Construction Assistance | AiDomes

 

 

Three 22' domes under construction.  Contractor/Builder Dusty Rhoades, his wife Marilyn and helper Bob assembled the dome kits for the dome owners. Because the job site was remote, Dusty was very creative in the panel assembly.  He piled dirt to elevate his back hoe so it could reach the height he wanted.  Panels that were not hand installed were lifted into place with the back hoe.

Three 22′ domes under construction. Contractor/Builder Dusty Rhoades, his wife Marilyn and helper Bob assembled the dome kits for the dome owners. Because the job site was remote, Dusty was very creative in the panel assembly. He piled dirt to elevate his back hoe so it could reach the height he wanted. Panels that were not hand installed were lifted into place with the back hoe.

How do you assure that the Contractor pays for the supplies and pays the subcontractors?  Each person building a home needs to know about Lien Releases and Mechanics Lien.

Per the book The Complete Idiots Guide to Building Your Own Home: “What’s a Mechanics Lien? You’re building a house, not a car. So, why should you care about a mechanics lien? Anyone who helps you build your house, investing time and/or money, is considered a mechanic by law. And a lien is a piece of paper that offers your property as security until payment for services is made.

For example, the plumber comes out and puts in all the plumbing and fixtures in your beautiful new house, but you run out of money and can’t pay him. If the plumber was smart, he had you sign a mechanics lien before starting work. He can sue you for the money and force the house (with his plumbing) to be sold to pay him off.

If the lender is smart (and she is), draws may not be paid to the plumber until the bill is submitted along with a lien release. The plumber gets the check and simultaneously releases any rights to sue for the house.

A mechanics lien is a little better than a typical lien (at least for the mechanic) because it says, “Hey, I participated in the construction of this house and should get priority in payment over other types of creditors.” So, who are all these mechanics? You, the lender, the general contractor (if any), subcontractors, suppliers, and —everyone’s favorite—the IRS.

If you sign a mechanics lien, make sure you understand what it’s saying and who gets priority. And make sure, when the work is done, that the contractor signs a lien waiver when the check is disbursed.

Code Red: Your contractor gets the check for the plumber, but doesn’t pay him, so the plumber files a mechanics lien on your house. Ouch! Make sure your contracts cover this potential problem. Alternatively, have the lender or an escrow officer pay the bills and draws to make sure it’s all legal.”

For more information on liens click on: http://www.saroff.com/examples/businessdebt/lien-release.htm

Another view of panel being installed in third row of panels.

Another view of panel being installed in third row of panels.

By clearly defining the level of participation you wish to have in the construction process, and you select a contractor with a suitable program, chances are you will have an enjoyable building experience.

If you choose to not be an owner builder, then you may want to hire a contractor to coordinate all the phases of your dome construction. To learn about choosing a contractor, click on Contractor.

To view pictures of the kit assembly, click on Dome Kit Assembly and Construction Overview.

To review the planning phases to own a dome home click on Planning Process. Remember you can hire a Kit Assembly Consultant who will supervise your workers or your contractor’s concrete workers to assemble the dome shell with first layer of concrete in the seams and on the entryways and dormers. That way your contractor will feel more comfortable bidding the dome and its finishing costs.

When contracting the construction of your new steel reinforced concrete dome, you will most likely use a residential building contractor who will work with you in one of four ways:

1. Bid or Estimated Price: Your contractor takes the set of plans, bids out all phases of the project to subcontractors, and provides you with a total cost to build your home (gross dollar total or total cost per square foot). In this case, you place all responsibility for the project in your contractor’s hands.

2. Cost Plus Flat Fee: Contractor does the same as described in the first version, but adds a flat fee dollar amount to cover for his/her involvement in the project. This allows you more participation in the building process, and covers your contractor for their time.

3. Cost Plus Percentage Fee (Cost Plus Contract): If you anticipate a good deal of participation in the building process, including changing and/or upgrading as you proceed through construction, many contractors will bill you a percentage fee based on the completed cost of the home. It is a way to cover you and the contractor when you make changes not anticipated during planning and bidding phases.

4. Fee Percentage Contract: When you wish to be extremely active in all aspects of construction and material selection, your contractor will offer you a fee percentage contract, or a percent of the total cost of building your home, no matter what you decide throughout the process.

 

This page contains listing of builders & assemblers by state and country.  American Ingenuity’s concrete dome homes can be owner built or hire a builder who hires the independent Kit Assembly Consultant for kit assembly.

 

Caribbean

  • Robert Stephens with Pragma Consultants Ltd. at 110 Old Hope Road, Kingston 6, Jamaica purchased an assembled 45′ Aidome linked to a 34′ dome in Runaway Bay Jamaica and finished its interior and exterior.  He will bid the kit assembly and the building of an Aidome in Jamaica and the Caribbean. His contact info is  876-909-6338- Mobile.  Email is  rspragma@yahoo.com

 

COLORADO:

  • If you are looking for a reputable Geothermal Company, contact Major Heating: main office in Wheat Ridge 303-424-1622  and outlet in Steamboat 970-870-0983.

Florida:

  • For Lee and Collier Counties: Contact Bill Towler with Philip C Lemke Construction Company. His cell is 239-989-8140 email is BillT@PhilipCLemke.com   Their company address is 4290 Sunshine Blvd, Saint James City, Florida 33956. They will be finishing a 27′ Aidome and are interested in bidding the dome kit assembly and finishing of other Aidome projects in Lee and Collier Counties.
  • Andy St. Laurent is licensed builder in the Ft Lauderdale area. He is building a 40′ Aidome on concrete columns, concrete platform in the Florida Keys.   His phone number is 954-789-6544.  During the assembly of the dome kit, the independent kit assembly consultant was hired to supervise Andy’s workers.  He is interested in building other Aidomes.
  • Joe Galloway was the slab sub and assembled a 36′ kit with the assistance of a Specialist in Palaka Florida.  Joe is now a Florida certified builder.  He will travel to job sites outside Palatka. His phone info: W 386-684-4213, cell 386-972-4544.
  • James Randy Dixon with R. Dixon Construction. Inc assembled a 36’ dome in Trenton Florida in 2015 and are assembling two other Aidome kits in 2017.  He & one associate can travel to your job site to supervise your local builder’s workers for one week.  During that time, the builder will understand the kit assembly and can finish the kit assembly with his workers & call Randy with any questions he may have.  His address is 1549 SW 22nd Court, Bell Fl.  Phone: 352-949-2166  Email: dixonjames444@gmail.com  He will also travel as a Kit Assembly Consultant through out the USA and internationally supervising your workers or your builders workers to get the dome kit assembled.
  • Michael Lanigan with Von Alan in Lutz Florida will travel 60 miles from their area to build Aidomes.  His contact info is MKLBC13@gmail.com   813-898-4363
  • Jay Long with Veteran Garage Solutions &  Lifestyle Screens  has a patented screen to roll up under a garage door. He can be contacted at 407-608-2602 C VGSforyou@gmail.com  14900 E. Orange Lake Blvd. #303  Kissimmee, Fl 34747
  • Hernando County:  Jeff West with Cornerstone Builders will bid the installation of the foundation and the finishing of the dome once the kit is assembled.  His number is 352-279-6855.
  • Jeff Hoot Bryceville: 32009 904-266-4000, hoot@thequadruped.com Built his own Ai 40’ dome. He is interested in building domes for others. Nassau County. 
  • Charles Lovelace North Ft. Meyers: 33917 N Ft Meyers Fl 33917 239-823-7044. He is a subcontractor, will coordinate all subs for the job and help get the building permit, with client being owner builder.  Lee County.
  • David Jones Midwest Florida: 904-795-3722 Has built Ai domes. He knows of carpenters/cabinet installation, will travel within 40 miles of Citrus County. 
  • Rickey Schrader New Smyrna Beach: Built an Ai dome in New Smyrna Beach FL, 2414 Juniper Dr. Edgewater Fl 32141 Phone (904) 428-5488. Volusia County
  • Liz Davis Live Oak: 32060 386-658-2122, Cell 941-456-5696. She did a good job as owner builder of her own Ai dome. She has good workers to pass on.  Suwanee County

Florida Slab Subcontractors:

  • 36’ slab was installed in the Palatka area for $6,000 a few years back. The man that installed that slab is Joe Galloway.  He is now a licensed Florida contractor.  His number is 386-684-4213.  His email is jgallowayconstruction@yahoo.com
  •  Rockledge is slab subcontractor named Billy Brooks who has installed slabs for a dome owner that had three domes: 36’ screen dome, 40’ dome home and 27’ garage in Lee County.  Billy’s info is 321-863-8911  His email is billybrooks25@yahoo.com
  • Alfred “Billie”  Brinkley is located in Palatka Fl. Has not installed a dome slab but is willing to bid on and install.   386-697-3562
  • Hamilton Masonary –  Gray Hamilton is owner (yes GRAY) address is 2805 Kirby Circle, Palm Bay. Work 321-837-1447  Built stem wall under 40’ dome in Melbourne Beach, Fl. in 2013.

GEORGIA:

  • James Randy Dixon with R. Dixon Construction. Inc was the contractor on a 36’ dome in Trenton Florida in 2015. He & his two man crew are interested in bidding for future Ai dome shell assembly and interior construction from central Florida to northern Florida into southern Alabama and southern Georgia. He built the inside of the Walker 40′ & 34′ domes in Bell. FL.    His address is 1549 SW 22nd Court, Bell Fl.  Phone: 352-949-2166  Email: dixonjames444@gmail.com  He will also travel as a Kit Assembly Consultant through out the USA and internationally supervising your workers or your builders workers to get the dome kit assembled.
  • Bill Moorehead 706-213-0455 built his own 27’ wood dome and has also built an Ai Dome. He is interested in building domes for others. Elberton GA 30635.
  • Peter Kelley W: 404-782-2524, H: 404-782-6300 fax: 1-800-332-3827, PO BOX 167 or Oasis Dr. Lake Mont, GA 30552. Has built many domes including an Ai dome.

IDAHO:

  • Ron Reese Construction. He has built an Ai Dome in Sagle, ID 208-263-6193, 208-265-0702.

 IOWA: 

  • Contact Heather with StoneKing Enterprises. stonekingenterprises@gmail.com  work 319-393-1763; cell 319-521-5465. Builder in Robins and Cedar Rapids and surrounding areas.  Address 100 Front Street, Robins, IA 52328. Will bid Aidome kit assembly and finishing.

Pre-Construction Consulting 

This page is being revised.

Building an American Ingenuity dome building kit can be a Do It Yourself project or a Kit Assembly Consultant can be hired to supervise your workers or your builder’s workers.  Please scroll down this page to learn 1) about this specialist; 2) materials/tools/equipment needed for kit assembly; 3) charts showing approximate assembly time and approx. costs by dome diameter size when hiring the consultant.

 

Third row panel being lifted into place.

Third row panel being lifted into place.

The dome kit can be assembled by owner builders or the home owner or the home owner’s builder can hire the independent Consultant to supervise their workers to assemble the dome kit to the stage of having all the panels placed with one layer of concrete in the seams and on all the entryways and dormers.  The consultants travel through out the USA and internationally.   When hiring a local builder, best to pay him cost plus versus an overall bid. 

Great news,  Ai knows of a licensed Florida Builder, Randy Dixon, who will travel to some USA areas with 1 associate to assemble the kit using your local workers on your prepared foundation. Then yourself or your local builder’s subcontractors can install the doors and windows, prime/paint the exterior and finish the interior with locally purchased materials.  If his associate cannot travel to your area, Randy will travel as independent consultant.  If you are considering hiring Randy and his crew, it is best to pay them by the hour rather than have him bid the project where he will need to include in the bid a cushion. 

Ai knows of three other independent kit assembly Consultants, Kevin Killian (Florida), Steve Cooke (California) and Bob Bailey (South Dakota) who will travel to your site to supervise Aidome kit assembly as well.  

In Brevard County Florida, Builder Ray Vince with Pistolatun Inc. will bid the dome kit assembly and the finishing of the dome and complete the financing for those who qualify.   He also has land to sell in Palm Bay Florida plus knows of our property for sell in the County.  His info is 76 E. Merritt Island Cswy. #205, Merritt Island Fl 32952.  His phone number is 321-284-8116

Within the building plans is a nomenclature sheet where each panel is identified with numbers or letters showing where each panel is installed.

To view an article which covers why build a geodesic dome for your new home that summarizes the major info about the Aidome building system and component panel, please click on Why Build a Geodesic Dome.

If you have a deadline for your kit assembly or are assembling the large 45′ or 48′ dome, consider hiring the consultant to save  up to  2-3 weeks of labor costs.  Please scroll down to view charts listing estimated kit assembly times.  Click on Kit Assembly and Construction Overview to view other assembly photos.  Our finished cost per sq.ft. page discusses geodesic dome cost.  To view stock dome floor plans, click on Plans.

The Consultant will travel to your construction site and supervise your workers or subs or your contractor’s workers for the dome kit assembly with the first layer of concrete in the seams and a “scratch coat” on the entryways and dormers….and then he goes home.  FYI, he does not apply concrete….that is done by your concrete workers.  He supervises that the fiber concrete is mixed properly and installed properly.  The dome owner or their builder hires a finish stucco person, to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of finished concrete can be applied in around one hour per seam for a flat seam or up to 1 1/2 hrs for a custom rounded seam.  Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′-27′) has around 62 seams.   Prior to second layer of concrete, a bonding agent supplied by Ai is applied to the first layer of concrete that needs to set 30 minutes prior to the second layer of seam concrete being applied. The interior finishing is completed by you or by your contractor hiring local conventional subs (plumbers, electricians, drywall finishers, framers, etc.) to complete the interior finishing and the installation of your locally purchased doors and windows per your dome plans.

Prior to the availability of a Kit Assembly Consultant to supervise the dome kit assembly,  some of Ai’s dome owners had to hire a contractor who generally had never assembled a dome before.  As a result the contractor would tend to over charge because he did not know how long it would take or what problems would arise.  The Kit Assembly Consultant can provide you with references from previous American Ingenuity Domes he has assembled so you can assure yourself that your building kit will be assembled correctly and in a timely fashion. This Consultant works directly for you or your general contractor as an Independent Sub-Contractor.  The standard daily rate for the independent Kit Assembly Consultant/Specialist is $300.  If the Specialist is not paid mileage to drive to your site, he is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availabilty in vicinity of grocery store & restaurants.

The use of a consultant for one week can save up to two to three weeks on your shell assembly time and assures the kit is assembled accurately per the building plans.

The cost of materials to complete the assembly of the kit are not included in the labor estimates.  Many times rental costs are less for one month than daily or weekly rental costs.  As a result sometimes monthly rental is shown because it is cheaper. Equipment rental costs are from United Rentals.  

Estimates below are based on 2015-2016 construction data.  In 2017 there is a shortage of concrete workers which drives their pay up.  We will review the estimates in this post and update as data is collected.

The assembly time estimated below is based on a dome kit having one entryway, two dormers and no cupola built on a slab foundation.  

  • For each additional standard entryway: add one day for the consultant and 24 hours for the workers.
  • For a garage entryway two frequency: add 1 day for the consultant and 24 hours for the workers.
  • For each additional window dormer: add 2 hrs for the consultant and 12 hours for the workers.
  • For each additional door dormer: add 3 hrs for the consultant and 18 hours for the workers.
  • Cupola: takes three partial days because the concrete has to have time to cure during each process.  First partial day of 5 hrs: concrete beam around top opening is formed and poured.  Second partial day of 5 hrs: concrete corner columns are framed and poured.  Third partial day of 5 hrs: set top five panels, attach overhang panels & apply first coat of concrete in the seams.  During the rest of the partial days, workers can complete window dormers or door dormer installations.If the rib system has not been cut and prepared: add one day for the consultant and 8 hours for the workers.
  • If you want to speed up the kit assembly, consider renting a scissor lift for inside personnel movement (instead of using ladders and scaffolding) and renting a Straight boom lift – man lift or cherry picker- for outside personnel work (instead of ladders, planks and scaffolding).   A 19-foot electric scissor lift approx. rental is $350 to $500 per week, and $900 to $1,200 per month.  A 40′ straight boom lift approx rental is weekly $956 or monthly $1,915.
Labor & Equipment Estimates for AiDome Shell Assembly
Utilizing an Independent Kit Assembly Consultant

 Estimate For  22′ Dome Shell Assembly
With First Layer of Concrete in Seams & on entryways & Dormers

Consultant Days 14 $300/day $4,200
Worker Hours & Cost if $18/hr 328 $18/hr* $5,904
Worker Hours & Cost if $25/hr

Rental, Fork Lift (days)

328

1

$25/hr*

$405/day

if $25 hr -$8,200

$405

Rental Variable Reach Lull  two weeks  $1,169/wk $2,338
Rental, Scaffolding (days)$15- $50  14 $15/day $210
Rental, Mortar Mixer (days) 8 cu.ft. 14 $50/day $700

Approx Sub Total  For One Layer of Concrete in Seams & on 1 entryway & 2 dormers:  $13,757 – $16,053

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

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

*Worker Hourly Costs vary depending on your construction location. Plus travel costs or airline ticket for the Consultant. The Consultant is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availability in vicinity of grocery store & restaurants.

The dome owner or their builder hires finish stucco person(s), to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of  seam concrete can be applied in 50 minutes per seam for a flat seam or up to 1 1/2 hrs for a custom seam.  Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′ – 27′)  has around 62 seams.

 

 Estimate For 27’/30′ Dome Shell Assembly
With First Layer of Concrete in Seams & on Entryways & Dormers

Consultant Days 16 $300/day $4,800
Worker Hours & Cost if $18/hr 384 $18/hr* $6,912
Worker Hours & Cost if $25/hr

Rental, Fork Lift (days)

384

1

$25/hr*

$405/day

if $25 hr – $9,600

$405

Rental Variable Reach Lull two weeks  $1,169/wk $2,338
Rental, Scaffolding (days) $15-$50 15 $15/day $225
Rental, Mortar Mixer (days) 8 cu.ft. 15 $50/day $750

Approx Sub Total  For One Layer of Concrete in Seams & on 1 entryway & 2 dormers:  $15,430 – $18,118

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

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

Worker Hourly Costs vary depending on your construction location.  Plus travel costs or airline ticket for the Consultant, The consultant is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availability in vicinity of grocery store & restaurants.

The dome owner or their builder hires finish stucco person(s), to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of  seam concrete can be applied in 50 minutes per seam for a flat seam or up to 1 1/2 hrs for a custom seam.  Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′ – 27′)  has around 62 seams.

 

  Estimate For 34’/36′ Dome Shell Assembly
With First Layer of Concrete in Seams & on Entryways & Dormers

Consultant Days 17 $300/day $5,100
Worker Hours & Cost if $8/hr 408 $18/hr* $7,344
Worker Hours & Cost if $25/hr

Rental, Fork Lift (days)

408

1

$25/hr*

$405/day

if $25 hr – $10,200

$305

Rental Variable Reach Lull two weeks  $1,169/wk $2,338
Rental, Scaffolding (days) 17 $15/day $255
Rental, Mortar Mixer 8 cu.ft. month $620 $620

Approx Sub Total  For One Layer of Concrete in Seams & on 1 entryway & 2 dormers: $15,962 – $18,818

*Worker Hourly Costs vary depending on your construction location.  Plus travel costs or airline ticket for the Consultant. The Consultant/Specialist  is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availability in vicinity of grocery store & restaurants.

The dome owner or their builder hires finish stucco person(s), to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of  seam concrete can be applied in 50 minutes per seam for a flat seam or up to 1 1/2 hrs for a custom seam.  Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′ – 27′)  has around 62 seams.

 

Estimate For 40′ Dome Shell Assembly
With First Layer of Concrete in Seams & on Entryway & Dormers

Consultant Days 20 $300/day $6,000
Worker Hours & Cost if $18/hr 640 $18/hr* $11,520
Worker Hours & Cost if $25/hr

Rental, Fork Lift (days)

640

1

$25/hr*

$405/day

if $25 hr -$16,000

$405

Rental Variable Reach Lull month $2,346 $2,346
Rental, Scaffolding (days) 20 $15/day $300
Rental, Mortar Mixer  8 cu.ft. month $620 $620

Approx Sub Total  For One Layer of Concrete in Seams & on 1 entryway & 2 dormers: $21,191 – $25,671

*Worker Hourly Costs vary depending on your construction location
Plus travel costs or airline ticket for the Consultant
The Consultant/Specialist is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availability in vicinity of grocery store & restaurants.

The dome owner or their builder hires finish stucco person(s), to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of  seam concrete can be applied in 50 minutes per seam for a flat seam or up to 1 1/2 hrs for a custom seam.  Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′ – 27′)  has around 62 seams.

 

 Estimate For  45′ Dome Shell Assembly
With First Layer of Concrete in Seams & on Entryways & Dormers

Consultant Days 23 $300/day $6,900
Worker Hours & Cost if $8/hr 736 $18/hr* $13,248
Worker Hours & Cost if $25/hr

Rental, Fork Lift (days)

736

1

$25/hr*

$405/day

if $25 hr – $18,400

$405

Rental Variable Reach Lull month  $2,346 $2,346
Rental, Scaffolding (days) 23 $15/day $345
Rental, Mortar Mixer 8 cu.ft. month $620 $620

Approx Sub Total  For One Layer of Concrete in Seams & on 1 entryway & 2 dormers: $23,864 – $29,016

*Worker Hourly Costs vary depending on your construction location
Plus travel costs or airline ticket for the Consultant
The Consultant/Specialist is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availability in vicinity of grocery store & restaurants.

The dome owner or their builder hires finish stucco person(s), to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of seam concrete can be applied in 50 minutes per seam for a flat seam or up to 1 1/2 hrs for a custom seam. Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′ – 27′) has around 62 seams.

 

 Estimate For  48′ Dome Shell Assembly
With First Layer of Concrete in Seams & on Entryways & Dormers 

Consultant Days 26 $300/day $7,800
Worker Hours & Cost if $18/hr 832 $18/hr* $14,976
Worker Hours & Cost if $25/hr

Rental, Fork Lift (days)

832

1

$25/hr*

$405/day

if $25 hr- $20,800

$405

Rental Variable Reach Lull month  $2,346 $2,346
Rental, Scaffolding (days) 26 $15/day $390
Rental, Mortar Mixer 8 cu.ft. month $620 $620

Approx Sub Total  For One Layer of Concrete in Seams & on 1 entryway & 2 dormers: $26,537 – $32,361

*Worker Hourly Costs vary depending on your construction location
Plus travel costs or airline ticket for the Consultant
 The Consultant/Specialist is reimbursed for a round trip airfare, round trip shuttle transport cost between his home & the airport & car rental cost for the time at the job site.  The dome owner arranges and pay for lodging with Wi-fi availability in vicinity of grocery store & restaurants.

The dome owner or their builder hires finish stucco person(s), to apply and finish the second layer of concrete in the panels seams and on the entryways and dormers. Usually second layer of  seam concrete can be applied in 50 minutes per seam for a flat seam or up to 1 1/2 hrs for a custom seam.  Approximate number of seams in a three frequency dome (30′ – 48′) is 126 – number varies depending on number of entryways and dormers. A two frequency dome (15′ – 27′)  has around 62 seams.

 

To view info about the DVD that shows dome assembly, click on View.  To view the video free, click on DVD.

To unload the dome kit from the semi-truck, rent a fork lift and have 2-3 workers available.  Ai provides a document that describes the unloading process.

The dome owner provides three to five good concrete workers (depends on dome size).  Materials used in the shell construction are to be provided by the dome owner on site before the Kit Assembly process begins.  The bags of cement don’t have to all be delivered in advance but as soon as first needed during the assembly.

To view what items are included in the Dome Building Kit, click on Kit Contents.  To view what items are not included in the kit, click on Items Not Included.

Due to possible injury on a job site, have some form of insurance.

The following are items required at your job site:

Cement
  • Portland Cement in 94 pound bags (prefer Type III) (first number is the diameter of the dome/second number is bags of cement):  22′ – 30, 27′ – 40 (two frequency dome panels are larger so require less cement), 30′ – 70, 34′ – 79, 36′ – 83, 40′ – 90, 45′ – 100, 48′ – 106.  These bag numbers are based on the dome having two entryways, four window dormers, one door dormer and no cupola.
  • For each additional entryway add: 22′ – 3,  27′ – 3.5, 30′ – 4.0, 34′ – 4.5, 36′  – 4.5, 40′ – 5.0, 45′ – 5.0, 48′ – 5.5
  • For a cupola add: 30′ – 4, 34′ – 4.5, 36′ – 4.5, 40′ – 5.0, 45′ – 5.5, 48′ – 6.0.
  • For an additional door dormer on any size dome add 2.5 bags of cement.
Masonry or Stucco Sand
  • Sand in cubic yards; 27′ – 5, 30′ – 8, 34′ – 9, 36′ – 9, 40′- 10, 45′ – 11, 48′ – 12.  These computations are based on the dome having two entryways, four window dormers, one door dormer and no cupola.
  • For each additional entryway add cubic yards of sand: 22′ – 0.3, 27′ – 0.4, 30′ – 0.4, 34′ – 0.4, 36′ – 0.5, 40′ – 0.5, 45′ – 0.5, 48′ – 0.6.
  • For a cupola add cubic yards of sand: 30′ – 0.4, 34′ – 0.5, 36′ – 0.5, 40′ – 0.5, 45′ – 0.6, 48′ – 0.6.
  • For an additional door dormer on any size dome, add 0.3 cubic yards of sand.
Misc Items:
  • 2×4’s cut to length, holes drilled & ends painted for the temporary wooden rib system…can be purchased from Ai.
  • Water Source and water hoses
  • #3, #4 and #5 rebar (per the Building Plans)
  • Concrete Blocks; 8″x16″
  • Electric Power or Generator
  • Extension Ladder; 26′
  • Mortar Mixer – Do not use a cement mixer because it does not have spinning paddles.  Spinning Paddles are required to obtain a thorough mixing of the cement, sand, fibers and admixtures.
  • Lumber for Bracing the steel hubs, entryways and dormers
  • Wheelbarrows
  • Step Ladders
  • Two Saw Horses
  • Tarps to cover Cement and Sand
  • Ropes and chains
  • 5 gallon Buckets
  • Toilet facilities
  • Brushes to apply bonding agent
  • Soft Steel Tie Wire
  • Wire Cutters
  • Sponges to sponge finish final layer of concrete
  • Place to store boxed items out of the weather….C rings, pliers, cans of expanding foam, 1″ EPS Sheets, etc.

Additional Items Required:

  • Steel Hubs for Rib System (borrowed from Ai with a deposit placed)
  • Purchase bolts, nuts, washers to use with the hubs (purchased from Ai). During dome assembly most of these items are damaged; therefore they are not returned to Ai.
  • 2×4′ ribs for temporary wooden rib system – cut to length, holes drilled and ends painted. Can be purchased from Ai.
  • 9/16″ socket & ratchet and one 9/16″ wrench (use for bolts with HUBS)
  • Lifting Spikes set of 4 (purchased from Ai for $100). During panel lifting the spikes get damaged. If you have two domes, please order two sets of lifting spikes.
  • Panel Lifting Harness – custom make the harness from Ai sketch using four strands of 1/4″ chain 7 foot long & Quick Links.
  • Zinc or Galvanized Quick Links – To make the harness purchase Quick Links: 1 – 3/8″, 2 – 5/16″, 8 – 1/4″   2 – 3/8″, 4 – 5/16″.  During panel lifing the Quick Links are disconnected quite often so the threads become damaged.  Purchase additional Quick Links to have on hand for replacements….8 – 1/4″, 2 – 5/16″
  • Hoisting Mechanism; preferably rent 45′ Man Lift for dome on a slab or rent a 60′ Man Lift for dome built on basement.
How Long Will Shell Assembly Take with a Consultant?

Using three to five good concrete workers and depending upon the size dome, soil condition around the dome to allow movement and placement of the panels, type of hoisting mechanism and prevailing weather, shell assembly can take from 9-16 days if your dome kit includes two entryways, four dormers and no cupola and if dome on a slab. Once you know how many entryways and dormers are needed for your floor plan, Ai’s office can give you a more specific estimate on shell assembly time.  Click on Hoisting Mechanisms to learn more.

Typically it is cost effective to only have the Consultant stay for the assembly of the temporary wooden rib system, all panel placement including building options (entryways, dormers, link, cupola, etc.)  are assembled which includes the first coat of concrete in the seams and a “scratch coat” on the entryways and dormers.  Then your workers can:

  • apply the bonding agent and finish coat of concrete in the seams and on the building kit options. Remember to always water down all “old concrete” in the area you are working and all around the area working before applying bonding agent.
  • Follow Waterproofing document in the manual. The type of primer, tape and paint that is used, determines whether primer is applied before any areas are taped or patching compound applied prior or after priming.  Two coats of paint are applied. The following paints have been used by Ai dome owners:Behr’s top of the line exterior latex paint is Marque. Seabrook Texas dome owner loves this paint. He uses semi-gloss.  Marque has the most titanium.  – Home DepotBehr’s Premium Elastomeric Masonry, Stucco & Brick Paint –Home DepotAmes Research Labs: Maximum – Stretch, at participating ACE & True Value Stores (if using Ames see separate Ames doc because specific type sealants and primer need to be used with Ames Paint….TT3 sealant cannot be used)Sherwin Williams: Loxon XP Paint, Loxon Primer and ConditionerRichards Paint:  Rich Flex 245; use Rich Flex Alkali Resistant 100% Acrylic Masonry PrimerSeal Krete Paint (pigmented) –Home Depot
  • frame in and install the exterior doors and windows. (can be done earlier)
  • complete rough framing, electrical, plumbing
  • finish the interior shell wallboard with fiberglass adhesive  tape/joint compound. To blend the drywall seams to the DensArmor, skip trowel joint compound over the dome shell drywall.
  • prime then paint the dome shell interior gypsum
  • complete rest of construction phases.

As far as finishing the exterior seams with a second layer of fiber concrete, no need to pay to have the consultant on- site for this.  Best to hire a local finish stucco person by the hour with the conditions if he does timely work and good work, you will retain him.  If you are not satisfied with his work or speed, pay him for the time worked and replace him.  The second layer of concrete can take 20-30 minutes to apply per seam after the bonding agent is applied.  The bonding agent supplied by Ai needs to set 30 minutes before the second layer of concrete is applied. Approximate number of seams is 126…number varies depending on number of entryways and dormers.

Once your Building Plans have been ordered, American Ingenuity can estimate the number of days needed to assemble the shell.  Each floor plan varies as to the number of building kit options (components) needed to complete the shell kit; i.e. cupola, link, entryways, door dormers and window dormers.  Building Options take longer to install than triangles do.  To learn more about Building Options, click on Options.

You or your contractor hires local subcontractors to perform the typical jobs like forming and pouring the slab, plumbing, electrical, framing, drywall finishing, etc. Ai does not believe you should pay someone to come in from out of county or state to do work that your local subs can perform.  Click on Finished Cost, to learn about what it will cost to finish your dome home.  Click on Builders and Assemblers to learn more.

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

Contact Ai if you are interested in utilizing the Consultant/specialist…..321-639-8777…..9-5 Eastern Time.

If you are employing a contractor to assemble the kit, an experienced consultant on the construction site will make the assembly go faster and reduce costs.  The contractor provides the additional workers needed and the consultant directs them through the assembly of the kit.

If you choose to hire the Kit Assembly Consultant, the following labor estimates assume the following:

  • You have hired three to five good concrete workers depending on the size dome.
  • The slab/foundation and floor are completed.
  • A Hoisting Mechanism/Lifting Device/Boom Truck or Crane or Man Lift is on site to move the panels, to set the panels in place and lift buckets of concrete.
  • Additional equipment is on site, e.g.: wheelbarrows, ladders, scaffolding, mortar mixer, etc.
  • The first floor of the dome is not elevated above ground level.
  • The construction site is readily accessible for equipment and personnel.
  • Your local Laborer cost per hour is $15.  The labor cost per hour varies depending on your construction site location.  In California labor costs can be $25 to $30 an hour.