Prices & Finished Cost | AiDomes

Building Plan Composition 

To keep things simple, the basic dome building kit comes with all the prefab panels for the dome shell and panels for one entryway.  Each floor plan layout varies as to the type and number of entryways and dormers needed for that plan.  For dome structural integrity, wherever an opening will be located in the dome shell where your locally purchased doors and windows will be framed in, a structural awning has to be installed. We call these structural awnings building options and name them entryways and dormers.  Where a vertical framed wall is wanted or where French Doors or multiple windows or large windows are framed in on site, an entryway is installed – it can be standard (8′ tall) or high profile or garage.  High profile is used in a high vaulted ceiling areas and can have fixed glass above standard 6’8” doors.  Or in a HP entryway, tall 8’ doors could be installed with fixed glass above. During the plans design, Ai emails you elevation views of the entryways and dormers showing the width and height available for windows/doors or single windows or single doors.  Our Computer Aided Drafting Department, CAD, makes recommendations for door and window sizes.  But because you have the elevation views,  you can choose to have larger or smaller windows or doors. Where a single window will be framed in a window dormer is installed. Where a single door will be framed in a door dormer is installed.

What are the contents of your Building Plans? Stock sets generally have 13-17 pages per each set. Building plans include the basic drawings for the dome that are needed when acquiring a building permit. They are composed on our computer aided drafting system as stock plans, or based on your individual requirements and design. Some of the pages are a 3-D elevation and a 3-D perspective view.

American Ingenuity’s Building Plans contain all of the typical drawings and details found in new home plans – usually 13-17 sheets. The blueprints included in your plans are based on the type of entryways, dormers and foundation that are designed in your plans. Some of the Blueprint names are:

    • Cover Sheet
    • Legend Sheet
    • First Floor Plan
    • Second Floor Plan
    • Dome Panel Nomenclature
    • Exterior Elevations
    • 1st Floor Electrical Plan (shows location of electrical outlets, lighting fixtures, smoke detectors)
    • 2nd Floor Electrical Plan (shows location of electrical outlets, lighting fixtures, smoke detectors)
    • Foundation Plan
    • Foundation Details
    • 2nd Floor Framing Plan
    • Typical Dome Section
    • Standard Entryway Details
    • High Profile Entryway Details
    • 1st Floor Window Dormer & Door Dormer Details
    • 2nd Floor Dormer Details
    • Stair Details
    • Cupola Blueprint if ordered
    • Link Blueprint if ordered

 

To obtain a building permit, the following items may be needed: Engineer Seal on the Building Plans, Structural Calculations, Energy Report, Engineering Statement,

It is Ai’s philosophy that each Buyer pays for only what they need. Ai does not burden the price of the building kit with building plan’s pricing, engineer seal cost, structural calculations or energy report cost.  Building plans are purchased three months  to two 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 buyer pays for their plans separately from the building kit and pays for a seal, calculations and energy report only if their building department requires them.  If you give us your property address or tax ID number & building department name, at no cost to you, Ai will call the plans examiner, email a sample of building plans if needed and inquire what is needed to obtain a building permit on the American Ingenuity dome kit.

Once Ai knows which size dome and whether you prefer a stock plan or modified or custom plan, Ai can complete a Plans Quote that lists regular and sale price on the dome plans, other plans if not slab foundation (basement, pilings, etc.), Engineer seal cost and energy report cost if required by your Building Department and any engineer design fees.  Once you agree to the Plans Quote and pay in full, Ai will start the design of your building plans.

Although over 30 different engineers have reviewed our Building Plans over the years, the plans do not come with an engineer’s seal for the following reasons.  About half of our dome owners need engineer sealed Building Plans to obtain a building permit. Rather than adding the engineer cost to all plans or burden the price of the building kit, it is more economical for each buyer to pay for the engineer if needed.

  • As the designer and manufacturer, Ai would not hesitate to guarantee the structural integrity of our dome and we do just that with our 225 wind and EF4 tornado warranty.
  • Each state only accepts a seal from an engineer who is registered in that state which prevents us from applying a seal that would be universally accepted.
  • When an engineer seals a set of plans he is taking responsibility for the structural design for a single dome in the location intended and the seal would not apply to other projects

Engineer Seal Cost  & Engineer Design Fee For Foundations Other Than Slab

Professional Engineer (PE) Seal Cost:  If required by your building department a PE Engineer licensed for your state affixes his seal on the structural pages in the blueprints and signs each seal.  For all states other than Florida, the PE engineer seal fee for one dome on a slab is $600. Two domes on slabs is $900.  For Florida Ai utilizes a different PE engineer to seal the plans.   His seal fee for one small dome on a slab is $450.   His fee for one 36′ or larger dome on a slab is $500.  Fl Seal Fee for two domes on slabs is $800.

Florida Licensed PE Engineer design fee for foundations other than slab:   Standard foundation is monolithic slab.  If basements or stem wall,  design fee is $200 to $300.  Call for Pilings and Concrete Columns design fee.

Engineering Statement comes with Engineer Sealed Building Plans at no additional cost. To view an example of an Engineering Statement on Aidomes, click on Statement.

Structural Calculations Fee

If required by your building department, an engineer licensed for your state can perform structural calculations for your specific floor plan and dome  size based on your area’s design criteria. PLEASE NEVER ASK A BUILDING OFFICIAL IF THEY REQUIRE STRUCTURAL CALCULATIONS BECAUSE THEY WILL SAY YES.  Always wait and see if the subject comes up.  Generally the engineer seal on the plans and the engineering statement should be sufficient.

For example Structural Calcs were completed at a cost of $1,400 on one of Ai’s largest size domes –  a 48′ dome built in Banning California with design criteria of Seismic Zone D, Wind Speed 110, Wind Exposure C, Snow Load 38 psf.   Costs for calculations for smaller domes are less than $1,400 and vary based on dome size and whether Seismic criteria has to be included.

Energy Report Fee

Some building departments require an Energy Report when the building plans are submitted.  The Report calculates the energy efficiency of the building envelope….walls, exterior doors and windows.  In most states other than California, Florida and possibly Washington, if an Energy Report is required, the building department will accept a Rescheck Energy Report.  Ai can complete this report once you provide specific door, window and equipment answers.  Ai has a questionnaire which we email each buyer that lists data we need to complete the report.

The fee to complete the report for one dome on a slab is $190. Two domes on slabs is $270.  One dome on a basement – $270

What paperwork is required to obtain a building permit in Florida? To obtain a building permit for new construction in Florida, Florida Engineer Sealed Building Plans and a Florida Energy Report are required along with other paperwork. The seal and energy report can be purchased from Ai.

Can American Ingenuity complete the California Title 24 Energy Calculations that are required to obtain a building permit in California? No, but we can put you in contact with a California firm who can complete the Title 24 energy calculations for Ai’s dome. Normally their fee is $200 to $300 for one dome on a slab.

 Dome Building Kit Shipping Costs

Why did a buyer near Australia pay $18,000 in shipping costs to receive one 34’ dome kit shipped in a 40’ high cube container?  And why did a California buyer pay $6,500 for one truck to deliver their 48’ in diameter dome kit.  Simply put, these buyers could not build a home or buy any house that has the energy efficiency, strength and noncombustible concrete exterior that the American Ingenuity dome has.  

The Ai dome is more energy efficient, stronger & has less exterior maintenance than a conventional house or mobile home: Why?

  1. Because of the thick insulation which is comparable to 11” of fiberglass batting (A conventional house would need min 2×12 walls filled with 11” 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 (30% less than a conventional house so less exterior walls for your AC and Heat to pass through)
  3. and because the exterior walls of Ai dome contain no wood to interrupt the insulation.
  4. There is no wood in or on the dome shell to rot or to burn or for termites to eat.  (The Ca buyer purchased the dome because their wood house burned and they wanted a new home with a noncombustible concrete exterior that was super-energy efficient.)
  5. There is no roof to replace every 11-12 years.  After the dome kit is assembled, the exterior concrete is primed and painted with two coats of breathable elastomeric paint.  The exterior concrete is repainted every 4-5-6 years.
  6. The dome is stronger (225 mph wind and F4 tornado due to aerodynamic shape, continuous steel reinforced concrete exterior and triangle panel shape.  To view Ai dome advantages summary, click on Summary.

Shipping Costs:  Each dome kit 27’ thru 48’ requires one semi-truck for delivery. Ai does not provide any interior fittings or interior walls (i.e. plumbing, kitchen, flooring), nor do we supply windows and doors (standard sizes used, locally available, purchased by you). Ai believes the buyer should not pay shipping costs on another truck to receive items that can be purchased locally (windows, doors, flooring, bathroom fixtures, kitchen cabinets, etc.).

Shipping: Minimum shipping cost is $800 within Florida. If delivery is into southern Florida, kit shipping will be more than $800. Shipment out of Florida is approximately $2.50 – $2.90 per mile for a 53′ long step deck semi-truck. Shipping is from Ai’s plant in Rockledge, Florida (zip 32955).  Please call for quote. One truck can carry one 27’, 30′, 34′, 36′, 40′, 45′, or 48′ Kit or one 22’ & one 27’ kit or two 22′ Kits with standard 7″ insulation. 45′ or 48′ kits with 9″ insulation require two trucks for delivery. USA arrangements for shipping is made by American Ingenuity or you can coordinate with Ai for your semi-truck to pick up the kit.  Shipping costs can change without notice due to fuel costs, fuel surcharges, distances, etc.  Please call our office, 321-639-8777, to find out our latest shipping information.

Finished Cost Per Sq.Ft.

To view our web site file that talks about how to calculate square footage costs to build and finish a home, please click on Square Footage Costs.

 Approximate Finished Price Document 

The two page document, gives a general idea of the overall cost of a kit, plans, seal, Parts List, etc.  On the second page you will see finishing costs, which presents an approximate cost to build your dome home (based upon moderately finished interior.  These figures are based upon Central Florida, the cost to build varies from state to state, county to county and city to city.  Please take note of the website mentioned www.Building-cost.net, (by following the parameters listed in the approx. kit pricing document) you can get a clearer idea of the cost to build in your desired location.

American Ingenuity’s Two Page Order Form Lists

Parts List Items Included w’ the Dome Kit & Items Which Can Be Purchased From Ai

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.

 

Estimate Dome Kit Assembly Time & Costs

As we have described the Dome Kit can be assembled by an owner builder or the owner can hire a builder. Either way if desired the independent Kit Assembly Consultant can be hired to supervise your workers or your builder’s concrete workers. Click on Kit Assembly Consultant to view an article which contains charts showing kit assembly times for kits which have two entryways and four dormers. Also in the article are materials needed at the site for kit assembly.

Temporary Wooden Support System

During Dome Kit Assembly the prefab panels are supported by a temporary wooden rib system assembled in the geodesic shape.  After the panel seams are concreted and the entryways and dormers are concreted, the dome is self-supporting and the rib system is removed. The Rib System consists of using your own 2x4s, bolts/nuts/washers purchased from Ai ($100) and steel hubs on loan from America Ingenuity to assemble a free standing framework which matches the geometry of the dome.  Or Ai can cut, drill and paint the ribs and ship the 2×4’s on the truck with your building kit.  Hub deposit is $800 for five months rental. Thereafter is $20 a month rental cost.  After hubs are returned, deposit is refunded.

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
  • For four freq: 60’ dome there are 210 – 2×4’s  approx . price $1,999.

The temporary support system requires 2×4’s cut to a precise length, holes drilled 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.

During Kit assembly a temporary wooden rib system is installed that supports the panels and shows correct panel locations.  Once all the panel seams and entryways and dormers are concreted, the dome is self-supporting and the rib system comes down.  In a conventional house the roof trusses need supports.  Most of the wood from the rib system can be recycled for interior framing – some can be used to install the second floor perimeter knee wall that hides the perimeter short space and perimeter suspension rods.  Behind the knee wall HVAC ducts or wiring can be installed or doors can be installed in the knee wall so the area can be used for storage.  Ai can email the cutting specs for the wood.  The panels are hoisted into place with some sort of hoisting mechanism.

The kit can be assembled by an owner builder because there is an Assembly Manual (which can be shipped after signed order forms and deposit is placed) and all the panels come marked with numbers and letters to match the Nomenclature blueprint in the building plans.   Because the panels can be assembled by an owner builder, money is saved on the assembly of the dome shell and the home has greater advantages over a conventional shaped house or mobile home —greater energy efficiency, greater strength and exterior walls which contain no combustible materials.

The following info covers 12′ Pod Utility Domes from American Ingenuity

dark pic Utility Dome finished

 A no rust, insulated, low maintenance, 12′ diameter 110 sq.ft. dome kit. 

To view info about Tiny Home Kits 15′, 18′, 22′, 30′, 34′, click on Tiny Homes.

Utilize the Pod Utility Dome:

  • As a no concrete shed to store house and lawn equipment, store pool and sports gear, store all those cumbersome items that collect and clog up your garage.
  • Store tools during construction of your dome home.
  • Make your gardening or fix-it jobs easier with a potting shed or work shop.
  • Build a backyard dome playhouse with your children.
  • Build a Hunting Refuge.
  • Well pump cover.
  • Animal Shelter in Nature Preserve

Lemur preserve bought utility domes

Lemurs catching rays on top of 12′ Utility Dome built in Lemur Preserve in Florida

 SPECIFICATIONS:

  • Expanded Polystyrene 2″ thick panels (EPS – white rigid insulation), R-8 insulation. The kit includes the 2″ EPS panels and panels for one entryway. The panels are not prefabricated with a steel reinforced concrete exterior or interior wall board as are the prefab panels for the Ai 22′ thru 60′ domes.  After you assemble the panels, it is most cost effective for you to concrete the exterior and interior of the EPS insulation on site.  Within the entryway, install a 2×4 framed wall and install your locally purchased 6’x6′ (max) door.  Or install one 3’x6′ door and install a window or vent next to the door.
  • Diameter 12′, Center height 9’ 4”, Floor area 110 sq.ft.
  • The geometry is a one half sphere of a two frequency icosahedron on a 40″ riser wall

PRICING does not include USA common carrier shipping costs of $270 to $600. (If shipped to Florida addresses, add applicable sales taxes.) The pod ships on one 4’x4′ pallet with weight of 200 lbs from our Rockledge, Florida factory.  The truck that delivers the pod has a  lift deck and pallet jack.  So the driver unloads the pallet and moves it onto your property.  Shipping estimates: within Florida less than $200; Texas around $280; California $500.  Call us (321-639-8777) with your zip code and we can quote shipping costs.

  • 12’ Pod with one entryway  $750.  40” risers.
  • 12’ Pod with two entryways $790.  40” risers.
  • The Pod can be reinforced with galvanized steel mesh and #5 wire.  Please call Ai for Accessory Package pricing The Package consists of four foot tall roll of 1/2″x 1/2″ galvanized steel mesh (400 sq.ft.), 2 lbs. small C-rings, 1 lb large C-rings; 1 pair C-ring pliers and seventy eight feet of #5 galvanized wire.  When strengthening the pod with galvanized steel mesh; the following additional galvanized wire is needed:
    • 12 each 24″ long #5 wire comes with the kit – 8″ extends into the footing.  When adding steel mesh to the dome, the #5 wire out of the footing needs to extend up into each 40″ vertical riser seam and overlap horizontal #5 wire three inches. This results in 27 inches of #5 wire being purchased from Ai for 12 seams or twenty seven feet of additional #6 wire is needed.
    • When adding mesh to the dome, thirty one feet of #5 wire is C ringed to the top of the overlapped galvanized steel mesh in the horizontal seam at top of the 40″ risers.    
    • When adding mesh to the dome, 20 feet of #5 wire should be added around the lip edge of the entryway panels.

12′ Pod with 3 1/2″ EPS R14 Insulation

As of October 2016, Ai can manufacture a 12′ pod kit with one entryway and 3 1/2″ R14 EPS insulation for $989.  The EPS panels DO NOT have exterior concrete, DO NOT have galvanized steel mesh and DO NOT have 1/2″ drywall.  The kit panels do not fit in boxes but ship via a semi-truck on what is called a partial load.  If you are purchasing one 22′ dome kit or one 27′ dome kit, the 12′ pod with 3 1/2″ eps fits on the same semi-truck.

R-8 KIT CONTENTS:

  • 2″ EPS insulation panels consisting of 37 precut triangular, 12 precut 40″ high riser panels and 6 precut entryway panels. (to fit in boxes triangles and risers are cut in half and will be glued together before assembly begins)
  • 1 gallon Concrete Admixture
  • 1 bundle of 16d finishing nails
  • 1 bundle 16d nails
  • 1 large sponge
  • 2 cans spray adhesive
  • 12 ea. 24” #8 galvanized reinforcing wires
  • 1 insert about panels cut in half
  • Detailed slab plans
  • Assembly Instructions

The 2″ EPS panels are not prefabricated panels as are the panels in American Ingenuity’s 22 ft. – 60 ft dome kits.  The EPS panels are not pre-concreted since it is most cost effective for you to apply the exterior ¼” concrete over the entire dome at one time. Steel mesh is not installed on the panels. However if you want a stronger dome you can purchase ¼”x ¼” galvanized steel mesh to tie wire to the EPS before you apply the thicker ½” concrete.  Accessory Package includes 340 sq.ft. of steel mesh, C’rings, C’ring pliers and #8 galvanized wire. Call Ai at 321-639-8777 for accessory package pricing.

Pods are available with 2 sets of Entryway panels with 34 precut triangular, 8 precut 40″ high riser panels.  Two Pods may be linked together by joining the optional second entryway.  The two entryways are 144 degrees apart; therefore; the entryways are not opposite each other.  If the first entryway is at six o’clock, then the second entryway can be at eleven o’clock or one o’clock.

Materials and Tools Required:
To make a concrete slab need about 1 & 1/3 cubic yard of concrete and 2 – 20 ft. long #3 rebars or 40’ of #8 galv. wire (used w/ fences).

  • 2 – 94 lb. Bags Portland Cement for a 3/16″ thick exterior coating.
  • 3 cans spray foam
  • 45 Gallons (¼ cu. yd.) Sand
  • 5 Gallon Bucket
  • 3 Pressure Treated 2×4’s x8′
  • Materials for Doors (2 sheets of plywood, hinges & hasp)
  • Hammer, Trowel, Shovel, Step Ladder
  • Areas subject to hurricane force winds may require twice the amount of Portland cement and sand with the exterior of the dome reinforced with galvanized steel mesh before exterior concrete is applied.  Utility Dome/Pod does not come with 225 mph wind or F4 Tornado guarantee.

Kolb UD panels propped up and taped 041

 

Kolb UD constru 026

ASSEMBLY, FINISHING

  • First follow the insert about the panels cut in half & glue the triangles & riser pieces together.
  • Spray Foam is used as an adhesive by, applying a small bead along the edge of one of the adjoining panels.  Momentarily join the panels together to disperse the foam and hold them apart till the foam becomes tacky.  When the two panels are then rejoined they will hold together with less drying time.
  • Assemble the EPS panels by rows, attaching them to your prepared foundation and to one another with nails and adhesive & duct tape if preferred.
  • Install 2X4 Pressure Treated (P.T.) doorway framing under the entryway.
  • Install your own 6’x6′ (max)door, window or vents to suit within the entryway framed wall.
  • Coat the entire exterior with a 1/4″ layer of concrete, then paint the concrete with concrete primer and paint.
  • Attach electrical wiring for outlets or lighting to the panels.
  • Finish the interior of the EPS with joint compound, plaster or stucco.

FOUNDATION

The Pod foundation is a concrete slab. The footers will be 8” thick and 6” wide with 2” thick slab reinforced with #4 rebar (40’).  Foundation requires 37 cubic feet of concrete, 1 & 1/3 cubic yards of concrete.  A slab foundation design with dimensions and details is provided with the instructions.

CONNECTING DOME PODS

If you want to connect two pods together, one of the pods needs to have two entryways. There are no extra link panels, just the entryway panels that connect together.  This will give you one entrance into the first dome which will be connected to the other dome with no other exit available.  If you want a second exit out of the second pod, then you will need two pods, each with two entryways.

PICK UP INFO

  • The Pods can be picked up at American Ingenuity’s factory using a pickup with trailer with prior arrangements. Call our office at 321-639-8777 for details.  Office hours are Monday – Friday 9-5 eastern time.
  • Or the Pod may be shipped on the same truck as a Dome Building Kit (if there is room on the truck) at no additional charge.
  • Or the kit can be shipped on one pallet via common carrier, NIShippers, anywhere in the USA for approx. $270 to $600.  Please give American Ingenuity your zip code and we will confirm your shipping cost before you purchase the Pod.

Vehicle, Trailer and Strap Requirements for Pod pick up at American Ingenuity’s Factory in Rockledge Florida:

  • If you have a full size pickup truck the boxes will stick up above the cab by 3’ to 4’….which is dangerous.  To pick up the boxes, a Pick Up with small trailer is required or pull a 10’ trailer behind a vehicle.
  • Please bring straps and rope to tie down the six or seven boxes depending on whether your Pod has one entryway or two.

PACKAGING

The Pod with one entryway or two entryways is packaged in 6 boxes with the approximate dimensions.

  • 3 boxes: 47.5”x24”x16.5” @ 20 lbs each
  • 1 box:    48”x24”x16” @40 lbs each
  • 2 boxes: 34”x23.5”x24.5”@15 lbs each

MISC. INFO

  • The dome’s attachment to the foundation, and the doors and/or windows purchased and installed, limit the maximum wind force that the dome will withstand. Ai had one of its pods survive Hurricane Andrew with no structural damage.  (The pod had not been reinforced with galvanized steel mesh or thicker concrete).
  • Make the Pod stronger (it does not come with a 225 mph wind or tornado guarantee) by purchasing  accessory package from American Ingenuity that includes one four foot tall roll of galvanized ¼”x ¼” steel mesh, C’ rings, C’ ring pliers and #8 galvanized wire. Then concrete the dome with one half inch or three quarter inch concrete.   The seam areas will have thicker concrete.

  

 

To view the file named Thicker Insulation, please click on Thicker Insulation.

 

To view the file named Insulation Comparisons, please click on Comparisons.

 American Ingenuity’s component panels for the 15′ – 48′ domes contains seven inch thick rigid Expanded Polystyrene (E.P.S.) insulation which has an R value of 28.  The seven inch thick insulation is comparable to eleven inch thick fiberglass batting. There is no wood in the American Ingenuity Dome shell to interrupt the insulation or to rot or to be eaten by termites or to burn. However, a temporary wooden rib system is utilized to support the panels during the dome assembly until all the seams between the panels and the entryways and dormers are concreted and then the system comes down.  The dome is self supporting. The exterior is steel reinforced concrete that is primed and painted.  Your locally purchased doors and windows are installed in pressure treated wood framed wall under the entryway and dormer panels.

1. What’s the benefit of insulating my home?

  • Insulation can help reduce the cost of your heating and cooling bills by preventing the flow of heat into your house in the summer time and reducing the flow of heat out of your home in the winter time. In short, you can save money.

2. What’s the most important thing to know about insulation?

  • Its “R-value.” The R-value of an insulation product gauges the resistance the insulation has to the flow of heat.The higher the R-value, the better the product will resist heat flow. R-values are standardized, so you can compare different brands and types of insulation, and still know their relative ability to resist heat flow.

We have all heard builders claim to build “R-13” or “R-21” walls with wood frame construction. The problem is that only the highest rated component in the wall – the insulation itself – performs at these stated R-values. A wood frame wall is made up of several components, not all of which have the same R-value. For instance, a 2×4 or 2×6 stud has an R-value of about R-5 or R-7. Every 16 inches or so, one of these components breaks the insulation layer and forms a “thermal bridge”, conducting heat through the walls at high rates in addition to being a major cause of mold in standard construction. Adding up the area of studs, plates, and headers, 12% to 16% of the total wall area is an R-5 or R-7 thermal bridge, all detracting from the stated R-value. In addition, batt insulation tends to sag over time and leave spaces without any insulation! How can those builders claim only the highest-component R-value? From a whole-wall perspective, framed walls operate at far lower R-values – sometimes only half of the advertised value.

American Ingenuity’s (Ai’s) prefab panel contains seven inch thick Expanded polystyrene (EPS) insulation which consists of a solid piece of  EPS that provides a continuous layer of insulation rated at R28. From a whole-wall perspective, an EPS wall actually lives up to the advertised R-values because thermal bridging is absent.

Thermal conduction is not the only mode of energy loss in a building. In fact, conduction often contributes less to energy losses in wood frame buildings than convection, which is not even measured by R-values.

Thermal Convection is heat transfer by movement of currents within fluids or gases. When considering energy performance of buildings, it’s the air moving between the inside and outside or “air infiltration”.  A common measurement is ‘Air Changes per Hour’ at a blower-door induced pressure differential of 50 Pascal (ACH50). US Energy Star standards for new homes require less than 4-7 ACH50. In comparison, Canadian R-2000 standards are 1.5 ACH50, and Swedish standards are 0.5 ACH50 or less.

  • In wood frame buildings convection can be felt as drafts and is usually the biggest source of energy loss. Air infiltration accounts for up to 40% of the energy losses of a wood framed structure. Energy escapes via conditioned air leaking through thousands of cracks, openings, and joints between all the “matchsticks” of the building shell. Major culprits include framing connections, wall, floor & roof intersections, shrinkage of wood and caulking, and poor installation of components and sealants. A typical new wood frame home has between 1.75 and 3 air changes per hour (ACH50) and after some years it’s often between 5 and 10 ACH50 as the wood shrinks and sealants deteriorate. Old wood frame homes commonly have 10 to 20 ACH50.
  • EPS walls & roofs are an effective air (and vapor) barrier because the concrete is solid without passages for air to leak, thus eliminating a major percentage of air infiltration. EPS buildings consistently get results of 0.5 to 2.5 ACH50 and less, largely depending on the installed roof type and sealing. Most air infiltration in an EPS home is through a conventional roof and around windows & doors, so pay attention to these areas. Adequate air exchange in very airtight buildings must be ensured, typically using mechanical ventilation. Mechanical ventilation can be combined with ‘heat/energy-recovery’ units and/or ground heat exchangers for additional savings where conditions & budgets allow it.

R-Value Table: Insulation Values For Selected Materials

Use the R-value table below to help you determine the R-value of your wall or ceiling assemblies. To obtain a wall or ceiling assembly R-value you must add the r-values of the individual components together.

This method ‘Wall Assembly R-Value” gives incorrect results for MASS walls such as the All Wall System.

Example of error, as defined by ORNL research papers.

When compared to a 6” R-20 framed Wood Wall a Foam Block (ICF) wall performed with a 9% better Energy Savings.

A wall built like All Wall performed with an 18% better Energy Savings. (9% over the Foam Block walls) because of the concrete being in direct contact with the interior.

See ORNL’s report conclusions by clicking here. Oakridge National Laboratory

Example:Wall Assembly R-Value Example:

Component R-value
Wall – Outside Air Film 0.17
Siding – Wood Bevel 0.80
Plywood Sheathing – 1/2″ 0.63
3 1/2″ Fiberglass Bat 11.00
1/2″ Drywall 0.45
Inside Air Film 0.68
Total Wall Assembly R-Value 13.73

R-Value Table

Material R/
Inch
R/
Thickness
Insulation Materials
Fiberglass Bat 3.14
Fiberglass Blown (attic) 2.20
Fiberglass Blown (wall) 3.20
Rock Wool Bat 3.14
Rock Wool Blown (attic) 3.10
Rock Wool Blown (wall) 3.03
Cellulose Blown (attic) 3.13
Cellulose Blown (wall) 3.70
Vermiculite 2.13
Air-entrained Concrete 3.90
Urea terpolymer foam 4.48
Rigid Fiberglass (> 4lb/ft3) 4.00
Expanded Polystyrene (beadboard) 4.00
Extruded Polystyrene 5.00
Polyurethane (foamed-in-place) 6.25
Polyisocyanurate (foil-faced) 7.20
Construction Materials
Concrete Block 4″ 0.80
Concrete Block 8″ 1.11
Concrete Block 12″ 1.28
Brick 4″ common 0.80
Brick 4″ face 0.44
Poured Concrete 0.08
Soft Wood Lumber 1.25
2″ nominal (1 1/2″) 1.88
2×4 (3 1/2″) 4.38
2×6 (5 1/2″) 6.88
Cedar Logs and Lumber 1.33
Sheathing Materials
Plywood 1.25
1/4″ 0.31
3/8″ 0.47
1/2″ 0.63
5/8″ 0.77
3/4″ 0.94
Fiberboard 2.64
1/2″ 1.32
25/32″ 2.06
Fiberglass (3/4″) 3.00
(1″) 4.00
(1 1/2″) 6.00
Extruded Polystyrene (3/4″) 3.75
(1″) 5.00
(1 1/2″) 7.50
Foil-faced Polyisocyanurate
(3/4″)
5.40
(1″) 7.20
(1 1/2″) 10.80
Siding Materials
Hardboard (1/2″) 0.34
Plywood (5/8″) 0.77
(3/4″) 0.93
Wood Bevel Lapped 0.80
Aluminum, Steel, Vinyl
(hollow backed)
0.61
(w/ 1/2″ Insulating board) 1.80
Brick 4″ 0.44

 

Interior Finish Materials
Gypsum Board (drywall 1/2″) 0.45
(5/8″) 0.56
Paneling (3/8″) 0.47
Flooring Materials
Plywood 1.25
(3/4″) 0.93
Particle Board (underlayment) 1.31
(5/8″) 0.82
Hardwood Flooring 0.91
(3/4″) 0.68
Tile, Linoleum 0.05
Carpet (fibrous pad) 2.08
(rubber pad) 1.23
Roofing Materials
Asphalt Shingles 0.44
Wood Shingles 0.97
Windows
Single Glass 0.91
w/storm 2.00
Double insulating glass
(3/16″) air space
1.61
(1/4″ air space) 1.69
(1/2″ air space) 2.04
(3/4″ air space) 2.38
(1/2″ w/ Low-E 0.20) 3.13
(w/ suspended film) 2.77
(w/ 2 suspended films) 3.85
(w/ suspended film and low-E) 4.05
Triple insulating glass
(1/4″ air spaces)
2.56
(1/2″ air spaces) 3.23
Addition for tight fitting drapes or shades, or closed blinds 0.29
Doors
Wood Hollow Core Flush
(1 3/4″)
2.17
Solid Core Flush (1 3/4″) 3.03
Solid Core Flush (2 1/4″) 3.70
Panel Door w/ 7/16″ Panels
(1 3/4″)
1.85
Storm Door (wood 50% glass) 1.25
(metal) 1.00
Metal Insulating
(2″ w/ urethane)
15.00
Air Films
Interior Ceiling 0.61
Interior Wall 0.68
Exterior 0.17
Air Spaces
1/2″ to 4″ approximately 1.00

The standard seven inch thick (R-28) expanded polystyrene insulation (E.P.S.)  in the American Ingenuity 22′ thru 48′ dome building kits can be upgraded to nine inch thick (R-36) E.P.S.  See below for pricing.  To view the detailed data and characteristics of E.P.S. insulation, please click on Panel Composition and scroll down the page to view the EPS data.

Cold northern climates like Vermont and Wisconsin, etc. are appropriate areas to build Ai dome kits with the thicker 9″ (R-36) insulation. If a 45′ or 48′ dome’s insulation is upgraded, your shipment will require two semi-trucks for delivery.  The Ai dome with 7″ E.P.S. will easily outperform conventional housing with 11″ thick fiberglass insulation. Instead of purchasing thicker insulation from American Ingenuity consider applying the money you would have spent for the thicker insulation to purchase thermal coverings for windows, triple paned windows and insulated doors.

E.P.S.- Expanded Polystyrene Insulation

E.P.S. is frequently mistakenly referred to as “Styrofoam”. Although they both come from the same “base” material, polystyrene, the two products differ in many respects. “Styrofoam” is the registered name of Dow Chemical Co. and refers to the extruded polystyrene insulation product produced and marketed solely by that company. “Styrofoam” is generally blue in color and has a minimum density of about 1.80 pounds per cubic foot. It has a different cell structure (like hollow bubbles) and has a marginally lower better R value, but is considerably more expensive, not only per board foot but even more so on a “cost per R” basis. E.P.S. is available from more than 100 manufacturers throughout the country in a variety of sizes, densities and forms. “Styrofoam” is only available from one company in a more limited range of sizes.

Seven inches of sturdy, rigid R-28 expanded polystyrene (E.P.S.) insulation forms the core of each American Ingenuity component panel. This insulation is permanent, chemically and thermally stable, and resistant to mildew, provides no nutritive value to animals, plants, microorganisms, is non-irritating to skin, and is Chlorofluorocarbon (CFC) and formaldehyde free. This E.P.S. insulation will not rot, shrink, absorb moisture, compact, or deteriorate due to age or weather. It also acts as a vapor barrier for your home, providing stable performance year after year.

The E.P.S. that Ai uses is sometimes referred to as bead board and sometimes incorrectly referred to as Styrofoam (Styrofoam is the trade name for extruded polystyrene manufactured by Dow Chemical Co). Ai does not use Styrofoam.

American Ingenuity uses the one pound per cubic foot density, closed cell E.P.S. which has a thermal resistance (R-value) of 4.17 per inch of insulation at near freezing temperatures. This also explains why it is a very common insulation used in housing and sold at hardware stores. Ai uses the 7” thick E.P.S. which has an R-value of about 28.

Ai chose the expanded polystyrene over the extruded polystyrene because the extruded polystyrene is almost twice the cost with only a slightly better R-value.

When should you purchase the 9″ thick E.P.S.? If you have five or more days a year where the temperature reaches zero degrees then you may want to purchase the thicker 9″ insulation. If you have hotter days than most climates, we leave it up to you whether you need the 9″ thick E.P.S.. On the price list go to the Building Options and look down the list for 9″ Insulation.

Ai does not recommend that you purchase the 11″ E.P.S. insulation unless you live in a severe climate like the Northwest Territory of Canada.

Insulation Comparisons:

  • 2×4 solid wood with 3 1/2″ fiberglass is about R-8.
  • 8″ Concrete Block, with 3/4″ air, 3/4″ Celotex is about R-9.
  • 2×6 Solid wood construction with 5 1/2″ fiberglass is about R-11.
  • 2×4 solid wood with 3″ urethane is about R-13.
  • 7″ E.P.S. insulation is R-28 and is comparable to 11″ of fiberglass insulation.
  • 9″ E.P.S. insulation is R-36.
  • 11″ E.P.S. insulation is R-44.

American Ingenuity’s component panels for the 22′  thru 48′ domes includes the R-28 insulation and most of the steel reinforced concrete exterior finish and all the interior shell wallboard. Typically, in wooden domes you will likely have to purchase the insulation, wallboard and roofing materials for extra costs.

2015 Pricing For Thicker 9″  E.P.S. Insulation
22′
27′
30′
34′
40′
45′
48′
call for pricing
call for pricing
$2,650
$3,090
$3,715
$4,305
$4,795

 

If you upgrade your 40′, 45′ or 48′ dome with 9″ EPS more semi-trucks will be needed for delivery.  The 40′ or 45 ‘ & the 48’ kit will require two trucks for delivery. All Kits whose insulation is upgraded are considered Specialized Orders and are custom made for that Buyer.  These orders require a 50% deposit to start manufacturing.  If the specialized order is cancelled any payments made are non-refundable.

Q: Why are your dome homes so energy efficient?
A:
You can save 50-70% on heating and air-conditioning costs with your American Ingenuity dome over a conventionally built home. Some of the reasons for this superb energy efficiency are:

  • Super insulation that does not degrade with time, moisture, or compaction.
  • Spherical shape means reduced exposed surface.
  • Airtight exterior virtually eliminates energy leakage.
  • Solid thermal envelope.
  • Uniform R-value. The insulation is not interrupted with structural members (e.g. 2X4’s roof trusses). The only breaks are for doors and windows.
  • Downsized heating and cooling equipment.

Your kit comes with lifetime R-28 E.P.S. insulation or if you choose, thicker R-36 E.P.S. insulation is available. Even in cold climates, you may find that a single ventilating wood stove can heat a smaller dome (22′, 27′ or 30′) will provide all the heat your home will need. Larger domes need a centralized ducting system or mini-split ductless unites to disperse the heated or cooled air throughout your dome.

 ANALYSIS OF EXPANDED POLYSTYRENE INSULATION (EPS)

The Expanded Bead Polystyrene (E.P.S.) Insulation that American Ingenuity utilizes is seven inches of sturdy, rigid R-28 modified E.P.S. insulation that forms the core of each component panel. The E.P.S is one pound per cubic foot density (pcf).

The E.P.S. insulation will not rot, shrink, absorb moisture, compact, or deteriorate due to age or weather. It also acts as a vapor barrier for your home, providing stable performance year after year.  The E.P.S. is:

·         permanent

·         chemically and thermally stable

·         resistant to mildew

·         provides no nutritive value to animals, plants, microorganisms

·         non-irritating to skin

·         Chlorofluorocarbon (CFC) and formaldehyde free.

 

The following info pertains to stock plans sale prices & kit sale prices for each of American Ingenuity’s stock plans.  Please scroll down this article to find the chart.  The Chart lists the name of a stock plan, the number and type of building options (entryways and dormers) for that plan and the regular and sale pricing for the building plans and the regular and sale pricing for the dome building kit specific to that plan.  

Below the chart, there is info and  various costs or fees for items that can be purchased from American Ingenuity:  Building Plan Contents,  Engineer Seal Cost for the Plans,  Engineer Design Fee for any foundation other than monolithic slab,   Energy Report Fee,   Structural Calculations Fee,   American Ingenuity’s Parts List Pricing,   Shipping Costs,   Kit Assembly Time & Costs  and   Finished Costs per sq.ft. 

Above American Ingenuity Dome Kit   Assembled and Finished on Basement

Ai Dome is perfect for wooded areas because – no wood in or on the dome panels to burn

 15% DISCOUNT* OFF AMERICAN INGENUITY’S

DOME KIT WITH ONE ENTRYWAY PRICING 

 IF ORDER PLACED BY  August 16, 2017

SAVE $2,412- $9,017 – accept delivery by November 15, 2017

PREFAB PANELS  INCLUDE 7″ EPS (R-28) INSULATION, 1/2″ DENSARMOR GYPSUM DRYWALL
& 3/4″ EXTERIOR CONCRETE REINFORCED W’ GALVANIZED STEEL MESH & FIBERS

15% off basic dome kit with one entryway pricing
25% off — All Stock, Modified or Custom Residential or Commercial Dome Building Plans 

If ordered prior to  August 16, 2017

American Ingenuity’s (Ai’s) stock floor plans show the locations for your locally purchased doors and windows.   For structural integrity where ever your exterior doors and windows will be installed, an “awning” or “eyebrow” is installed on your dome. Ai calls these “awnings” or “eyebrows” entryways and dormers and gives them a category name called Building Options. Under these entryways or dormers you or your framing subcontractor frames in a vertical wall and installs your windows and doors.  To view sale pricing on the Tiny Domes – 15′, 18′, 22′, 27′, 30′, & 34′, click on Tiny Home Sale Pricing.

The basic dome kit consists of all the prefabricated component panels for the dome shell and panels for one entryway. The discount is taken on the kit with one entryway pricing.  Because we do not know which plan you will select, Ai starts with a dome kit with one entryway pricing and adds on the exact type and number of building options at current pricing per your plan selection.

The kit includes no windows, exterior doors, or any interior items other than the 1/2″ DensArmor drywall on the prefab triangle & riser panels.  One 27’ or larger dome kit requires one semi-truck for delivery. American Ingenuity believes the dome kit buyer should not pay shipping costs for another truck to receive items that can be competitively priced & purchased locally; i.e.  windows, doors, flooring,  bathroom fixtures, kitchen cabinets, etc.

There is a diagram below the pricing chart which helps clarify what the entryways and dormers look like.

  • Stock plans have a predetermined type and number of entryways and dormers.  These building options are listed next to the stock plan name.  Of course you can change any of these options by having our design team modify a stock plan or design a custom plan from your sketches on the dome planners….these stock plans are simply a starting point.  To learn about modified or custom plans, view Custom.    To learn more about the options (entryways and dormers) view Building Options.
  • Ai’ standard foundation is monolithic slab. However Ai can design other foundations; i.e. stem wall, basement, pilings, concrete block columns, etc. We do not sell Basement Kits. Although we do provide stock or custom basement building plans. Basements are built locally using standard items; i.e. concrete blocks, insulated concrete blocks (ICF), premade concrete walls or on site poured concrete walls. View Basements to learn more.  For Ai to design a foundation over than a slab, an engineer fee is added to the Plans Quote to cover the cost for an engineer to calculate the load of the dome and the load of the two floors within the dome and give joist/edge beam size/spacing and foundation design to our CAD department to incorporate within the plans.
  • To name the stock plans, Ai uses Greek words (Omega, Alpha, Delta) and numbers (21, 22, etc) along with the dome diameter. For example 27 Alpha 11: the first two digits are the dome diameter in feet, a Greek word and then a number.
  • Near the end of this article is info on  Building Plan Contents, Engineer Seal Cost for Plans, Energy Report, Structural Calculations, Parts List Items, Shipping, Kit Assembly time and costs and finished cost per sq.ft..

Please call American Ingenuity Mon-Fri 9-5 eastern time at 321-639-8777 for further clarification.

Within the Sale Pricing Chart Below Ai uses Abbreviations

to designate the type of entryways and dormers that are in each plan 

These are the Definitions.

Entryway – Structural Awning under which on site a 2×4 or 2×6 framed wall with headers is installed to frame in your locally purchased doors and windows or a bank of windows.

1E – One Standard Entryway
4E – Four Entryways
1HP – One High Profile Entryway
1GE – One G Type Entryway

Window Dormer – Structural Awning under which on site a 2×4 or 2×6 framed wall is installed to frame in a single window.

1WD – One Window Dormer – 1st floor
2WD – Two Window Dormers – 1st floor
1WD2 – One Window Dormer – 2nd floor
2WD2 – Two Window Dormers – 2nd floor

Door Dormer – Structural Awning under which on site a 2×4 or 2×6 framed wall is installed to frame in a single door.

1DD – One Door Dormer – 1st floor
2DD – Two Door Dormers – 1st floor
1DD2 – One Door Dormer – 2nd floor
2DD2 – Two Door Dormers – 2nd floor

Link – Connects two domes together.  Its location is where first floor door dormer panels or entryway panels would have been installed. Consists of either 3 1/2″ or 7″  Expanded Polystyrene (EPS) insulation, 1/2″ Drywall adhered to EPS interior with drywall adhesive. On site galvanized steel mesh and fiber concrete are applied to the exterior of the EPS.  On site the link panels are custom fitted  to the dome panels.

Riser Panel Heights – All dome kits come with standard 4’ vertical riser panels.  However the 22’ & 27’ kits can have custom 5’ risers instead of 4′ risers.  The 30’ or larger domes can have a custom two foot riser installed above the standard 4’ risers.   The 15’ & 18’ kit pricing includes 4’ risers plus 2’ risers.

 Dome Diameters and Typical Bedroom/Bath Numbers For Each Size Dome

15′  – one bedroom/one bath – no 2nd floor w’ sq.ft of 172
18’ – one bedroom/one bath – no 2nd floor w’ sq.ft. of 249
22′ – one bedroom/one bath – 1st floor of 370 sq.ft.  Can have optional storage loft.
27′ – two bedroom/one bath – 1st floor of 555 sq.ft. – 2nd floor of max 231 sq.ft to equal 786 sq.ft. max.
30′ – one bedroom/one bath – 1st floor of 665 sq.ft. w’ optional 2nd floor for storage, office, craft room.
34′ – two bedroom/two bath – 1st floor of 852 sq.ft.  w’ 2nd floor max of 427 sq.ft. to equal  1,278 sq.ft. max.
36′ – two/three bedroom/two bath– 1st floor of 946 sq.ft. w’ 2nd floor max of 470 sq.ft. to equal 1,418 sq.ft. max.
40′- three to four bedroom/two bath – 1st floor of 1,178 sq.ft. w’ 2nd floor max of 667 sq.ft. to equal 1,845 sq.ft. max.
45′- four bedroom/two half baths – 1st floor of 1,489 sq.ft. w’ 2nd floor  max of 951 sq.ft. to equal 2,440 sq.ft. max.
48′- three/four/five bedroom/two or three bath– 1st floor of 1,693 sq.ft. w’ 2nd floor max of 1,137 sq.ft. to equal 2,830 sq.ft. max.

To view Kit Sizes & square footages, click on Specs.

Dome Diameter and Dome’s Maximum Square Footage Converted to Meters

Ai can convert its Building Plans from Feet & Square Feet to Meters & Square Meters for Small Fee

Diameter in feet converted to Meters:

15′ = 4.60 M
18′ = 5.49 M
22′ = 6.71 M
27’ = 8.23 M
30′ = 9.14 M
34′ = 10.36 M
36′ = 10.97 M
40′ = 12.19 M
45′ = 13.72 M
48′ = 14.68 M
Maximum Square Footage for each Dome Diameter converted to square meters

15’ – 179 sq. ft. = 16.63 sq. meters
18’ – 272 sq. ft. =  25.27 sq. meters
22’ – 370 sq. ft.  = 34.37  sq. meters
27’ – 786 sq. ft. = 73.02  sq. meters
30’ – 878 sq. ft. = 81.57  sq. meters
34’ – 1,278 sq. ft. = 118.73 sq. meters
36’-  1,418 sq. ft. = 131.73 sq. meters
40’ – 1,845 sq. ft. = 171.41 sq. meters
45’ – 2,440 sq. ft. = 226.68 sq. meters
48’- 2,830 sq. ft. = 262.92 sq. meters

 First Floor Square Footage converted to square meters:

15’ – 179 sq. ft. = 16.63 Sq. Meters
18’ – 272 sq. ft. = 25.27  Sq. Meters
22’ –  370 sq. ft. = 34.37 Sq. Meters
27’  – 555 sq. ft. =  51.56 Sq. Meters
30’ – 665 sq. ft = 61.78 Sq. Meters
34’ – 852 sq. ft =  79.15 Sq. Meters
36’ – 946 sq. ft. = 87.88 Sq. Meters
40’ – 1,178 sq.   =  109.44 Sq. Meters
45’ – 1,489 sq. ft.  =  138.33  Sq. Meters
48’  – 1,693 sq. ft. = 157.29 Sq. Meters

Second Floor Square Footage converted to square meters

27′ – 231 sq ft – 21.46 sq meter
30′ – 213 sq ft – 19.70 sq meter
34′ – 427 sq ft- 39.67 sq meter
36′ – 470 sq ft- 43.66 sq  meter
40′ – 667 sq ft- 61.96 sq. meter
45′ –  951 sq ft. -88.36 sq. meter
48′ – 1,137 sq ft. – 105.63 sq. meter

Optional Third Floor Loft Square Footage converted to square meters

40′ – 112 sq ft = 10.41 sq meters
45′ – 142 sq ft = 13.19 sq meters
48′ – 162 sq ft = 15.05 sq meters

All Domes Can Be Designed Without a Second Floor

To view stock plans for One Story Prefab Kit, click on One Story Residence.  This link has all the Stock Plans layouts for each stock plan listed below.   Any of the domes can be designed for a commercial structure.

 

The Plan Sale Price in the Chart Below includes the 25% Plans Discount.
The Kit w’ Option’s Sale Price in the Chart Below
Includes the 15% Kit w’ one entryway Discount.

 

American Ingenuity’s basic kit pricing includes all the triangular and four foot vertical riser panels for the dome exterior walls and panels for one entryway.  Your floor plan selection, determines the type and number of the entryways and dormers. Due to small size of the 15′ & 18′ tiny homes, these kits have standard four foot risers and additional two foot risers.  22′ & 27′ kits can have five foot riser instead of the four foot riser.  30′- 48′ kits can have taller entryways and custom two foot risers installed above 4′ risers which results in 9’6″ or 10′ first floor ceiling heights in rooms that have second floor above them.  To view the building options available for each size dome, click on Options.

To view Ai’s current discount on the dome kit with one entryway, view Sale.  To view sale pricing on Tiny Homes, click on Tiny Domes. To view info and stock plans for the Tiny Homes, click on Tiny Plans.

After the panels are installed, the galvanized steel mesh from one panel over laps the steel mesh from another panel, is locked with C rings & pliers and depressed into the seam with on site special fiber/admixture concrete applied into the seams in two applications. The seam areas average two inches thick concrete.  Engineers tell us the seam areas act like steel beams.  The process of assembling the prefab panels produces the structural components, completes the finished exterior surface, installs all the insulation and installs all the shell drywall.  As a result the Aidome kit allows for reduced on site labor and quicker shell assembly time versus conventional construction

Why do I need entryways and dormers to install windows and doors? At specific locations around the perimeter of the dome, triangles and riser panels can be left out to provide openings where you or your framer installs a framed wall with your locally purchased doors and windows. To compensate for the triangle and riser panels being left out, these “structural awnings” – entryways and dormers have to be installed.  Diagram below helps clarify what these items look like. Please call American Ingenuity Mon-Fri 9-5 eastern time at 321-639-8777 for further clarification.

Diagram Identifying

3domes

 

Skylights or Solar Tubes can be purchased from other companies and installed in the prefab panels on site. Just do not cut within eight inches of the center of a seam.  If you tell us what size dome you are interested in, we can give you the size skylight which could be installed in that dome’s panel.  For additional light max out the number of second floor window dormers and second floor door dormers (install a tall window instead of a door for extra light on the second floor).

The building plan’s pricing listed below does not include an engineer seal on the plans or energy report or fee for an engineer to design basement/stem wall/ columns, pilings, etc.  It is Ai’s philosophy 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, structural calculations or energy report cost. Building plans are purchased three months  to two 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 buyer pays for their plans separately from the building kit and pays for a seal, calculations and energy report only if their building department requires them.  If you give us your property address or tax ID number & building department name, at no cost to you, Ai will call the plans examiner and inquire what is needed to obtain a building permit on the American Ingenuity dome kit.

Payment:  Building Kit orders require a 30% deposit for 22′ through 36′ domes and 40% for 40′ through 48′ domes along with a signed Order Form, Conditions of Sale (Warranty) and Specialized Material Agreement. The final payment (balance including shipping) is in the form of a cashier’s check or bank check or wire transfer 21 days prior to kit shipment. For Building Kits shipped to Florida sites, add 6% sales tax plus your counties surtax.  Plans are paid in full prior to scheduling design. Clients pay mailing costs for the plans.  Your building plan pdfs are emailed so locally sets of blueprints can be plotted for subcontractors, etc.  Plans can be paid via Visa, Master Card, Discover, personal check or money order. Ai does not accept American Express.

Shipping: Minimum shipping cost is $800 within Florida.  Shipment out of Florida is approximately $2.70 – $2.90 per mile per one semi-truck with 53 foot step deck from Ai’s plant in Rockledge, Florida to your site.   One truck can carry one Kit with 7″ EPS insulation for the sizes 27′, 30′, 34′, 36′, 40′, 45′, or 48′.  Or one truck can carry one 22’ & one 27’ kit or two 22′ Kits.  Two trucks are required for the 60′ dome.   The 45′ or 48′ kits with 9″ insulation require two trucks for delivery.  USA arrangements for shipping is made by American Ingenuity. Or  you can coordinate with Ai for your semi-truck to pick up the kit.  Shipping costs can change without notice due to fuel costs, fuel surcharges, distances, etc.  Please call our office, 321-639-8777, to find out our latest shipping information.

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

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

Delivery:  Allow 2 – 4 weeks for Stock Floor Plans. Allow at least 5 weeks for modified plans and 10 weeks for custom plans. Depending on time of year, for Building Kits allow 6 to 8 to 12 weeks after completing building kit orders and placing deposit.   Plan pricing is for one dome & two sets of plans. If two domes then pricing is based on the diameter of each dome.  The Plans Pricing does not include an Engineer Seal or an Energy Report or structural calculations. These items can be purchased from American Ingenuity if required by your building department to issue a building permit. Conditions and costs may change requiring our prices to increase without prior notice.

Below is listed info and  various costs or fees for items that can be purchased from American Ingenuity:  Building Plan Contents, Engineer Seal Cost for the Plans,  Engineer Design Fee for any foundation other than monolithic slab,   Energy Report Fee,   Structural Calculations Fee,   American Ingenuity’s Parts List Pricing,   Shipping Costs,   Kit Assembly Time & Costs  and   Finished Costs per sq.ft. 

 

 

 

Continued…

Building Plan Composition 

 

Charts are Examples of Ai Dome Kits Shipped

For examples we are listing charts for a 34′ dome building kit shipped to a Florida site, a 48′ kit shipped to a Florida site and a 40′ kit shipped to Trinidad.  

The following three charts list the pricing for each dome kit and items associated with that kit’s building plans.  Ai’s philosophy is that each Buyer pays for only what is needed for their dome kit and what is needed to obtain a building permit.  Ai does not burden the price of the building kit with the price of the building plans, engineer seal on the plans or Energy Reports.  Some building departments do not require that the plans be engineer sealed by an engineer licensed for your state and do not require an Energy Report;  therefore if not required those buyers only purchase the building plans and do not purchase a seal or energy report.

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), what building code is enforced, site preparation based on soil and whether the dome is built by a local Contractor/Builder or is Owner Built.  Every area varies on what the finished price per sq.ft. is because labor costs, site development costs and building code requirements vary by area.

The Dome Building Kit’s Special Prefabricated panels fit on one semi-truck when insulation is standard R28.  Ai believes you SHOULD NOT PAY for another semi-truck’s shipping cost to have exterior doors, windows, kitchen cabinets, bathroom fixtures, flooring, etc. delivered. These items are conventional items which can be locally purchased after competitively shopping prices at Home Depot, Lowes, eBay, Craig’s List, etc.

 

  • In Florida all new home construction requires Building Plans be sealed by an engineer licensed in Florida and an Energy Report.  For this above Florida Buyer their plans were $993; Florida Engineer seal for 34’ dome on slab was $600; Florida Energy Report was $190 for total of $1,783.  If your building department does not require a licensed engineer for your state to seal your plans & does not require an energy report, you do not purchase those items.
  • The total price for the 34′ Dome Kit & the Fl Engineer Sealed Plans and Energy Report was $34,887.
  • The estimated finished price for this Florida 34′ dome which includes the total price of $42,021 but not including the land cost, utility hook up costs, driveway installation or site preparation is $135,792.  To calculate the finished price take the number of square feet in the dome plan times the finished cost per sq.ft. for your area.  In this case in Central Florida building costs are around $123 a sq.ft.  Their floor plan has 1,104 sq.ft. resulting in the $135,792.  FYI the costs for the land, site preparation, driveway installation and utility hook ups WILL BE THE SAME whether it is a dome or a conventional house being built.
  • Free Web Site To Calculate Finishing 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.

    To view the floor plan layout for the 34′ dome, click on these pdfs.

Online Viewing – Opens in Browser
34′ Dome Plans 1st Floor
34′ Dome Plans 2nd Floor

The total price of the 34′ Dome Kit to a Florida site including Parts List Items, 2×4’s for temporary wooden support system, shipping, sales tax, shipping and steel hub deposit was $42,021. 

The price can vary because:

1) your floor plan selection determines the type and number of entryways and dormers.  This dome had two entryways, one window dormer and one second floor door dormer resulting in Kit with Building Options pricing of $33,104.

2) the Buyer chose to purchase 135 precut, drilled & painted 2×4’s for the temporary wooden support system – price of $1,134.  If you choose to not purchase the 2×4’s and cut them on site then subtract $1,134 from the total above. (Once the kit is assembled, seams between the panels concreted and entryways and dormers concreted, the dome is self-supporting and the support system comes down.  There is no wood to interrupt the Aidome panels.

3) Their Parts List Items totaled $1,448.  Each floor plan varies as to how much of the second floor is installed. This determines the number of suspension rods, Simpson hangers for the second floor joists, etc. This buyer chose a floor plan design which had half of the second floor installed.  Therefore this Parts List total will be more if you have more of the second floor installed.  Once your plans are finished Ai will know the specific Parts List items required.  To view an article which describes the contents of Ai’s two page Order Form, click on Order Form Description.

4) This site was in Florida so state sales tax and surtax had to be paid of $2,141. If your kit is shipping out of Florida you will not pay sales tax or surtax.

5) The $1,610 deposit for the steel hubs is refunded when the hubs are returned per the rental agreement.

6) Shipping cost for one semi-truck was $800.  If your site is outside of Florida then the shipping cost is based on the number of miles from our Rockledge Fl factory to your site. Currently that cost is $2.70 a mile.  Please call with your zip code and we can estimate shipping costs for one semi-truck.

 

    • In Florida all new home construction requires Building Plans be sealed by an engineer licensed in Florida and an Energy Report.  This Florida Buyer’s plans were $1,313; Florida Engineer seal for 48’ dome plans on slab is $600; Florida Energy Report for one dome on a slab is $190 for total of $2,103.  If your building department does not require a licensed engineer for your state to seal your plans & does not require an energy report, you do not purchase those items.
    • The total for the 48′ Dome Kit and the Fl Engineer Sealed Plans and Energy Report was $59,786.
    • The estimated finished price for this Florida 48′ dome which includes the $69,246 but not including the land cost, utility hook up costs, driveway installation or site preparation is $232,064.  To calculate the finished price take the number of square feet in the dome plan times the finished cost per sq.ft. for your area.  In this case the building costs are around $112 a sq.ft.  Their floor plan has 2,072 sq.ft. resulting in the estimated $232,064.  FYI,  the costs for the land, site preparation, driveway installation and utility hook ups WILL BE THE SAME whether it is a dome or a conventional house being built.
    • Free Web Site To Calculate Finishing 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.
    • To view the floor plan layout for the 48′ dome, click on these pdfs.
Online Viewing – Opens in Browser
48′ Dome Plans 1st Floor
48′ Dome Plans 2nd Floor

The total price of the 48′ Dome Kit to a Florida site including custom two foot additional risers, Parts List Items, 2×4’s for support system, shipping,  hub deposit and sales tax was $69,246.

This price can vary because:

1) your floor plan selection determines the type and number of entryways and dormers.  This dome had two standard entryways, one High Profile entryway, two first floor window dormers, two second floor window dormers and one second floor door dormer and custom two foot risers; resulting in Kit with Building Options pricing of $57,683.  If your 48′ floor plan includes fewer entryways and dormers then the kit cost will be less.  If your 48′ floor plan has a greater number of entryways and dormers then the kit cost will be more.

2) Their Parts List Items totaled $2,251.  Each floor plan varies as to how much of the second floor is installed. This determines the number of suspension rods, Simpson hangers for the second floor joists, etc. This buyer had most of his second floor installed. Therefore if the plan you select has less of the second floor installed, your Parts List total will be less.  Once your plans are finished Ai will know the specific Parts List items required.  To view an article which describes the contents of Ai’s two page Order Form, click on Order Form Description.

3) the buyer chose to have ten foot tall ceiling heights in the first floor rooms that had a second floor installed above them.   As a result this added $2,809 to his kit price.  If you choose to not purchase taller risers then costs for additional risers will not be included in your kit.

4) the Buyer chose to purchase 135 precut, drilled & painted 2×4’s for the temporary wooden support system – price of $1,134.  If you choose to not purchase the 2×4’s but cut them on site then subtract $1,134 from the total above.

5) This site was in Florida so state sales tax and surtax had to be paid of $3,664.  If your kit is shipping out of Florida  no sales tax or surtax will be paid.

6) The $1,610 deposit for the steel hubs is refunded when the hubs are returned per the rental agreement.

7) Shipping cost for one semi-truck to their Florida site was $800.  If your site is outside of Florida then the shipping cost is based on the number of miles from our Rockledge Fl factory to your site.  Currently shipping cost is $2.70 a mile.   Please call with your zip code and we can estimate shipping costs for one semi-truck.

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    • This Trinidad Buyer did not need an engineer seal on the building plans or an Energy Report to obtain a permit.  Therefore he purchased the building plans only.  His Plans were for a 40’ dome on a full basement. The dome and basement plans were $1,863.  If your building department requires a licensed engineer for your state to seal your plans & requires an energy report, then you purchase those items.  The seal cost for one dome on a slab is $600.  The seal for one dome on a basement is $900.  If stem wall is to be designed to get the footer below the frost line, add $200.  An Energy Report for one dome on a slab is $190; one dome on a basement $380.  If in California, hire a local company to complete California’s Title 24 Energy Report.  Ai will email them R value info and dimensions on the dome so they can complete the report. 
    • The total for the Dome Kit & the Building Plans was $44,108.  Total for all items was $50,505.  Shipping cost at the time was $4,531 for a total of $55,036.
    • The estimated finished price for this Trinidad 40′ dome on a full basement which includes the $55,505 but not including the land cost, utility hook up costs, driveway installation or site preparation is $285,200.  To calculate the finished price take the number of square feet in the dome plan & basement plan times the finished price per sq.ft. for your area.  In this case the building costs are around $100 a sq.ft.  Their floor plan includes 1,420 sq.ft in the dome and 1,161 sq.ft. in the basement for a total of 2,581 sq.ft. resulting in the estimated $258,100.  FYI, the costs for the land, site preparation, driveway installation and utility hook up costs WILL BE THE SAME whether it is a dome or a conventional house being built.
    • Free Web Site To Calculate Finishing 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.
    • To view the floor plan layout for the Trinidad dome, click on these pdfs

Trinidad Dome: The total price of the 40′ Dome Kit including Parts List, Rental of telescoping forklift to load the container, 2×4’s for support system and purchase of the steel hubs for the support system was $50,505.   The buyer paid the shipping cost directly to the shipping company.  

This price can vary because:

1) your floor plan selection determines the type and number of entryways and dormers.  This dome had three standard entryways, two first floor window dormers, two second floor window dormers and one second floor door dormer; resulting in Kit with Building Options pricing of $42,245. If your floor plan includes fewer entryways and dormers then the kit cost will be less.

2) Their Parts List Items totaled $2,193.   Each floor plan varies as to how much of the second floor is installed. This determines the number of suspension rods, Simpson hangers for the second floor joists, etc. This buyer had most of his second floor installed. If less of your 40′ dome second floor is installed, your Parts List total will be less.  Once your plans are finished Ai will know the specific Parts List items required.  To view an article which describes the contents of Ai’s two page Order Form, click on Order Form Description.

3) The Buyer chose to purchase 135 precut, drilled & painted 2×4’s for the temporary wooden support system – price of $1,134.  If you choose to cut them on site then subtract $1,134 from the total above.

4) the buyer paid $800 rental costs for telescoping forklift for Ai to load the container.  If the kit is shipped within the USA, the $800 rental will not be paid because Ai can load a flat bed truck with our fork lift.

5) Because the kit was shipping out of the United States it would be too expensive for the international buyer to ship the hubs back to Ai for a refund; therefore the buyer purchased the hubs for $2,070.  USA buyers place a deposit of $1,610 for the steel hubs. The deposit is refunded when the hubs are returned per the rental agreement.

6)  The buyer paid the shipping costs directly to the vessel line.  If your site is outside of Florida then the shipping cost is based on the number of miles from our Rockledge Fl factory to your site.  Shipping costs outside of Florida range from $2.70 to $2.90 per  mile. Please call with your zip code and we can estimate shipping costs for one semi-truck

 

Is the American Ingenuity (Ai) steel reinforced concrete geodesic dome kit  less expensive than the materials cost for the exterior walls and roof of a conventional house or wood dome or log cabin or monolithic concrete dome?  Yes.   American Ingenuity’s dome shell kit price (not the finished home cost) is about one third to one half less in cost than what the materials cost for the exterior walls and roof of a wood dome, gunited concrete dome or conventional house (exterior walls, roof trusses, plywood, tar paper, shingles, 3 1/2″ thick insulation, siding, soffits, gutters, drywall for exterior walls & the ceiling, etc.).

Calculating Finished Cost

The dome can be built and finished for about the same finished price per sq.ft. as a conventional house or business built in your neighborhood; however you receive more with the dome – greater energy efficiency, greater strength & fire resistant concrete exterior.  Each area of the country varies as to what construction workers and subcontractors charge per hour.   As a result check with a local builder to see what it costs per sq.ft. to build a moderately finished conventional house – Formica kitchen counter tops, no high end kitchens or high end bathrooms or high end flooring, etc. This is the approximate per sq.ft. finished cost the dome can be built for.

This means if it costs $110 a sq.ft to build a moderately finished conventional house in your neighborhood; then that is the approx. price per sq.ft. the dome can be built for.  For example if you built a three bedrooms/two bath size dome (40′ Theta 11 plan) with 1,521 sq.ft. for $110 a sq.ft. then the approx finished price is around $167,310.  This price includes the dome kit, kit assembly costs and labor and materials to finish the dome interior.  However it does not include 1) the price of the land; 2) driveway installation costs; 3) site development; 4) utilities – water, sewer or electric.  FYI, the costs for the land, site preparation, driveway and utility hooks will be the same whether it is a dome or a conventional house being built.

Because the American Ingenuity dome home is assembled from prefabricated panels, the kit can be assembled quicker; thus providing more savings over stick built houses, log cabins or pumped concrete domes.

Please compare apples to apples when trying to calculate finished cost of an American Ingenuity dome.  A conventional house would need walls greater than 2×10 with exterior reinforced with rebar and super thick concrete and still not come close to the advantages of an American Ingenuity dome.   A conventional house would need 11″ of fiberglass batting requiring over 10″ thick insulated walls (this is with our standard 7″ EPS R-28 value insulation) as well as additional roof strapping, rebar and concrete against storms, and still not be equal to one our structure’s insulation and strength. So please compare apples to apples!  Our kit comes with all the interior shell 1/2″ gypsum drywall installed, all the R28 insulation installed and 80% of the prefinished roof….and no wood to interrupt the insulation to rot, burn or be eaten by termites.  No shingles to blow off in high winds. Exterior concrete is primed and painted.

An Owner Builder or the dome owner’s builder can hire the independent  Kit Assembly Consultant to supervise their workers to get the dome kit assembled. Then conventional subcontractors frame in the doors and windows, prime & paint the dome exterior, complete the interior finishing – framing, electrical, plumbing, installing kitchen & bathroom fixtures & cabinets, drywall finishing, etc.

 

Materials Cost-Finished Cost

Total Materials Cost:  If you select standard items to finish the interior of your dome, the materials cost for your dome might be $50 or more per square foot. So the minimum materials cost (no labor costs) for a 40′ dome of 2,000 sq.ft. could be $100,000 (this includes the kit cost of $47,000).

Finished Cost of the house:  Finished price is more than the materials cost because it includes the labor costs plus the materials cost. So how does dome finishing costs compare to conventional house finishing costs?  If the finished price per square foot to build a conventional house in your area is $100 per square foot and you desire a 2,000 square foot house then the finished price for the conventional house would be about $200,000, if you do no labor yourself.  The finished price of the dome would be the same about $200,000 less the savings on the dome shell materials….. But you end up with more with the American Ingenuity dome. You receive a super-insulated, super-strong house whose exterior dome walls have 225 mph wind and F4 Tornado warranty. .To view summary of the advantages of Ai dome, please click on Summary.  To view info on cooling costs on 34′ dome home, please click on 1,075 sq.ft. home.

To view stock plan layouts for each size dome kit, click on Stock Plans.  To view the sale price of the building plans and dome kit, click on Plans & Kit Sale Pricing.  To view photos of finished pics of dome exteriors and interiors, click on Photos.  To view photos of Kit Assembly, click on Assembly.

Your interior materials cost varies depending on your selection of locally purchased interior items such as:

  • Formica kitchen counter tops versus granite
  • Oak kitchen cabinets versus cherry or mahogany
  • Vinyl flooring versus ceramic tile versus hard wood floors
  • Ceramic tile versus marble
  • Plastic shower stalls versus tiled showers
  • Plastic tubs versus Jacuzzi tubs
  • Jeld-wen windows versus Pella or Anderson windows
  • Standard light fixtures versus specialty
  • Standard kitchen appliances versus Thermador or Dacor appliances
  • Standard bathroom fixtures versus Aquaware or Boffi

A helpful web site is rsmeans.com It has construction manuals, construction estimating CD’s, etc.

Estimating Costs

The following information came from the book, The Complete Idiot’s Guide to Building Your Own Home by Dan Ramsey.

Can you afford to build the house you want? In Chapter 9 it states:  I’ll help you get a comprehensive estimate of your construction costs. For now, though, let’s make a rough estimate.  First, understand that whatever house you build will probably cost as much or more than that of your neighbors — unless you plan to do it all yourself. Based on this fact, let’s look at your neighbor’s houses.

As mentioned in Chapter 1, the typical house built today is about 2,300 square feet in size, and sells for around $225,000 depending on where you live. The actual price in your area may be half of that or 10 times that amount.

So, how can you get a good rule-of-thumb for your area? Of course, you can talk with contractors who will throw out numbers like $100 or $200 per square foot. That’s a wide range. What does it include? House only? House and land? Landscaping, too?

It’s smarter for you to get your own local building costs. Here’s how. Talk with a local real estate agent about new construction. It’s best if you can compare apples to apples, so ask about new homes and lots in the area you want to build. The agent should be able to tell you the lot cost, the asking price, and the square foot size of a few comparable homes. You can figure things from there.

You now have a base from which to guesstimate the approximate cost of your new house. Then you can factor in the following:

  • If you want a nicer view lot, add to the land costs.
  • If you will be your own general contractor, reduce the total by 10 to 20 percent.
  • If you will be a subcontractor, reduce the total by the sub’s fees.
  • If you want to enhance the design, tack on the additional costs or get a square-footage cost for better quality homes.

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

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

This page covers importing geodesic dome home kits.  The Kits can be shipped in containers to any destination in the world.  International Buyers purchase the American Ingenuity dome and pay USA inland trucking costs & ocean shipping costs, because they know they cannot build or buy any conventional home as strong or fire resistant or energy efficient as an American Ingenuity concrete dome. Below are answers to our most frequently asked importing questions and info on what size containers are needed to ship each dome kit size.   To view the dome kit sizes converted to meters, click on Sizes in Meters.

importing Faroe Island Dome

American Ingenuity Dome Being Built on Basement – North Of England

To date Ai has sold dome kits into 47 U.S.A states and fourteen foreign areas. American Ingenuity has exported domes into Hawaii, Puerto Rico, the Virgin Islands-St. Kitts and St. Croix, the British Virgin Islands-Tortola, West Indies-Nieves, Canada, Israel, Jamaica, Trinidad, Bahrain, the Faroe Islands (between Iceland/Scotland/Norway) and Tasmania (near Australia). 

Please note the wooden 2×4 rib system is temporary, once all the panel seams/entryways/dormers receive two layers of on site fiber concrete and the entryways and dormers are framed in, the dome is self supporting and the wooden rib system is removed. Some of the wood can be used for interior framing & framing of second floor perimeter knee wall.  There is no wood in or on the American Ingenuity dome exterior walls to rot or to be eaten by termites or to burn.  There are no shingles to blow off in high winds.  No shingles to burn in a forest fire.  The exterior concrete is primed and painted.  The entryways and dormers are framed in with pressure treated wood to accept your locally purchased doors and windows.  To view our web site page that lists what comes in a kit, click on Kit Contents.  To view dome home plans for each size dome, click on Dome Home Plans.

 

Container shipping

Container With 34′ Dome Kit Inside –
ready for semi-truck to pick up and take to USA port for shipment to Tasmania

The following is a list of our most commonly asked importing questions with their answers. 

Q: Do you export the concrete dome kits?

A: Yes. Ai. domes have been exported outside the continental USA. Requests for shipment into your area are best handled by freight forwarders located at your local ports.  Call Ai and give us the receiving port name and names of freight forwarders you want Ai to call about shipping costs and Ai will call for quote.  The freight forwarder will give costs for inland trucking company to bring the container(s) to our factory to be loaded and returned to USA port and ocean shipping costs to your port.

To work with your freight forwarder and assist them with the international paperwork, there is a fee of $200.

Q: What is the most shipping cost paid by dome buyer to receive their Dome Building Kit?

A:  Ai had a buyer in Tasmania (near Australia) who paid $18,000 to ship one 34’ Dome kit with 7” EPS insulation in one 40′ high cube container.  He paid this shipping cost because he knew he could not build or buy any conventional home as strong or fire resistant or energy efficient as an American Ingenuity concrete dome.

The Ai dome is more energy efficient than a conventional house, because of the thick insulation, the reduced exterior surface area and because the exterior walls of Ai dome contain no wood to interrupt the insulation.

Q: Does American Ingenuity have an engineering statement about your dome panels?

A:  Yes, to view the statement click on Engineering.

Q: Please explain about the temporary wooden rib system which supports the panels during kit assembly:

A: American Ingenuity’s Dome Building Kits are erected using a wood rib system to temporarily hold the panels in place until the seam concrete, concrete on the entryways, dormers, cupola and link has cured and the entryways and dormers are framed in. The system is dismantled upon completion of the dome and the 2x4s are recycled as part of the interior framing. Shorter 2×4’s can be used to frame the second floor perimeter knee wall. Behind this knee wall, electrical, plumbing or ducting can be run or the second floor perimeter space can be used for storage.

The Rib System consists of using your own 2x4s, bolts/nuts/washers purchased from Ai and steel hubs purchased from America Ingenuity to assemble a free standing framework which matches the geometry of the dome.  Or Ai can cut, drill and paint the ribs and ship them in the container with your building kit.

Q: Due to high shipping cost to return steel hubs to American Ingenuity from out of country, can the steel hubs be purchased from American Ingenuity? 

A: Yes for three frequency domes (30′ – 48′) the 46 Hubs are purchased from Ai for approx. price of $2,070.  For two frequency domes (15′,18′, 22′ & 27′) the 26 steel hubs are purchased for approx. price of $1,170.

Q: A container has all sides enclosed except for the end versus a kit shipped within the USA is shipped on a semi- truck that has all sides open. How do you load the dome kit into the container?

A: For loading a container Ai has to rent a telescoping forklift which allows the forks to extend into the container to place stacks of panels 39 feet back into the container to load the container. As a result Ai’s forklift cannot be used to load the kit into the container. The rental cost on the telescoping fork lift is $800 for one day rental. If your order includes two or more containers, the telescoping forklift will need to be rented for two days or more. Two day rental cost is approximately $1,235.

Onsite the panels are unloaded by hand one at a time. 

Q: Besides the dome kit and the misc. parts that I can order from American Ingenuity, can I purchase cut, drilled, painted 2×4’s to erect the temporary wooden rib system?

A: Yes the 2×4’s can be purchased from Ai with Ai cutting them to specific lengths, drilling holes and painting the ends. The steel hubs have each leg painted a specific color to match the same color 2×4.  Due to fluctuating 2×4 prices we cannot list exact price. 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 the actual 2×4 cost determines the pricing.

For two freq domes (15′, 18′, 22’ or 27’) there are 75 – 2×4’s for approx. price of $605. For three freq domes (30′ – 48’)  135 – 2×4’s can be purchased for approx.price of $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 wall, and ends painted red, white or blue to match the steel hub leg color. Ai can email the cutting & drilling specs for the 2×4’s to be cut, drilled & painted on site. We realize this cutting, drilling and painting is difficult and time consuming for our clients; therefore, the 2×4’s can be purchased from Ai.

Q: Isn’t shipping expensive to export your kit into my country?
A:
Yes, but if you look at the low cost of the Ai building kits….usually the kits are one third to one half less in cost than the cost for materials to build the exterior walls and roof of a conventional house in your area….that savings can typically cover your shipping costs and more…hoisting mechanism,etc.  Plus you receive more from the Ai Dome, greater strength (225 mph & F4 tornado guarantee) and greater energy efficiency (insulation comparable to 11″ of fiberglass batting) than a conventional house can offer.

American Ingenuity’s manufacturing costs in Florida are well below the national average, which offsets any long distance shipping expenses. Ai can actually manufacture a kit in Florida and ship it to countries cheaper than we could manufacture it there.

PRICING COMPARISONS: When you research other building kit pricing, generally you will find that Ai’s kit pricing is about one third to one half less than conventional building kits. The reason Ai’s kits have a better price is not magic.

  • The primary reason is the design concept. It is far more practical to build a dome with concrete than wood and applying the concrete to rigid foam insulation produces a component panel that provides structure, exterior finish, the insulation and the shell wall board.
  • Our philosophy of each person paying for only what they need; results in a lower kit price as our literature prices are based on their printing costs and only our clients who need an engineering seal, energy report, engineering calculations, etc. pay for those items.
  • Ai’s staff is not on commission.
  • Due to lower labor costs in Florida, Ai can manufacture in Florida and ship to any other location cheaper than it would cost to manufacture in that area.

Remember to compare apples to apples when pricing each company’s building kit. Ai’s panels include all the R-28 insulation already installed, 80% of the dome’s prefinished concrete exterior reinforced with fibers and galvanized steel mesh and all the interior 1/2″ DensArmor shell drywall. In conventional houses you will likely have to purchase the roof trusses, exterior walls, insulation, roofing and ceiling wall drywall and pay for the installation of the trusses, exterior walls, insulation, roofing and drywall. With Ai’s kit the assembly process is placing panels on a temporary wooden rib system, cementing entryways, dormers and the seams between the panels and filling the shell interior wall board seams with joint compound and tape.

Q: What size containers are required to ship American Ingenuity Dome Building Kits?
A:
Until we see the floor plan that you select for your dome(s) we cannot quote the exact number of 20′ high cube container or 40′ high cube container(s) or 45′ high cube container(s) that will be needed.   Your floor plan selection determines the type and number of building options (entryways, dormers, link, cupola, additional risers, etc.) that will be included with your Building Kit.  The following number of containers could increase if all the building options for that size dome are purchased.

To save space Ai usually ships most of the same size items together. So until we can add up each size panel for your floor plan, we do not know the number of containers that will be needed for your order.  Due to the large size triangles of a 40′, 45′ and 48′ domes, the triangle shaped H panels will not fit in the container.  American Ingenuity trims the EPS/wallboard tips off the H panels so that the remaining H panel will fit in the container.  On site during assembly, the tips are reattached with expanding foam supplied with the kit at no cost.

The following info about riser height is explained, because the height of the riser panels effects how many containers are needed for shipment.

Q:  Please explain about the Riser Panels that come with each kit.

A: American Ingenuity includes a four foot tall riser panels in the building kit at no extra cost.

The four foot tall riser panels allow for more vertical space near the perimeter of the first floor.  Because of the spherical dome shape, usually 30% to 50% of the first floor is left open so that the living room and dining room are located under high vaulted ceilings.  This allows for a partial second floor to be installed.  The first floor ceiling height in the 22′, 27′, 30′, 34′  & 36′ domes that have a second floor above them is 7 1/2 feet.  The first floor ceiling height in the 40′ and larger domes that have a second floor built above them is 8′.

Q: Can the first floor ceiling height in rooms that have a second floor built above them be taller than 7 1/2′ or 8′?

A:  Yes.  Custom Two Foot Tall Riser Panels can be  installed above standard four foot tall risers. To achieve a taller ceiling height in first floor rooms not under high vaulted ceilings purchase a 2′ tall riser to be installed above the standard 4′ riser.  This results in the first floor ceiling height of rooms not under high vaulted areas

  • 9’6″ for 27′, 30, 34, 36′ (with second floor door dormer)
  • 10′ for 36′ dome with out second floor door dormer
  • 10′ for 40′, 45′ and 48′ domes.

Possible Containers needed to ship American Ingenuity dome building kits.  Because a container has sides, Ai has to rent a telescopic forklift boom to load the container.  Call for current equipment rental costs.

The Ai dome building kits 30′ thru 48′ come with a standard 4′ tall vertical riser panels.  The 15′ & 18′ kits come with 4′ riser panels & 2′ riser panels. The 15′ & 18′ kits can be purchased with 3 1/2″ EPS instead of standard 7″ EPS.  The 22′ & 27′ kits come with either four foot riser or five foot riser panels.  Ai cannot manufacture kits larger than 18′ with 3 1/2″ because the thinner insulation makes the larger panels too flexible causing the concrete to crack.

  • One 15’ – kit with 3 ½” EPS (4’ risers plus 2’ risers) (with 2×4’s) and one 22’ with 7” EPS, ½” drywall (4’ risers) (with 2×4’s) can fit in one 40’ high cube container. H panel tips are not trimmed.
  • One 15’ kit with 3 ½” EPS (4’ risers plus 2’ risers) (with 2×4’s) (no link) (can have ½” drywall) can fit in one 20’ standard container
  • Two 15’ kits with 3 ½” EPS with one entryway on each kit (4’ risers plus 2’ risers) (can have ½” drywall) (no 2×4’s) (no link) will fit in one 20’ standard container.
  • One 15’ kit and one 18’ kit each with 3 ½” EPS with one entryway on each kit (4’ risers plus 2’ risers) (no ½” drywall) (no 2×4’s) (no link) is a real tight fit in one 20’ standard container.
  • Four 15′ kits with 7″ EPS, 1/2″ drywall, standard 4′ risers & 2′ risers & two sets of 2×4 ribs can fit in one 45′ high cube container.
  • Eight 15′ kits with 3 1/2″ EPS, no drywall, standard 4′ risers & 2′ risers & two sets of 2×4 ribs can fit in one 45′ high cube container.
  • One 18’ kit with the panels having 7” eps, ¾” concrete reinforced with galvanized steel mesh and fibers and ½” DensArmor Drywall with one entryway and one window dormer will fit in one 20’ standard container. The kit has 4’ risers and additional 2’ risers made from 7” eps/concrete/drywall.
  • Two 18′ kits with 7″ EPS, 1/2″ drywall, standard 4′ risers & 2′ risers & one set of 2×4 ribs can fit in one 45′ high cube container.
  • One 18’ kit with 3 1/2 “ EPS (4’ risers plus 2’ risers) (with 2×4’s) (no link) (can have ½” drywall) will fit in one 20’ standard container.
  • Two 18’ kits with 3 ½” EPS WITH NO DRYWALL AND NO STEEL REINFORCED CONCRETE will fit in one 20’ standard container.   The kit has 4’ risers and additional 2’ risers made from 3 ½” eps.   On site after the panels are assembled, hand tie galvanized steel mesh on the exterior and apply fiber concrete over the entire exterior.  1,000 sq.ft. of 1”x1” galvanized steel mesh is needed.
  • Four 18′ kits with 3 1/2″ EPS, no drywall, standard 4′ risers & 2′ risers & one set of 2×4 ribs can fit in one 45′ high cube container.
  • One 22′ kit w’ 7″ EPS with standard 4′ risers will fit into one 20′ high cube container.  However it is a very tight fit.  2×4’s for temporary rib system will not fit.   Link will not fit.  
  • One 22′ kit with 7″ EPS with 5′ risers, 2×4’s for temporary rib system and link panels will fit in two 20′ high cube containers.
  • Two 22′ kits w’ 7″ EPS with 4′ or 5′ risers can fit in one 40′ high cube container. 2×4’s for rib system will fit. Link will not fit.
  • One 27′ kit w’ 7″ EPS with 4′ or 5′ risers can fit in one 40′ high cube container.  Link and 2×4’s for rib system will fit.
  • One 22′ kit w’ 7″ EPS with  4′ risers and one 27′ kit with 4′ risers require one 45′ high cube container.
  • Two 27′ kits with 7″ EPS will not fit in one container or on one semi truck.
  • One 22′ kit w’ 7″ EPS with 4′ risers and one 27′ kit with 4′ risers can possibly fit in one 40′ high cube container and possibly one 20′ container.
  • One 30′ kit w’ 7″ EPS with 4′ risers requires one 40′ high cube container or two 20′ high cube containers. Link will not fit. 2×4’s for rib system will fit.
  • One 34′ kit w’ 7″EPS with 4′ risers  requires one 40′ high cube container or three 20′ high cube containers.
  • One 36′ kit w’ 7″ EPS with 4′ risers requires one 40′ high cube container.  2×4’s for rib system will fit. Link will not fit.
  • One 36′ kit w’ 9″ EPS w’ 4′ risers requires one 45′ high cube container.
  • One 40′ kit w’ 7″ EPS with 4′ risers requires  one 45′ high cube container. 2×4’s for rib system will fit. Link will not fit. H panel tips may need to be trimmed.
  • One 40′ kit w’ 9″ EPS with 4′ risers requires one 45′ high cube container. 
  • One 40′ kit w’ 7″ EPS with 4′ risers can be shipped in one 45′ high cube container or  three 20′ high cube containers. H panel tips may need to be trimmed.  2×4’s for rib system will fit.  If a link is included may need one other 20′ high cube container. (due to shape of triangles and size of 20′ container there is wasted space in the 20′ container versus shipping in 40′ high cube containers)
  • One 45’ kit W’ 7″ EPS with 4′ riser requires one 45′ high cube container and one 20′ high cube container.  H panels will need to be trimmed. A link will fit.  2×4’s for rib system will fit.
  • One 48′ kit w’ 7″ EPS with 4′ risers requires one 45′ high cube containers and one 20′ container. H panel tips will need to be trimmed to fit in the container.

Q: Do you have freight forwarder who can estimate the shipping cost on the containers?
A: Yes. 
SR International Logistics, Inc. is a full service international freight forwarder.  David Ross at SR International Logistics Inc. info is www.SRInternational.com 2525 16th Street #208 Denver CO Tel: 1-720-855-3115 Fax: 1-720-855-6464  email: dross@srinternational.com  

Q: Do you have any information on shipping one 40′ high cube container to Port of Spain, Trinidad Tobago?
A: Yes, here is container trucking info and ocean shipping quote to Port of Spain Trinidad as of October 2015.  One 40′ kit can fit in one 40′ high cube container. (H panel tips are cut off to fit in the container and reattached with Enerfoam on site.)

MSC– William Diaz 1 305-477-9277 Ext 75042 email: wdiaz@msn.us
Trucking Cost – 1,496.00 (drop container at Ai factory and pick up next day & delivery to port)
Ocean Shipping – $2,935.00 from Port Everglades, Florida to Port of Spain, Trinidad
Hazardous fee – $100.00 (cans of Enerfoam (adhesive) and cans of cleaner for enerfoam metal dispensing gun cause container to be labelled Hazardous. Results in $100 fee)
Total Trucking & shipping on one Hazardous 40’ High Cube Container  – $ 4,531.00

Q: Do you have any information on shipping to Hawaii?
A:
Yes, shipping to Hawaii involves: containers being delivered to our factory to be loaded; once loaded the containers are transported by truck to a port in California. Then the containers are loaded onto a ship. The company that delivered the containers to our factory was Falcon Transport, Inc. at POBox 411 , Bird-In-Hand, Penna 17505-0411; their phone number is 717-687-0471.

A past rate to have a 40 foot container spotted at our factory here in Rockledge, Fl 32955 and shipped through to Port Hilo, Hi was $14,618. Matson Navigation jhorbaczewski@matson.com at 415-957-4000 handled the boat shipping to Hawaii.

A 45’ kit  requires two containers. A 34’ kit requires one 40′ High Cube container for a shipping of about $14,618.

For example a 45′ kit and a 27′ kit requires two 40′ high cube containers and one 20′ high cube container.

Q: Do you have any information on shipping to Nieves in the West Indies?
A:
Yes, a past rate to have a 40 foot container spotted at our factory here in Rockledge, Fl 32955 and shipped through to Nieves was $8,812.

Q: Do you have any information on shipping to Puerto Rico?
A:
Yes, one of our clients in Puerto Rico purchased two domes, a 34′ and a 45′. Our client used two flat racks and one container that were shipped on Sea Star from the Jacksonville port to San Juan. The shipping was $2,612 for each 40′ flat rack or $5,224. The shipping on the 40′ Standard Container was $2,412, plus the following fees: delivery fee to Aguas Buenas $585, paperwork $140 for a total shipping cost of $8,361 for a 34′ and a 45′ dome.

The Sea Star contact was Jim Stoshak at 904-751-2110.

A Trucking Company that deliveries containers and flat racks to factories to be loaded for export to Puerto Rico: is Magic Transport Miami Fl 305-887-2424 or 888-693-7312, fax 305-887-0320.

Q: Have you exported into Europe?
A:
No but Ai can ship to Europe. We have exported into the Middle East but not into any European countries.

Q: Do you export to the Virgin Islands?

A: Yes. We have shipped two 40′ domes to St. Kitts. MVC Transportation Corporation brought the two 40′ Standard Containers and 40′ flat rack to our factory to be loaded. MVC’s mailing address is POBox 653808, Miami Fl 33265 phone 305-888-4MVC, fax 305-888-8011. The Consignor was Crowley Port Everglades Ft Lauderdale Fl. The Freight Forwarder was Caribbean Freight Systems, Inc. The Port of Loading was the Port Everglades. Port of unloading was St Kitts. Each container cost $5,200 for inland trucking costs and shipping from Port Everglades to Virgin Islands.

Q: Do you export to Mexico?
A:
We can.  Contact a Mexican importing person who can answer your border questions, such as “What are the duties? What paperwork is involved.” The kit is shipped on a semi truck from our Rockledge Florida factory. Your border person may know of Mexican trucking companies that carry loads into Florida. Once that truck’s Florida merchandise is unloaded, it would drive to our factory and be loaded with your kit. Brownsville Texas is about 1,200 miles from our factory. Shipping to that point would be about $2,650 US Dollars at $2.20 per mile estimated shipping costs
.

Q: Do you export to the Middle East?
A:
Yes. In 2004 we got an approximate shipping quote from Transgroup Worldwide Logistics on two 40’ containers being trucked from Miami to our factory, then delivered back to Miami and then shipped to Dubai, UAE for about $5,225. 42 days transit time. This pricing included two hours no charge for each container to be loaded and an additional loading time of two hours per container at $45 per hour ($180). Two drivers at $725 each to bring the container to our factory and take it back to Miami after loading ($1,450). Ocean freight of $1,750 per container from Miami to Dubai UAE ($3,500). And $95 for Documents and forwarding. This does not include any duties or documents for the Dubai port. This quote was from Transgroup Worldwide Logistics/Stephen Brown in Ocean Quoting at 321-868-2230.

Q: Do you export to Canada?
A: Yes. We have shipped domes into
Canada.  But none of our clients allow us to give out their name and numbers for referrals.  

The Canadian broker for L.M. Clark Broker is Steve Martonino, (905-673-8650 ext 224) who did the customs work for Donkers Harris LTD for one of our clients.

In Canada the building department will require the building plans to be engineer sealed prior to giving you a building permit. Ai knows of an engineer licensed to seal our building plans for most areas of Canada. A Canadian seal could cost from $900 to $1,500 to $3,000….depends on the size dome and the foundation type.

Shipping Information: American Ingenuity Dome Building Kits
Are Shipped Via Semi-Truck

Click on the photo to enlarge it:

Image Image
Four men loading truck with 45′ kit. Factory domes in background.    48′ Dome Panels strapped down ready for shipment.

semi - truck DSCN1643

The above photo illustrates 45′ Dome kit being strapped down prior to shipment to dome owner’s property.

All Panels Are Marked With Numbers and Letters to Match The Building Plan Nomenclature Blueprint

16.09 unloading truck Kaufman picture assembly 105

Semi-Truck Being Unloaded At Dome Owner’s Site 

Can be unloaded with all terrain fork lift or man lift following Ai’s Truck Unloading Instructions

16.15 un loading truckKaufman picture assembly 121

Another View of 45′ Dome Kit Being Unloaded From Semi-Truck

Q: As far as shipping costs: Why did a California dome kit buyer pay $6,450 for one truck’s shipping cost,  an Australian dome kit buyer pay over $18,000 to have container shipped for his 34’ kit and a Washington dome kit buyer pay $9,000 for one truck’s shipping cost?

A: Simply put, it is because the Buyer could not build a home or buy any house that has the energy efficiency, strength and noncombustible concrete exterior that the American Ingenuity dome home has. The Ai dome is more energy efficient than a conventional house, because of its thick insulation (comparable to 11″ of fiberglass batting), the reduced exterior surface area and because the exterior walls contain no wood to interrupt the insulation. The dome is stronger than a box shaped house (225 mph wind and F4 tornado) due to its aerodynamic shape, steel reinforced concrete exterior and triangle panel shape. Plus there is no roof to replace every 11-12 years. The exterior of the dome is fire resistant concrete.  To view Ai dome advantages summary, click on Summary.

Q: I understand the Dome Building Kits are shipped on semi-trucks. What is the shipping cost in Florida and outside of Florida?
A:
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 cheaper than we could manufacture there.  For example due to higher labor costs, if we manufactured out west or up north  we would need to increase the kit pricing 40%. So this means a 34′ kit whose approx. sale price is $26,000 would sell for $36,400 an increase of $10,400.

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 these independent trucking agencies. We contract to have these trucks carry your building kits outside Florida for approximately $2.70 to $2.90 per mile per semi-truck from our 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 we could do with our own trucks because if we used our own trucks, they would have to deliver the kit and return to Ai’s factory empty.

Per mile shipping costs and minimum shipping costs can vary due to fuel costs, fuel surcharges and travel distances.

If you are an International Client, your freight forwarder coordinates your container shipping. Click on Exporting to learn more. There is an extra fee of $800 per container because Ai has to rent a telescopic forklift boom to load each container.

Even though we have arranged the shipping, the truck carrying your kit does not belong to American Ingenuity, and the driver does not work for us. The driver is an independent driver, contracted for the delivery. Ai has found these drivers to be considerate, understanding and fair people. They are accustomed to transporting valuable merchandise and delivering it in the best possible condition.

Q: How many building kits with your standard R28 insulation fit on one semi truck?
A:
Five 15’s or two 18’s or one 30′, or one 34′, or one 36′, or one 40′, or one 45′ or one 48′ can fit on one semi-truck for delivery. Two 22’s can fit on one truck.  One 22′ & one 27′ can fit on one truck.  If you max out the number of entryways, purchase a link and the thicker insulation, your 45′ or 48′ building kit will require two trucks for delivery.

The 15′ & 18′ kits can be purchased with thinner 3 1/2″ R14 EPS insulation NOT R28 7″ EPS insulation and no 1/2″ dyrwall.  If so the thinner insulation allows for up to ten 15′ dome kits to fit on one truck and up to four 18′ dome kits on one truck.

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

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

For information on dome kits shipping to international areas in containers or flat racks, click on importing.

Q: Is there insurance to cover the load in case of a problem?
A:
Yes. Each shipping company has cargo insurance.

Q: How do I communicate with the driver and his dispatcher?

A: Ai gives you the name and phone number of the driver.

Q: How does the truck driver get directions to my construction site?

A: You fax or email directions to us describing how to get to your site from the nearest major interstates. Ai gives those directions along with your phone numbers to the driver.

Q: How is the shipping cost paid?

A: The trucking companies require that American Ingenuity pay them directly.  One to 3 months prior to your shipment date, Ai will contact the trucking companies for quotes and negotiate the lowest price possible.  21 days prior to the shipment date, mail a bank check to Ai which includes the balance due on your dome kit and the shipping cost.

 Q: How large will this truck be and how big a turn around area will it need?

A: The semi-truck will be about 70′ long and 8 1/2 feet wide. Consider where the semi can turn around. Semis need a large turning radius. The truck will need about 13 ½’ of clearance overhead.  Ai’s Plant uses a 35′ wide loading area (varies depending on type of forklift and terrain).  When one tiny home kit is shipped, the truck length may be shorter.

Plan sufficient room on both sides of the trailer for the forklift to approach it at a 90 degree angle, lift the load, back straight out until the lifted load completely clears the load on the trailer, then back and turn 90 degrees before proceeding toward the stacking area.

Q: What if my road is curvy or too steep and the semi- truck cannot go up the road?

A: You might have to off load the truck and stack the panels in an open area and use the fork lift or bob cat to take the panels up the curvy, steep road. Some of our clients have carried the panels up their narrow roads on a trailer or in the back of a pick up. If you will be obstructing traffic, have someone available with a flag to caution and direct approaching traffic. Coordinating with law enforcement may be needed in high traffic locations.

If you will be off loading onto a common area and not unloading at your construction site, the truck driver may have to stay longer than the normal three hour unloading time. If so the truck driver will need to be compensated $50 an hour for any time over the three hour unloading time. Let our shipping department know if you need additional time and they will work the additional cost out with the trucking company’s dispatcher.

Q: What damage can occur to the building kit during shipment?

A: The panels may have a small amount of damage from loading or transport. The straps that secure the panels to the truck may make indentations in the E.P.S. edges, which can easily be filled with expanding foam. Even it the panel gets cracked it will not have any structural significance. The crack can either be sealed after the dome is completed or in extreme cases, a layer of stucco applied. Any damage to the EPS can be repaired with the expanding foam provided with your kit. In general, a panel would have to fall off the truck for any appreciable damage to occur.

Q: What is the approximate shipping weight of the Building Kit?

A: 27’-13,000 LBS, 30’-15,000 LBS, 34’ 17,000 LBS, 40’-20,000 LBS, 45’- 22,000 LBS, 48’= 24,000 LBS. The building kits are not really heavy loads. Due to the 7″ thick Expanded Bead Polystyrene insulation, the load is a bulky one.


Even though American Ingenuity has arranged shipping and loaded the truck, the truck carrying your building kit does not belong to Ai and the driver does not work for us.

HAVE A FORKLIFT AND CREW READY TO UNLOAD

Forklift Requirement:

1. All-terrain type unless the entire operation will be on a paved surface.

2. 2,000 to 3,000 pound lift capacity.

3. 48″ long forks are required to unload the 48’ and 45’ kit.

The longer and wider forks will minimize indentations of the panels.

4. Experienced person to drive the forklift .

5. Two additional able-bodied people are needed to assist and to lift non-concreted panels and items from truck.

Try to avoid renting huge, high capacity fork lifts because they are heavy, bulky, and hard to maneuver in limited space.

If the forklift is unable to lift an entire stack of panels it will have to first reach and remove the top half which is apx. 8 ft. above ground level.

48” long and 12” wide strips of ¾” plywood connected to the tops of the forks will also minimize indentations on the panels.

An experienced forklift driver will save you potential damage and unloading time. See Time To Unload below.

Assistance is needed to place the foam blocks on the ground under each stack, remove components that have to be lifted by hand, guide the driver whose view is obstructed by the stack of panels, etc.

The truck driver is not required to direct or unload the ruck.

PLAN THE UNLOADING SITE

1. Long before the kit is due to arrive, select the best place to park the semi truck and select a place to store the kit.

2. Make sure there is plenty of room on both sides of the Semi-Truck for the forklift to maneuver.

3. Overhead clearance of 13 ft.

STORAGE SITE

1. Choose a site close to the dome foundation.

2. Need an area approx. the size of 3 semi truck beds (8 ½ x 50’) to accommodate the panels in partial stacks.

The Semi Truck is 8 ½’ wide & 70’ long requiring a large turning radius.Plan for the truck to have room to turn around or back up to the primary road. If not paved, the surface must be fairly level and compacted, so the truck and forklift will not get stuck.Our plant uses a 35’ wide loading area (varies depending on type of forklift and terrain).

If necessary you could have the truck park as close as possible to the construction site and use the forklift to later carry the stacks of panels the rest of the way to the site.

If you will be obstructing traffic have someone available with a flag to caution and direct approaching traffic. Coordinating with law enforcement may be needed in high traffic locations.

TIME TO UNLOAD

· 3 Hours unloading is included in your truck charge.

· Time over 3 hours will result in an additional $50 per hour.

Loading the truck takes longer. Ai must precisely load the panels to fit in a limited area. Additional time is required to arrange the panels in each stack to line up with the tie down straps and withstand the forces when they are tightened.

PANEL ARRANGEMENT ON THE TRUCK

The concreted panels are grouped together on the truck according to type.

The triangular panels must be supported on the corners while they are being shipped therefore they are setting on foam block spacers and not pallets.

Stacks of smaller, lightweight panels may be secured for shipping with either wire or C-rings.

Cut these panels loose from each other using a diagonal wire cutter, before removing them from the truck.

E & F (Entryway)-panels my lay directly on the truck bed without spacers. With a helper, manually slide a set of 2 E panels aside toward the forks of the forklift, pick them up carefully at the edge and place a foam spacer under them. Now you are able to place the forks under the panel, lift and transport them.

Pentagon Panels labeled “P”, Hexagon Panels “H”, Riser Panels “R” and Entryway Panels “E, F, G”.

See Panel Identification in the Assembly manual.

 

All panels are shipped with the pre-finished concrete side up.

LIFTING PANELS OFF THE TRUCK

BEST OPTION:

Fast and efficient, an entire stack of panels is removed at once. Three people can unload the truck within 3 hours. One drives the fork lift, 2 people, acting as eyes, guide the fork lift driver, who’s view is obstructed by the load.

Unload panels alternately from both sides of the trailer, to keep the load on the truck balanced.

Other methods are less desirable as upper panels are 10-12 feet above the ground, weight 290lbs each.

To avoid breaking off the E.P.S. corners, do not lift heavy panels by their corners, rather lift the panels by holding the EPS at least 12” back from the corners

  • Place the first unloaded stack onto two, 2’ long pieces of 4×4. After the first stack has been unloaded you will be able to place the remaining stacks on the foam spacers which are approx. 3 ½”.
  • Look for spacers of 3½” EPS insulation provided at bottom and middle of H & P stack to accommodate the blades of the forklift. Save them to be used later in the construction process for filling in gaps, or for small repairs.
  • Place the foam spacers on the ground and put the panels on top.

BUILDING KIT INVENTORY

Your kit and components have been checked for quality and quantity three times by experienced employees before the truck left the plant.

Only in extremely rare cases has a part actually been missing.

It would be very time consuming to inventory all the items as the truck is being unloaded. Although you could check off many of the large, boxes, buckets, etc.

Obtain the Building Kit Inventory list from the truck driver.

Within a week of receiving your kit, complete a thorough inventory and assure that you have received all the items on the inventory sheet.

Kit items are listed in categories: Pre-finished Panels, EPS, Insulation Panels, Boxes (numbered consecutively), 5 gallon Buckets, and Bulk Items.

Please check and double check quantities if you think there is a discrepancy.

PANEL STORAGE & TOLERANCE

IN FREEZING CONDITIONS

If the wallboard has absorbed water and exposed to freezing temperatures while it is still damp the fiberglass on the interior surface may delaminate. In extreme cases the core of the board may disintegrate.

If these conditions occur the board can be repaired with joint compound or wallboard sealer. Contact us for assistance.

Some of the liquids will be damaged if they are allowed to freeze. Even the liquids that are not damaged may burst their container, therefore we recommend storing them inside.

Internal wallboard on dome panels is weather resistant. It can be stored outside for a limited period of time (apx. 2- 3 months) without significant damage.

In severe weather and for longer storage, we recommend covering the panels with tarps.

Water or freezing conditions does not affect EPS foam. But can affect the wallboard.

EPS Surfaces that are not covered or painted will very slowly erode if exposed to sunlight (ultraviolet light). The edges of the panels that have exposed EPS are painted at Ai Factory.  If your kit is going to be stored more than 3 months, additional paint will need to be applied on site to protect the EPS.

Items shipped in cardboard boxes, precut 2×4’s and items likely to be stolen should be stored inside.

Typical damage may include: 

  • Concrete corners cracked or EPS edges indented due to the straps.
  • Cracks in some of the thinner concrete, scratch coat, are non-structural and can be sealed later.
  • Damage to the EPS during shipping or construction can be easily repaired with expanding foam provided with your kit.
  • Ai has not had a panel fall off a truck although panels have dropped 10 ft. or more during construction and have been successfully repaired and used.
  • Panels will have some insignificant damage from loading, transporting and unloading.

The following info covers American Ingenuity’s Garage Domes which have R28 insulation. The 27′, 34′, 36′, 40′, 45′ & 48′ domes can be designed as a garage on the first floor with a second floor studio above.  If the entire second floor is built within a 27′, 34′ or 36′ or 40′ dome, the second floor could be designed for a studio apartment with one bedroom, one bath & kitchenette.  Due to the load of the second floor there could be a post in the center of the first floor if microlam beams are not designed to carry the second floor load.  The 40′, 45′ & 48′ dome’s second floor is large enough to have two bedrooms and one full bath with kitchenette.  

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

American Ingenuity’s 22’ & 27’ domes were specifically designed for garages. The 22′ is a one car garage dome with 9′ wide garage door.  The 27′ is a two medium car garage with 16′ wide garage door.  27′ dome can have a second floor for a one bedroom, one bath studio apartment. These garage domes are two-frequency icosahedron geometry whereas the domes (30′, 34′, 36′, 40′, 45′ & 48′) are three-frequency icosahedron geometry. The two frequency geometry differs from our other domes in that the 22′ & 27′ utilize fewer but larger panels.    For Ai to assure that the vehicle(s) you desire to park in your garage dome will fit, please give us your vehicle length, width, height and hood height.  At no cost to you, our design team will provide a plan proof  showing the vehicle sizes and whether they will fit or not.

Due to the size of the 22′ – 40′ domes three risers can be removed instead of two in order to have a wider entryway.  Due to the large size of the 45′ & 48′ dome only two risers can be removed for an entryway.  Because the 22′ & 27′ have fewer but larger panels than the three frequency domes, their risers are wider resulting in the 22′ dome  accepting a 9′ wide garage door. The 27′ dome can have a 16′ wide garage door.  Previously a 34’ dome was needed to pull two small to medium cars in side by side. Now there can be a two-car garage in a 27’ dome, which is more cost effective.  Either of these garage domes can be connected to another dome via a link that is one riser panel wide or the garage dome can be built independently from the house dome.

Garage Entryways take the place of three riser panels whereas standard and high profile entryways replace two risers. The 45′ & 48′ dome cannot have garage entryways due to their large size.

The 22′ and 27′ Garage Entryway panels are larger in size than the other dome entryways and are not preconcreted. The 22′ and 27′ entryway panels consist of 3 1/2″ EPS as the rigid form with no steel mesh or concrete applied.  The dome buyer can purchase galvanized steel mesh from Ai and at no cost Ai will affix the mesh to the 22′ or 27′ garage entryway panels.  On site fiber concrete is mixed and hand troweled to all sides of the entryway panels after their installation.

An Ai dome building kit includes all the panels for the dome shell and includes the panels for one entryway.  Each floor plan varies as to the number of entryways and dormers.  As a result the kit pricing only reflects the type and number of entryways and dormers that you chose to have in your floor plan.  The following Plan’s Price does not include an engineer seal, structural calculations or energy report.  If those items are required by your building department they can be purchased from Ai for a reasonable fee.

To view Discount on the building plans and the kit with one entryway, please click on Sale.  To view stock plans for these Garage Kits and stock floor plan layouts for dome homes for each of the ten dome kit sizes, click on Stock Plans. To view Sale Pricing on the Building Plans and the Dome Kit for each plan, click on Plans and Kit Sale Pricing.

Stock Dome Plan Name

Second floor can be built in 27′, 30′, 34′, 36′, 40′, 45′ & 48′

Building Options Plans Price without sale discount Kit with Option Price without sale discount R28 insulation

 

22 Gamma 1 Garage
1 Entryway, one 1st Floor Door Dormer
$1,134  $21,665
27 Gamma 1 Garage
1 Entryway, one 1st Floor Door Dormer
$1,134  $28,409
30 Gamma 1 Garage
1 Entryway, one 1st Floor Door Dormer
 $1,198  $31,739
34 Gamma 1 Garage
2 Entryways, three 2nd Floor Window Dormers
 $1,261  $38,506
36 Garage w’ studio
1 Entryway, one 1st Floor Door Dormer, 5 WD
$1,294  $41,989
40 Garage w’ 1 Bedroom
1 G type Entry, 1 Standard Entry, 1 DD, 4 WD
 $1,333  $48,471
45 Garage – approx. plan
1 G type Entry, 1 DD, 3 WD
 $1,427  $55,828
48 Garage – approx. plan
1 G type Entry, 1DD,  3WD
 $1,514  $61,556

Garage Domes w’ Second Floor Studio Apartments

Garage Dome Stock Floor Plans

GARAGE DOME, 22’: has 370 sq.ft. on the first floor and is designed for a one-car garage. A 9’ wide x 7′ tall garage door can fit in the garage entryway. There can be a loft area for storage. Due to small size of the second floor panels, the loft area cannot have any window or door dormers.  A link connected to a 22′ dome is about 5.5 feet to 6 feet wide with a standard length of five feet.

Garage Dome, 27’: has 555 sq.ft. on the first floor sq.ft. and is designed for a two medium car garage. It can have a 16’ wide garage door in the garage entryway. The second floor center height is 8′ 4″ sloping down to five feet to equal 231 sq.ft. on the second floor.  The second floor can have  window dormers but no door dormers. The second floor can have fire egress window; therefore the second floor can have a bedroom.  A link connected to a 27′ dome is about 6.75 feet wide with a standard length of five feet.

Garage Dome, 30’: has 638 sq.ft. on the first floor and is designed for two small cars with the cars pulling in one at a time and each car parking on a diagonal. The 30’ garage door is 12’ wide. The second floor center height is 7’4″ sloping down to five feet to equal 213 sq.ft. on the second floor.  Due to small size of dome’s second floor panels the second floor cannot have window or door dormers.  Therefore no bedroom can be designed on the 30′ second floor.

Garage Dome, 34’: has 846 sq.ft. on the first floor and is designed for a two-car garage with the garage door being 14’ wide. The second floor center height is 9’5″ sloping down to five feet of head room to equal 427 sq.ft. on the second floor.  The second floor can have window dormers & door dormers.  If balcony desired the door size is 2′ x 6′ tall with this door being custom cut on site.  The second floor can have a bedroom and bath.  For fire egress second floor window to fit a second floor door dormer has to be installed above a standard entryway. Instead of installing a door a fire egress size casement window is installed.

Garage Dome, 36′: has 940 sq.ft. on first floor and is designed for a two-car garage with the garage door being 14′ wide. The second floor center height is 10′ 4″ sloping down to five feet to equal 470 sq.ft. on the second floor.  The second floor can have window dormers & door dormers. If balcony desired the door size is 2’x6’8″ and is custom ordered. The second floor can have fire egress size window & is large enough to have a bedroom with bath.

Garage Dome, 40′: has 1,160 sq.ft. on the first floor and can be designed for a three to four car garage depending on the vehicle sizes. It would require two garage doors, each could be 16′ wide. Each set of two cars would share one garage door. The second floor center height is 10’4″ sloping down to five feet to equal 667 sq.ft. on the second floor.  The second floor can have fire egress windows and door dormers above standard entryways.  The second floor is large enough to contain two bedrooms and one bath.

Garage Dome, 45′: has 1,489 sq.ft. on the first floor and can be designed for a three to four car garage depending on the vehicle sizes and entryway locations.  It would require two garage doors, each 13′ wide.  The second floor center height is 13’7″ sloping down to five feet to equal 951 sq.ft. if the second floor is maxed out.  The second floor can have fire egress windows and door dormers above standard entryways.  The second floor is large enough to contain three bedrooms and one bath.

Garage Dome, 48′:   has 1,693 sq.ft. on the first floor and can be designed for a three to four car garage depending on the vehicle sizes and entryway locations.  It would require two garage doors, each 14′ wide.  The second floor center height is 14’10” sloping down to five feet to equal 1,137 sq.ft. if the second floor is maxed out.  The second floor can have fire egress windows and door dormers above standard entryways.  The second floor is large enough to contain three bedrooms and one bath.

Q: What is the tallest and widest garage door you can have and in what size dome?
A:
Current designs allow for a 16′ wide 9′ tall garage door in a 40′ dome with a 4′ risers with additional 2′ risers.  A 27′ dome because it is two frequency can have 16′ wide garage door 7′ tall with a four foot riser.

Q: Can the 45′ and 48′ domes be designed for a garage dome?
A:
Yes.The standard entryway in the 45′ with 4′ risers can have a 13′ wide x 7′ tall garage door for a two car garage. The cars would go in and out of the garage one at a time. In a 48′ dome there can be a 14′ wide garage door in a standard entryway and the cars come and go two at a time.  Due to the large size of the domes for structural integrity three risers cannot be removed ONLY two.    If the 45′ or 48′ dome are built with two foot additional risers the garage door for a 45′ can be 13′ x 9′ or 15′ x 7′.  The Garage door for the 48′ dome can be 14′ x 9′ or 16′ x 7′.

Q: What is the cost to build a garage dome?
A:
The cost to build a dome garage would be about the same as the cost of a garage for a conventional house. Whatever it costs per square foot in your neighborhood to build a conventional garage that will be the approximate cost to build the dome garage.  The construction cost will increase if a bedroom and bath is installed on the second floor above the garage.

Q: Are garage plans priced separately from the other plans?
A:
Yes since every building site is different, Garage & Basement Plans are priced separately from the dome home plans. Ai has Stock Plans for garages which may be linked to any dome where indicated or may be built separately. Or Ai can design custom garage plans.