuals wanting to live in strong (225 mph & F4 tornado warranty), energy efficient houses whose exterior concrete is fire resistant.  To view comparison of concrete dome kit to log cabin, click on log cabin.  To view info on Ai dome and tree impact & snow load, click on Tree.   To view complete summary of advantages of Ai dome, click on Summary.

Tiny Dome Building Kit Contents:

  1. 15’ & 18’ Kits consist of all the triangle prefab panels and standard 4’ risers plus 2’ riser prefab component panels for the dome shell and panels for one entryway. The kit can be purchased with 7″ EPS, 1/2″ Drywall & exterior 3/4″ concrete reinforced with galvanized steel mesh/fibers.  And only the 15′ & 18′ kits can be purchased with 3 1/2″ EPS, no drywall and no reinforced concrete.  The larger kits cannot be purchased with only 3 1/2″ EPS because this size insulation makes the larger panels to flexible causing EPS breakage.
  2. 22’ & 27’ Kits  consists of all the triangle prefab panels and standard 4’ riser prefab component panels for the dome shell and panels for one entryway.  5 foot tall risers can be ordered instead of the standard four foot tall risers. Your floor plan selection determines how many more entryways and dormers are in your kit.
  3. 30’ & 34’ Kits consist of all the triangle prefab panels and standard 4’ risers prefab component panels for the dome shell and panels for one entryway. To increase first floor ceiling height where a second floor is above, on site install a one foot tall or two foot tall perimeter wall to increase the height to 8’6″ or 9’6″.  Your floor plan selection determines how many more entryways and dormers are in your kit.

Each triangle and riser prefab component panel consists of exterior ¾” fiber concrete reinforced with galvanized steel mesh, center core of 7″ R-28 expanded polystyrene (EPS) insulation with interior special moisture resistant, mold resistant 1/2″ gypsum drywall from Georgia Pacific called DensArmor Plus. During kit assembly it can rain. Water does not harm this special DensArmor drywall. The 15′ & 18′ kits can be purchased with 3 1/2″ R14 EPS insulation and no drywall. 

The dome kit’s prefab concrete panels can be assembled by owner builders and is a true Do It Yourself kit. All the panels come marked with numbers and letters to match the building plans and the Assembly Manual. On site,  fiber concrete is troweled into seams between the panels and on the entryways or dormers. Seam concrete average thickness averages two inches. An Independent Kit Assembly Consultant can be hired to supervise your workers or your Builder’s workers during kit assembly.

10% Discount Tiny Dome Housing Kits*
If Deposit & Order Placed per Coupon

  •  To schedule your kit for manufacturing, Ai requires signed Order Form, Conditions of Sale (Warranty), Specialized Material Agreement and kit deposit (Check is made payable to American Ingenuity).
  • Accept delivery of your Kit per Coupon allowing Ai to select the week/day of shipment within the month agreed upon by Buyer & Ai to make 20% discount possible.
  • To acquire a building permit, building departments usually require engineer sealed building plans and an Energy Report. Stock or Custom plans take 2-10 weeks for delivery. Allow 4-8-12 weeks for kit manufacturing time.
  • Standard Building Kits contain all the triangular & riser panels to complete the dome shell and one entryway. Each floor plan varies as to the number of entryways, door dormers and windows dormers. Additional Entryways, Dormers, Risers are offered at current pricing.
  • This special incentive cannot be combined with other discounts or savings offers.

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Where doors & windows are located in the dome, structural awnings called entryways and dormers must be installed. The number of entryways and dormers are determined by your choice of floor plan. Entryway panels consist of 3½” EPS with no steel mesh or concrete. Steel mesh is purchased from Ai and attached on site with panels requiring on-site concreting. Dormers consist of 3 ½” EPS wrapped with steel mesh & require on site concreting. Call for Link pricing. Links can be purchased with 1/2″ DensArmor drywall. Links consist of precut 7” EPS. Steel mesh can be purchased from Ai. The link requires on-site mesh installation and concreting. American Ingenuity Domes are designed with flexibility, allowing you to create your own personal home and floor plan layout. Exterior doors & windows are purchased locally and installed onsite within the entryways and dormers using locally purchased materials. Solar tubes can be installed onsite within a panel. (Do not cut within 8” of a seam).

PAYMENT: Tiny Home Building Kit orders require a 30% deposit. The balance including USA shipping costs, in the form of a bank check, is due 21 days prior to shipment.  If kit to shipping to a Florida site, add Florida sales tax & your Florida’s county surtax. No credit card charges. *Pricing does not include shipping or building plans. If kits are exported, buyer pays freight forwarder directly for inland trucking costs and ocean shipping costs.

SHIPPING:  American Ingenuity can arrange shipping on 53’ step deck semi-trucks. Freight varies from $2.50 to $2.90 per mile ($800 minimum) per truck, from American Ingenuity plant in Rockledge, Florida. One truck can carry five 15’ kits; or two 18’ kits;  or two 22’ kits;  or one 22’ kit & one 27’ kit; or one 30′ kit; or one 34′ kit – each with 7” EPS insulation.

15′ & 18′ Kit:  If 3 ½” EPS and no drywall one truck can carry up to ten 15’ kits; or up to  four 18’ kits. 22’, 27′, 30′ and 34′ kits cannot be purchased with 3 ½” EPS.  The panels are too large in these larger kits to manufacture with thinner 3 1/2″ insulation. The 7″ insulation is required so the panel is not flexible during movement.

The 15’ kit and 18’ kit (each with one entryway, 7” EPS & one set of 2×4’s for temporary wooden rib system) can be picked up by the buyer if the following size truck, trailer and straps are used.

15′ kit: 

1/2 ton truck minimum (Ai recommends 3/4 ton truck )
13 ea.  2″ x 30′  straps Working Load Limit 3000 lbs.
Trailer specifications
7′ wide 20′ long minimum
tandem axle 3000 lbs. each axle
axles with brakes
bed height of 48″ max

18′ kit: 

1/2 ton truck minimum  (Ai recommends 3/4 ton truck )
13 ea.  2″ x 30′  straps Working Load Limit 3000 lbs.
Trailer specifications
7′ wide 22′ long trailer minimum
tandem axle 3000 lbs. each axle
axles with brakes
bed height of 36″ max

15′ & 18′ Kit:  If 3 ½” EPS and no drywall one truck can carry up to ten 15’ kits; or up to  four 18’ kits. 22’, 27′, 30′ and 34′ kits cannot be purchased with 3 ½” EPS.  The panels are too large in these larger kits to manufacture with thinner 3 1/2″ insulation. The 7″ insulation is required so the concrete panel is not flexible during movement.

For international shipping the following number is the number of 15′ and 18′ kits can fit in one 45′ high cube container.  To learn about importing, click on importing

Four 15′ kits with 7″ EPS, 1/2″ drywall, standard 4′ risers & 2′ risers & two sets of 2×4 ribs.
Eight 15′ kits with 3 1/2″ EPS, no drywall, standard 4′ risers & 2′ risers & two sets of 2×4 ribs.

Two 18′ kits with 7″ EPS, 1/2″ drywall, standard 4′ risers & 2′ risers & one set of 2×4 ribs.
Four 18′ kits with 3 1/2″ EPS, no drywall, standard 4′ risers & 2′ risers & one set of 2×4 ribs.

AVAILABILITY:  Depending on time of year allow 4 to 8 to 16 weeks after deposit with  Kit Order Form, Conditions of Sale with Material Order Agreement.

25% Discount —Residential Building Plans For Tiny Homes
When Plans Ordered per Coupon

To view samples of floor plan layouts, click on Stock Plans. If you do not see a stock plan to fit your desires, Ai can modify or customize a plan from your sketches and descriptions.  Each Set of Building Plans includes the floor plan layout(s) and consists of 13 – 17 blueprints depending on type of entryways and dormers in your kit.  To view sale pricing on all the stock plans and the dome building kit for each plan, click on Stock Plans & Kit Sale Prices.

Ai’s philosophy is that each Buyer pays for only what they need.  Ai does not burden the price of the building kit with plan’s pricing, engineer seal cost or energy report cost. Building plans are purchased three months to -1 1/2 years prior to kit shipment.  About 50% of the building departments require engineer sealed plans and an energy report to issue a permit. As a result, each customer pays for their plans separately from the building kit and pays for a seal and energy report only if their building department requires them.

Building Departments vary by state as to what they require to issue a new home building permit.  If you give Ai your parcel ID number & building department name, we will call and email info to them and find out what is required for them to issue a permit.  Will they require the building plans to be sealed and stamped by an engineer licensed for your state? Will they require an Energy Report?  If required these items can be purchased from American Ingenuity. To learn more about building permit, click on permit.

The standard foundation under Ai’s domes is a concrete slab. Other types of foundations; i.e. basements, stem wall, pilings, require the hiring of an engineer. Call for engineer pricing. Each buyer tells Ai the type foundation they want designed.  The foundation type is determined by property terrain, building department requirements and requirements from a soil report.

Plans may be purchased with a credit card, check or money order. Stock plans utilize a concrete slab foundation and are delivered within 2-4 weeks, Allow at least 5 modified plans and 8-10-12 weeks for custom plans.

SPECIFICATIONS

AREA AND VOLUME:   15’, 18’ & 22’ can have attic/loft. 27’, 30’ & 34’ can have second floor. 27’ & 34’ dome second floor can have bedroom because window dormer accepts fire egress window. 30’ dome panels are too small to have second floor window dormer; as a result 30’ second floor can be utilized for rec room, office, craft room, bathroom…not a bedroom.

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HEIGHTS:  Ai dome kits come with standard 4’ vertical riser panels before triangle geometry starts. 15’ & 18’ Kits come with standard 4’ risers & additional 2’ risers. 22’ & 27’ Kits come with standard 4’ risers or custom 5’ risers can be ordered w’ taller entryway & taller first floor door dormer base panels. 30′ & 34′ Kits come with standard 4′ risers. Ai cannot ship 5’ risers for the 30’ – 48’ dome kits because the five foot risers do not fit on the truck. For 30’ & 34′ kits custom 2’ risers can be installed above the standard 4’ risers with taller entryway base panels ordered

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WIDTHS:

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PANEL WEIGHTS:

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Two diagrams below represent geometry for 15’ & 18’ w’ 4’ risers & additional 2’ risers. 22’ & 27’ have 4’ risers or 5’ risers. 30’ & 34’ have 4’ risers or additional 2’ risers can be installed above the 4’ risers.

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INSULATION:                                                     3 1/2″ EPS                                               7″ EPS
THERMAL RESISTANCE:                                R-14                                                          R-28
THERMAL CONDUCTIVITY:                            K=0.0714 BTU/hr./sq.ft./F                      K=0.0357 BTU/hr./sq.ft./F

DOME GEOMETRY:  Frequency is the number of intersections from the center of one pentagon to the next.

  • 15’, 18’, 22’, 27’ domes are 2-frequency, 1/2 spheres. 15’ & 18’ are on 4′ vertical risers plus 2’ risers. 22’ & 27’ domes are on standard 4 ’ risers or custom 5’ risers.
  • 30′ & 34′ domes are 3-frequency, 3/8 spheres on a 4′ vertical riser.  30′ & 34′ domes can have additional 2′ riser installed above 4′ standard riser.

 

Conditions and costs may change requiring our prices to increase without prior notice.

AMERICAN INGENUITY, INC.
8777 Holiday Springs Road, Rockledge, Florida 32955-5805
PHONE: 321-639-8777
email: GlendaB.Aidomes@gmail.com