Building a Dome | AiDomes

EXTERIOR Schoonover

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

Q: Why did the founder of American Ingenuity in 1975 decide on the dome shape for his commercial dome to be built in Melbourne Florida?  

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. 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 and received a patent.  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 exterior having a 225 mph wind and F4 tornado guarantee and super-energy efficiency.

The process of stacking the panels, overlapping/locking the 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 surface; and 3) installs all the R28 insulation.  Ai’s component panel building system is the most simplified way to build a commercial or residential building on the market today.  

During the past decade the buying public has experienced 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 kit home technology to help address these concerns. In the last decade, many people have discovered that the dome design offers a viable solution.

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 and cost-effectiveness in a single structure. In short, the building concept of a dome expands the range of simple and economic building options.

Why build a geodesic dome – Strength and energy efficiency.  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 will.  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.

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, domes greatly exceed the structural requirements of the major building codes in the United States.  Ai gives a 225 mph wind and EF4 Tornado warranty on the dome exterior walls.  The interrupted R28 insulation causes cooling and heating bills to be 50% to 60% less than the same size conventional structure.  In the Ai dome there is no wood in or on the exterior shell to interrupt the insulation, to rot, or to burn or for termites to eat.  There is no roof to replace every 11-12 years. The exterior concrete is painted  4-5-6 years with breathable elastomeric paint.

One of the most exciting architectural environments ever designed, a dome brings its best attributes to your 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.

 

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.

 

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

10th Step-Foundation, Kit Assembly.  Your Aidome building plans contain blueprints showing foundation type, dimensions and details for footers and  foundation rebar installation.  If you are located in the USA, after your plans are finished, two sets of building plans (either 18″ x24″ or 24″ x36″) will be shipped to you.

If Buyer lives outside the USA and the plans are not engineer sealed, there is no need for Buyer to pay shipping costs on the plans, Ai emails the finished plans pdfs for printing in your country.

Ai emails the finished pdfs to each Buyer so the pdfs can be emailed out to receive price quotes from subcontractors, or builder or the independent Kit Assembly Consultant.

Buyer can email the pdfs to Office Depot, or Staples, etc. and have extra sets of building plans printed locally.  These extra sets can be given out for bids on your foundation, dome assembly, exterior finishing and interior finishing.

Buyer accept bids for the foundation work and has the foundation installed. It is quite normal that the foundation does not get installed when planned due to weather, etc.   Accepting delivery of your dome kit is not dependent on your foundation being installed.  The dome kit can be stored on your site 2-3 months (in nonfreezing weather) waiting for the foundation to be installed.  Longer storage can be achieved by spraying another layer of paint on the EPS if needed.

After the foundation is installed, the kit assembly & temporary wooden rib system assembly begins.   There is a total of five rows of dome panels to be installed on to the temporary wooden supports. The first row of panels is installed directly onto the dome’s first floor. This floor is concrete if it is a concrete slab and wood if the dome is built on a basement.  All the prefab panels are numbered with numbers and letters to match the nomenclature blueprint in the Building Plans and the Assembly Manual that is shipped with each dome kit.   After a kit deposit and signed Order Forms are received, Ai can mail the manual to Buyer.

Once all the panels are installed with two layers of concrete in all the seams and on the entryways and dormers, link, cupola, etc., the dome is self-supporting and the temporary wooden rib system comes down.  There is no wood in the dome exterior walls to interrupt the insulation or to burn or to rot or for termites to eat.  Most of the wood can be used for interior framing, especially the knee wall around the second floor perimeter area.

In the dome there are two main sizes of triangle panels, named P or H.  Five P panels are installed together to make a Pentagon configuration.  Six H panels are installed together to make a Hexagon configuration. So when a panel calls for a P, your workers look in a stack of P panels and pull a P panel.  When the plan calls for an H, your workers look in the stack of H panels and pull a H panel.

The entryway and dormer panels are identified with specific numbers and letters and are installed in the row of panels shown on the blueprints. At specific locations around the perimeter of the dome, triangles and riser panels are left out to provide openings where the dome owner or their framer installs locally purchased exterior doors and windows. To structurally compensate for the triangle and riser panels being left out, these “structural awnings” – entryways, dormers or link or cupola are installed.

The Ai dome kit consists of all the triangular panels, four foot tall riser panels for the dome shell and panels for one entryway.  The exterior of each triangle or riser panel is 3/4″ concrete reinforced with fibers and galvanized steel mesh with a center of  7″  R28 noncombustible Expanded Polystyrene insulation (EPS) with interior 1/2″ Georgia Pacific DensArmor (moisture resistant/mold resistant gypsum drywall) adhered to each riser and triangle panel with drywall adhesive.

Your floor plan selection determines how many more entryways (standard, garage or high profile), window dormers, door dormers, cupola, link, etc. will be ordered. The link is used to connect two domes together.

The building kit does not include any doors or windows and does not contain any interior items (except for the interior shell drywall and insulation).  American Ingenuity believes that you should not pay shipping on items which can be purchased locally.

8th Step – Site Clearing & Install Utilities.   Before removing any trees or disturbing any soil or plants obtain required permits.

Driveway ConstructionTo install a driveway from the main street or road to your house site, a permit may need to be issued showing culvert size, driveway width, driveway height, etc.  Please ask your building department about this.  The dome building kit will be delivered on a semi-truck that is 70 plus feet long.  If there is no turn around on your property, the truck can park at the street with the panels being forklifted or trailed to the site.  If the truck will be parked on the street, a permit may need to be obtained so you can block one lane of traffic.  Ai’s truck unloading document covers this possibility.

Install utilities as needed on your property

  1. If you have city water and sewer then there are minimum setbacks where nothing can be built next to these lines.  If you install a septic tank and drain field, the Health Department for your city or county will have requirements for size and setbacks from the tank and field where nothing can be built.
  2. Check your notes as you will have the phone number to call the Electric Power Company for installation requirements for your temporary electric power pole, lines & meter.

Clear site where your foundation will be installed and where dome panels will be stacked on pallets or boards.

To obtain the correct finished floor height, the building department will probably require a survey be taken from the crown of the nearest county or city maintained road to your building site location.  The floor is supposed to be so many inches above the crown of the road. Also if you property is in a flood zone, your floor height will be based on the mean high water mark when the property is flooded.  This height will determine if fill has to be brought in and compacted or if your home has to be built on pilings or columns. Soil under a foundation is to be compacted to 2,000 pounds per sq.ft load bearing pressure. If your soil will not compact to this number, the engineer could design the slab to be 6″ thick instead of 4″ and the footer size could change from 20″ tall to 16″ wide to 20″ tall and 20″wide. Each slab and footer size will be based on your soil psf.

If your home has to be built elevated, for Ai to design your foundation the independent engineer who assists in the design requires a soil report.   In this report a soil engineer recommends the type foundations which can be installed on that soil.  Ask local foundation subcontractors cost to build the different types of foundations and decide which one you want Ai to design.

4th Step – Property Checklist.  Below are some items to be considered before purchasing property.  Please see the buying land document for entire list of items to consider. Set up appointments with your County or City government officials to find out the following (keep their names and phone numbers as to who you talked to):

  1. Meet with someone in Zoning and find out the set backs on your property.  Front, back and sides.
  2. Meet with someone in Natural Resources
    • See if property is in a flood zone. If in a Flood Zone a FEMA Finished Floor Height Elevation certificate may be needed.   (is called different things, but basically FEMA knows the height your finished floor has to be in order for insurance companies to sell flood insurance to you. It is very important that you know this height and give it to Ai as the height has to go on your building plans.)
    • does the site have wetlands?  If wetlands, what areas on the property can be built on?  Do you have to mitigate wetlands in order to build on that property?
    • are there any endangered plants, trees, birds or animals on the property?  To know this do you have to hire person to evaluate the property and submit a report to the county?
  3. Meet with Plans Examiner and get a list of all paperwork that is required to be submitted for a new home building permit. In Florida all new home construction requires Fl engineer sealed building plans and passing Florida Energy Report. The plans, engineer seal on the plans & energy report can be purchased from Ai.  But what else do they require?   Site map, survey showing land elevation? permit for septic tank from Health Dept, well permit if not city water, electrical/plumbing/HVAC diagrams?, etc.
    • Obtain a copy of the front, back, and side setbacks.  And set backs from sewer or water lines or septic tank/drain field and well.
    • Is there a county maintained road for you to build a driveway off of?
    • Are you required to build a garage with the house? Is there a size requirement on the garage?
    • Is there a minimum size house requirement?
  4. Call the Electric company
    • Ask where the nearest electric pole is to access to get power to your site?
    • How much will it cost to get electricity to the property you are considering buying?
  5. Is there a survey of the property that shows the height of the property vs the height of the crown of the nearest county maintained road?  How much fill has to be brought in and compacted to get the finished floor height required for that area?
  6. Can you obtain a permit to stay in RV or temporary small mobile home, during dome construction if desired?
  7. Will the soil on the property perk for a septic tank permit if there is not city sewer?
  8. Can a well be drilled if there is not city water? Are there ledges of rock that cause a well to not be drilled?

Cement Home built on concrete slabs & two photo galleries.
One showing construction pictures, the other shows finished exterior & interior. 

“In the six years since we have moved into our double dome home (45′ & 34′) we have only increased our enthusiasm for this structure. There is something about the interior space that is very liberating and imaginative. One of the main reasons we built the Ai domes was its noncombustible concrete exterior. Our home site is surrounded by forests that can burn at any time. So it gives us great comfort knowing their is no roof to burn & no exterior wood framed walls to burn.”  (Ron Kaufman & Marti Leicester, happy Ai Dome Owners)  

To view an article about their domes published in the Butte Environmental Council’s (BEC) News, click on Chico News.

Photos of Dome Interior Finish

45′ & 34′ Kaufman/Leicester Domes in California

(Click on small images to change picture or use arrows in lower right side)

Assembly Photos California Concrete Dome Home

 

(Click on arrows left and right side of picture to view the next picture)

PDF for Downloading & Printing

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Stairs in dome.  Free form, L shaped, Spiral. Below is Photo Gallery showing various ways that stairs are built within the American Ingenuity dome. Stairs can be free form as shown in the Connecticut dome, built in with storage underneath, spiral stairs, welded contemporary stairs to traditional oak stairs. If a cupola is installed at the top center of the 40′ or 45′ or 48′ in diameter domes then a small loft above the second floor is possible. Access the loft with a drop down ladder or a ships ladder.

(Click small images to change picture or use arrows on lower right of picture)

Welcome to a Photo Gallery showing various dome exterior photos of the American Ingenuity Dome.  Depending on your exterior door and window selections, locations of entryways/dormers, decks and landscaping, the dome owner can design the dome exterior to fit their lifestyle.  Some owners decide to install all five of the first floor entryways to maximize natural light.  Other home owners desire a more private dome with fewer openings. All is up to you and your personal tastes.

(Click arrows in main picture to change pictures)

Interested in Tiny Dome Home Kits for Special Hideaway, vacation cabin, second home, guest house, hunting cabin, glambing, tiny home, micro home, cottages for resort, mother in law home, rental units for veterans, or starter home? The Ai dome is much stronger, has noncombustible materials in its wall panels, fire resistant concrete exterior & more insulated than a log cabin, concrete block house, framed structure, tent or yurt.  Exciting News 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. Below is single photo of 22′ dome and below that is Photo Gallery of various Tiny Home Photos.  Scroll below to see Ai’s sample stock floor plan layouts for Tiny Homes (172 sq.ft. to 1,278 sq.ft) and photos.  To view sale pricing for the kits shown in the layouts, click on Tiny Home Kit & Plans Sale Pricing.

22-woods-demo

Photo is of Assembled 22′ Kit – 370 sq.ft.
Ai has 15′ & 18′ & other Tiny Home Kits. See Below.

(click small images to change pics or use arrows on right side of main pics)

The following three floor plans are the layouts

that were built in the domes featured in the above photo gallery.

 New Mexico – Floor Plan -Three 22’ Domes

South Carolina – Floor Plan – 22’ Tiny Home

Florida – Floor Plan 22’ Workshop Dome

Within the top photo gallery there are pictures of three different 22′ domes which were built from customized 22′ plans. 

  1. The New Mexico – three 22′ domes were built for a 1,189 sq.ft. vacation home.  To view photo gallery containing other photos of the NM domes, click on three 22′ domes.
  2. The South Carolina 22′ dome was built as a one bedroom one bath tiny home of 388 sq.ft including storage area. Separate 12′ Pod has 109 sq.ft. for washer and dryer.
  3. The Florida 22′ dome was built for a 349 sq.ft. work shop.

American Ingenuity’s Tiny Dome Kit assortment consists of six kit sizes measured in diameter by feet: 15′, 18′, 22′, 27′, 30′ & 34′.  These domes have square footage from 172 to 1,278.   Below are stock plans for the 15′ – 34′ domes and pictures of a 34′ dome home with other info.  To view regular and sale pricing with specifications on the 15′, 18′, 22′, 27′, 30′ & 34 click on Tiny Dome

  1. 15′ – 172 sq.ft. – one bedroom one bath size – one floor with optional attic/loft.
  2. 18′ – 249 sq.ft. – one bedroom one bath size – one floor with optional attic/loft.
  3. 22′ – 370 sq.ft. – one bedroom one bath size – one floor with optional attic/loft.
  4. 27′ – 786 sq.ft. – two bedrooms two bath size – two floors. Two frequency geometry that allows for 2nd floor egress window.
  5. 30′ – 1,089 sq.ft. – one bedroom one bath size on first floor. No egress window on second floor (3 freq)…use second floor for storage, office, work shop, additional bathroom or craft area.
  6. 34′ – up to 1,100 – 1,278 sq.ft. – two bedroom two bath size – two floors.  Second floor window dormer panels will not accept fire egress size window. As a result  a second floor door dormer is installed above above a first floor standard entryway to frame in egress window.

As far as Tiny Homes meeting minimum size house requirements – in some areas groups are petitioning their county or their city governing bodies 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 172 sq.ft.

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15′ Tiny Dome Stock Floor Plans

15′ Dome: one bedroom one bath Tiny Home with first floor of 172 max square feet. The dome kit comes with standard 7″ R28 insulation, standard four foot risers and additional two foot risers. Please check your local building code requirements to see if there is a minimum size new home requirement. In Florida the minimum size new home that can be built is 170 sq.ft. or 500 sq.ft. or 800 sq.ft. or 1,000 sq.ft. And in some areas building code requires a garage. An attic loft can be designed.

15′ dome kit can be purchased with 3 1/2″ EPS and no 1/2″ interior drywall. Up to Ten 15′ kits with 3 1/2″ EPS & no 1/2″ drywall can fit on one 53 foot step deck semi-truck  Or up to five 15′ kits with 7″ EPS & 1 2″ Drywall can fit on one semi-truck.

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18′ Tiny Dome Stock Floor Plans

18′ Dome: one bedroom one bath Tiny Home with first floor of 249 max square feet. The dome kit comes with standard 7″ R28 insulation, standard four foot risers and additional two foot risers.Please check your local building code requirements to see if there is a minimum size new home requirement. In Florida the minimum size new home that can be built is 170 sq.ft. or 500 sq.ft. or 800 sq.ft. And in some areas building code requires a garage. An attic loft can be designed.

18′ dome kit can be purchased with 3 1/2″ EPS and no 1/2″ interior drywall. Up to four 18′ kits with 3 1/2″ EPS & no 1/2′ drywall can fit on one semi-truck. or two 18′ kits with 7″ EPS can fit on one semi-truck.

22′ Tiny Dome Stock Floor Plans

22′ Dome:  one bedroom one bath size dome home with only first floor with max square feet of 370. Please check your local building code requirements to see if there is a minimum size new home requirement. In Florida the minimum size new home that can be built is 500 sq.ft. or 800 sq.ft.   And in some areas building code requires a garage. A storage loft can be designed.

27′ Tiny Dome Stock Floor Plans

27′ Dome:  two bedroom one bath size dome home for max square feet of 786 on the two floors (555 on the first floor and max 231 sq.ft. on the second floor).   Due to spherical dome shape, the 27′ dome’s second floor exterior walls slope down from 9’1″in the center to the floor.  Code allows for square footage to be calculated to five feet of height.  The 231 second floor square footage in the 27′ dome is the area that is below the 9’1″ center to where the dome walls slope down to five feet tall.  Around the second floor five foot perimeter areas the following items can be placed:  headboard for bed, night tables, desks, or dressers.  

All American Ingenuity domes can be designed without a second floor.  The total amount of square footage in each plan varies depending upon how much of the second floor is designed and built. If you want to look at only plans with a bedroom on the first floor that can be utilized as master bedroom, we have added the words bedroom 1st floor with that plan name.

30′ Tiny Dome Stock Floor Plans

30′ Dome:  one bedroom one bath size dome house total 878 square feet on two floors.  Bedroom is designed on the first floor. The 30′ domes second floor panels are too small to accept a window dormer.  As a result a bedroom cannot be installed on the second floor because there is no fire egress window. The second floor could be used for storage or office area, craft room, etc.  (665 on the first floor and max 213 sq.ft. on the second floor).   Due to spherical dome shape, the 30′ dome’s second floor exterior walls slope down from 8’4″in the center to the floor.  Code allows for square footage to be calculated to five feet of height.  The 213 second floor square footage in the 30′ dome is the area that is below the 8’4″ center to where the dome walls slope down to five feet tall.  Around the second floor five foot perimeter areas the following items can be placed:  headboard for bed, night tables, desks, or dressers.  The 30′ dome can be built without a second floor.

34′ Tiny Dome Stock Floor Plans

34′ Dome two bedroom two bath size dome house total 1,278 max square feet on the two floors.  Bedroom & bath on first floor and bedroom & bath on the second floor.  (852 on the first floor and max 427 sq.ft. on the second floor).   Due to spherical dome shape, the 34′ dome’s second floor exterior walls slope down from 9’9″ in the center to the floor.  Code allows for square footage to be calculated to five feet of height.  The 427 second floor square footage in the 34′ dome is the area that is below the 9’9″ center to where the dome walls slope down to five feet tall.  Around the second floor five foot perimeter areas the following items can be placed:  headboard for bed, night tables, desks, or dressers.  

The 34′ dome can be designed without a second floor.  The total amount of square footage in each plan varies depending upon how much of the second floor is designed and built.  If you want to look at only plans with a bedroom on the first floor that can be utilized as master bedroom, we have added the words master 1st floor with that plan name.

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Have you dreamed about living in a super-Green, super strong home? Would you like good living in small spaces? American Ingenuity has the solution for you.  Choose from six sizes: 15′, 18′, 22′, 27′, 30′ or 34′ tiny domes. Or utilize the 15′-34′ domes to build a small vacation home, glambing dome, get-a-way or work shop dome. Can’t envision living in such a tiny home, view Ikea YouTube to see video filmed by an Ikea customer in Ikea store.
The 22′ dome can also be a built as a one car garage dome.   The 27′ dome can be built as a two small to medium car garage.  This link has garage dome info.22' Exterior solar Pineapple garage

 22′ dome utilized as one car garage linked to 34′ – 1,075 sq.ft. dome home

Each prefab panel’s core is 7″ EPS (expanded polystyrene) R-28 insulation precisely angle cut to form the geodesic shape.   Applied to the outside is pre-finished three quarters inch concrete, reinforced with galvanized steel mesh and fibers.  Applied to the interior is half inch Georgia Pacific DensArmor gypsum wallboard….gypsum’s facing is fiberglass instead of paper.  Wallboard is moisture resistant and mold resistant. No wood in or on the shell to rot or for termites to eat or to burn.  No shingles to blow off in high winds.  On site after the kit is assembled, the exterior concrete is primed and painted with paint. The 15′ and 18′ dome kits can be purchased with 3 1/2″ R14 EPS, no interior 1/2″ drywall & no steel reinforced concrete exterior.  Larger domes cannot be purchased this way because the larger size panels cause the EPS to be flexible and break.

The kit assembly begins after the foundation and floor are completed and a temporary wooden rib system is assembled in the geodesic shape.  The assembly process consists of stacking the panels on the 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 tape and joint compound.  This process produces the structural components, completes the finished exterior surface, installs the insulation and all the interior shell wallboard.  To view a video on the 22′ Assembly, view Special Hideaway.  To view pictures showing general panel assembly, view Dome 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.

All panels are premarked with numbers and letters to match the building plans and the Assembly Manual. The most successful dome kit assemblies result when the home owner hires the independent Kit Assembly Consultant to supervise the temporary rib system assembly & the kit assembly. If your budget is tight consider hiring the Consultant for a minimum of three days to supervise the rib system assembly, concrete mixing and first row of panel assembly…..just to get you started.  If you desire to hire a builder, he or she can hire the Assembly Specialist to supervise their workers to get the dome kit assembled with the first layer of concrete in the seams and on the entryways and dormers.  To view Ai’s web site file about the independent Specialist, view Specialist.

Prior to assembly of the dome kit, a temporary wooden rib system is assembled using your own 2×4’s cut to specific lengths (or purchase the cut, drilled, painted 2×4’s from Ai), bolts/nuts/washers purchased from Ai  and steel hubs borrowed from American Ingenuity by placing a $455 deposit.  This deposit covers a 5 month rental period ($20 a month thereafter).  Once the dome kit is assembled, the rib system is removed with the client mailing or UPSing the hubs back to Ai to receive a deposit refund.  Triangle Panels weight 155 to 180 lbs. Risers weight 255 lbs.  During assembly the panels are placed with some type of hoisting mechanism.  Lifting spikes are purchased from Ai.  To view American Ingenuity’s web site file that explains the rib system, view Support System. If importing the kit out of the USA, buyer purchases the steel hubs from Ai.

Please check with your building department, some have minimum house square footage requirements .  If the 15′, or 18′ or 22′ dome may not meet their requirements. Ai manufactures a 27′ in diameter dome that can have 555 sq.ft. on the first floor and 225 sq.ft. on the second floor for a total of 780 sq.ft.  To view Ai’s web page that lists the dome sizes with their square footages, view Dome Sizes.

Please contact your building department and ask:

  • If there is a minimum size new house requirement?
  • Do they require a garage to be built with the house?  If so is there a minimum size garage requirement?
  • What do they require to issue a building permit?  Do they require engineer sealed plans and an Energy Report?  If so, those items can be purchased through American Ingenuity. The Energy Report has evolved into a very specific and technical report that requires Ai to have specific window and exterior door info (frame type, double pane or impact resistant glass), Low E number, U factor, SHGC number to fill out the Energy Report.  This means the dome buyer will shop for their exterior doors and windows and provide detailed spec sheets to Ai about each door and window, their water heater and AC/furnace.

Payments: American Ingenuity kits are not stocked and are manufactured on a custom order basis and are considered a Specialized Order, made exclusively for the customer requesting it.  These Specialized Orders require a 30% to 40%  deposit, signed Order Form, Conditions of Sale and Specialized Material Agreement. Once Ai receives these items, materials will be purchased and manufacturing started to meet your shipment date. If you cancel your order after signing the Specialized Agreement 30% deposit on each kit is non-refundable and your rights to the kit(s) are forfeited.  The balance, in the form of a cashier’s check or bank check including USA shipping costs (made out to American Ingenuity) is due 21 days prior to shipment. Florida residents, add sales tax plus your counties’ surtax.  Credit Cards are not accepted on the building kit. If the building kit is shipped out of Florida, no Florida sales tax or surtax is paid. If kits are exported, buyer pays freight forwarder directly for inland trucking costs and ocean shipping costs.

Delivery and Availability:  Once Ai receives your 30% or 40% deposit (deposit amount depends on kit size) based on your Building Kit with options pricing and signed Building Kit Order Form, Conditions of Sale and Specialized Material Agreement, American Ingenuity schedules your kit for manufacturing. Depending on the time of year and size of dome, allow four to six to twelve weeks for manufacturing time.

SHIPPING: If your site is in the continental USA, American Ingenuity can arrange shipping on 53’ step deck semi-truck. Freight varies from $2.70 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.

For international shipping the following is the number of 15′ and 18′ kits that can fit in one 45′ high cube container. To learn about importing, click on importing.  2×4 ribs refers to 2×4’s that are cut, drilled & painted to specific specs for the temporary support system described above.

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.

The number of kits that can fit on one truck or in one container can change if the building kit contains maxed out entryways, dormers, link and thicker insulation. For example, a 48′ kit with 9″ EPS cannot fit on one semi-truck.  Entryways and a link take up more space than triangular and riser panels.  Once you select your floor plan, Ai can be specific about how many truck(s) or containers your order will take. Each International client hires a freight forwarder to coordinate their container’s shipping and pays their shipping and custom fees directly to the freight forwarder.

Ai’s manufacturing costs in Florida are well below the national average, which offsets any long distance shipping expenses. Ai can actually manufacture a kit here in Florida and ship to western states – Washington, California, Nevada, Oregon, Utah, Arizona, etc. cheaper than we could manufacture it 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. American Ingenuity contracts to have these trucks carry your building kit outside Florida for approximately $2.50  to $2.90 per mile per truck from Ai’s plant in Rockledge, Florida. Shipping within Florida is a minimum of $800. If your Florida building site is south of our factory, the truckers charge more because they have to drive south before they can drive north to leave Florida.  These trucking costs are less than Ai could do with our own trucks because if we used our own trucks, they would have to deliver the kit and return to our factory empty.

Per mile shipping costs can vary due to fuel costs and travel distances. View Shipping to learn more.

American Ingenuity’s Philosophy:

One of the main reasons American Ingenuity is very reputable is that we really try to treat all our customers the same. Our business philosophy and product is unique to the housing industry. Ai believes that each client should pay for only what they need.

  • Each person who wants to research our building kit further can do so by purchasing the Planning Kit with DVD or purchase the DVD separately.
  • None of Ai’s staff is on commission.
  • About 40% of Ai’s clients do not need engineer sealed building plans, or Energy Report or Structural Calculations in order to obtain a building permit. As a result the seal, energy report and calculations are separate costs and paid only by those whose building departments require them.

As a result of the above philosophy, the American Ingenuity dome shell kit costs about one third to one half less than the shell materials cost for a conventional house or wooden dome or sprayed concrete dome.

Due to spam filters your email requests may not make it to American Ingenuity and our email replies may not make it back to you.  If you email Ai and do not receive a reply in one to two days, please call us – 321-639-8777.  While you are on the phone, we will send you a test email and have you send your email to us.

The information below is in reference to a specific 22′ floor plan named Eco Custom Cottage.

This is a 22 foot in diameter dome kit, which Ai has customized. Please call for pricing. This custom 22’ in diameter dome when finished has a first floor living space of 371 sq. ft. with an optional attic of 127 sq. ft. Ai has raised the riser wall height from four feet to five feet.  The additional one foot in height increases the attic square footage to 127 sq. ft., which is an additional 46 sq. ft. over the basic 22’ dome building kit.  The exterior of each triangle & riser panel is steel reinforced concrete.   The middle of the panel is 7″ EPS insulation (R-28) with 1/2″ Georgia Pacific DensArmor Gypsum drywall adhered to the underside of the EPS with wallboard adhesive.  Ai has based the pricing for this kit upon Ai selecting the week/day of shipment during the month agreed upon by Buyer & Ai.

 

22 Ft Dome

 

22′ Eco Custom Cottage Floor Plan PDF Picture

This Eco Custom Cottage Kit consists of all the component prefab panels to assemble the dome shell, one entryway, two window dormers, one door dormer and misc items. No windows or exterior doors are included.  No interior items are included other than the interior 1/2″ Georgia Pacific shell drywall.  Call American Ingenuity for shipping details.   Does your building department require engineer sealed plans and an Energy Report to issue a building permit?  If so those items can be purchased through Ai.

Approximate room sizes once the interior walls are framed in:  Bedroom 10’10” x 7′; closet 2′ x 6′; living 7’5″ x 10’7″; kitchen 11′ x 10’7″; Washer Dryer area 3’5″ x 3’3″; Bath 7’3″ x 9′.  Approximate attic area between five feet six inches and seven feet ten inches in height is 109 sq.ft.

22’ Eco Custom Cottage Dome Building Kit Package Includes:

  • All the prefab panels to assemble the 22’ shell with 7″ EPS, five foot tall riser panels and the panels for one entryway, two window dormers, one door dormer.
  • Assembly Manual
  • Parts lists items to suspend the optional attic: 7suspension rods with top and bottom plates with Simpson Hangers.
  • 8 cans of expanding foam. Metal Dispensing Gun, and two cans of cleaner.
  • Five – 4×8 sheets of 1” EPS insulation for entryway, door dormer, window dormer framing
  • 134 sq.ft. of ¼” x ¼” galvanized steel mesh as lathe for entryway, door dormer and window dormer framing 
  • Misc. items: C rings, two pair C ring pliers, bonding agent, synthetic fibers and liquid admixtures A & B for cement and two steel cables (wrap around dome).

The Kit does not include building plans, engineer seal on plans, energy report, shipping cost, foundation (monolithic slab), assembly costs, purchase of lifting spikes , purchase of 144 bolts/nuts/washers, deposit on 26 steel hubs, precut 2×4’ ribs for rib system, framing for doors and windows, or any interior items except for the interior shell wallboard.  The deposit on the hubs is refunded once the hubs are mailed or UPSed back to Ai during the five month rental period. A rental costs for each month over five is $20. If importing kit, hubs are purchased, rental for telescoping for lift is added and $200 international paperwork fee. View Importing for complete details.