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Suitable Standard Door & Window Sizes

For American Ingenuity Domes

These tables contain CALL SIZES which are the customary size identification of the window industry. Call Size is the actual window dimension, for example Call Size 3/4 x 4/6 expresses 3’-4” x 4’-6”, which converts into 40” x 54”.  The horizontal dimension is always listed first x vertical dimension.  Check with your window supplier as to what sizes are best suited for fire egress windows in bedrooms to meet code.

H = Horizontal Sliding or Horizontal rolling windows

V = Vertical sliding, either double hung or single hung

C = Casement, swinging type window

F = French Door

22′
27′
30′
34’/36′
40′
45′
48′

1st Floor Window Dormer – Replacing a “H” Panel – Suitable Standard Window Size

2/8 x 3/2 V
4/4 x 3/0 V
2/0 x 3/2 VC
2/8 x 3/2 C
4/0 x 3/2 H
5/0 x 3/2 H
5/0 x 3/2 H
3/0 x 3/2 H
4/8 x 3/2 H
2/4 x 3/0 C
3/0 x 3/2 C
RO- 3/6 x 2/5 C
5/0 x 3/0 H
6/0 x 3/0 H
3/8 x 3/0 H
5/0 x 3/0 H
3/0 x 3/0 VH
RO – 2/5 x 3/6 C

1st Floor Window Dormer – Replacing a “P” Panel – Suitable Standard Window Size

NA
4/0 x 3/0 H
NA
NA
RO – 2/5 x 3/6 C
3/0 x 3/2 C
4/4 x 3/2 V
4/0 x 3/0 H
RO – 3/6 x 2/5 C
3/8 x 3/2 HV
4/8 x 3/2 H
3/0 x 3/2 C
3/4 x 3/0 HV
4/0 x 3/0 H
 

1st Floor Door Dormer – Replacing “H” or “P” Panels  – Suitable Standard Door Size

RED – “H” GREEN – “P”

22′

3/0″ x 6/8

27′
 
5/0″ x 6/8 F
30′
 
custom
34′ & 36′
 
2/6″ x 6/8
40′
 
3/0″ x 6/8
45′
 
5/0″ x 6/8 F
48′
 
5/0″ x 6/8 F
2/6″ x 6/8
3/0″ x 6/8
NA
NA
2/8″ x 6/8
3/0″ x 6/8
3/0″ x 6/8

2nd Floor Window Dormer – Recommended Window Sizes.  Window height is based on 7’6″ first floor ceiling height in the 22′, 27′, 30′ & 34′ domes.  Window height is based on 8′ ceilings on the first floor for the 36′ or larger domes. Both are based on 2×10 second floor framing.  Increase height 2″ for 2×12 framing.

 

To have a bedroom on the second floor of a 34′ dome, a fire egress casement window is installed in a door dormer NOT a second floor window dormer.  To have a door dormer on the second floor there must be a standard entryway below it.  The maximum size rough opening is 29″ x 42″ or 42″ x 29″.  Order casement window with egress hardware. 

A Second Floor Door Dormer can only be installed above a standard entryway. Due to the panel sizes in a 34′ dome, the second floor door dormer can only accept a custom door two feet wide by six feet tall.  Because of such a small door, this is why our web site states a second floor door dormer is not available on the 34′ dome.  However a second floor door dormer in stalled above a first floor standard entryway in a 34′ dome could be used to accept the required fire egress window.  This can be confusing, so please call for clarification…..321-639-8777.

2nd floor
dormer not
available use
solar tube
Fire Egress

RO 32″x42″ C

or RO 42″ x29″ C

order egress hardware

 

34′ 2nd floor door dormer only for fire egress window NOT WD
RO 29″x42″ C
or RO 42″x29″ C
order egress hardware

36 2nd floor door dormer only for fire egress window NOT WD

 

RO 29″x42″ C

RO 42″x 29″C

order egress hardware2/8 x 4/0 V

RO – 2/8 x 3/6 C

3/0 x 3/8 V2/4 x 3/5 C

3/4 x 3/0 V

3/8 x 2/8 H2/4 x 3/5 C

 

 

2nd Floor Door Dormer – Maximum Door Sizes.  First Floor ceiling height for 27′, 34′ and 36′ domes is 7′-6″.

22′ Dome
NA
27′ Dome
NA
30′   NA
34′ – 24″ x 60″
36′ Dome
24″ x 6/8
40′ Dome
2/6″ x 6/8
45′ Dome
2/6″ x 6/8
48′ Dome
3/0″ x 6/8

Cupola – Recommended Window Sizes – Horizontal Roller or Slider Type

22′
N/A
27′
5/6 x 2/0 H
2 – 2/8 x 2/0 H
30′
5/0 x 2/0 H
4/8 x 2/0 H
34′ & 36′
5/6 x 2/0 H
2 – 2/8 x 2/0 H
40′
7/0 x 2/0 H
2 – 3/4 x 2/0 H
45′
8/0 x 2/0 H
2 – 3/8 x 2/0 H
48′
8/0 x 2/0 H
2 – 4/0 x 2/0 H

Cupola windows can not qualify for egress because they are too high above the floor. Two standard vinyl horizontal roller or slide type windows are needed to fill one rough window opening of a cupola. They can be installed with a mullion in between them or custom windows can be installed.Florida and most other state’s code for Glass and Glazing requires tempered glass to be used in windows whose nearest edge is within 24″ radius of a door in closed position. Tempered glass is also required for glass panes with a bottom edge less than 18″ and a bottom greater than 36″ above the floor.

 

Maximum Rough Opening Sizes for Doors and/or Windows

Our Entryways and Dormers provide openings in the dome that accommodate conventional doors and windows that you purchase locally. The walls within these openings are built on-site to fit your choice of door and window sizes.

Typical heights (distance “D” from the floor to the top of the opening) are listed in the first column with the maximum available rough opening listed for each dome size.

Opening sizes are listed as Width x Height.

Entryway & High Profile Entryway – Maximum Size Rough Opening For Doors and/or Windows

D
22′
27′
30′
34’/36′
40′
45′
48′
Standard
80″
NA
NA
99″ x 82″
119″ x 82″
147″ x 82″
171″ x 82″
186″ x 82″
High Profile
96″
NA
NA
86″ x 96″
106″ x 96″
135″ x 96″
159″ x 96″
173″ x 96″

Garage Entryway – Maximum Garage Door Size

D
22′
27′
30′
34’/36′
40′
45′
48′
84″
9′ x 7′
16′ x 7′
12′ x 7′
14′ x 7′
16′ x 7′
n/a
n/a

Great News for Florida Customers.  One of our perspective dome buyers has discovered two companies in south Florida who sell Florida approved impact glass doors and windows and shutters at a reasonable price.

The factory for the Impact Glass Windows and Doors is:

Curv-A-Tech Corp.  930 West 23rd Street Hialeah,FL. 33010    curvatechcorp@bellsouth.net     Phone: 305-888-9631

 

The company for Hurricane shutters & Glass is:

DEPENDABLE SHUTTER & GLASS   

Phone: 888-694-6698    Fax: 954.791.0840   4741 Orange Drive, Davie, FL 33314  www.dependableshutter.com

 

Please use this chart for size estimating only. During Plans Design Ai will email elevation views showing possible rough opening door & window sizes.

1st-fl-window-and-door

2nd-fl-window-and-door

From Better Homes and Gardens – what to consider when replacing windows & buying windows.

In older houses, faulty windows can account for a third of the total heat loss in winter and as much as 75 percent of interior heat gain in summer. Look for the following telltale signs that a window has lost its effectiveness:

  • Stand inside your house on a windy day with a lit candle near the window’s operative edge. If the flame flickers or goes out, your weather stripping might be damaged.
  • During the winter, if a window develops ice buildup or a frosty glaze on the interior of the pane, the ventilation in your home may not be adequate. Another possibility is that your window may not be providing enough insulation value, a situation that can make your heating bills soar.
  • Sit near your window. If you feel cold air coming in during the winter or warm air during the summer, your windows have little insulation value. This means you’re paying more to heat and cool your house to compensate for the exterior air entering your home.
  • Do your windows get fogged with condensation? If so, you may have a seal failure and need to replace the glazing or the entire window.

In some cases, replacing broken panes and tending to loose or missing weather stripping may buy some time. If your windows are old and ill-fitting, however, you need more than stopgaps.

Replacement window options:

Wood is the choice of most homeowners. Wood is strong, insulates well, and has natural appeal and a warm look. It needs exterior maintenance, and interior surfaces can be painted, stained, or finished any number of ways.

Vinyl windows do not need to be painted or stained. They offer good insulation value and strength, making them a viable alternative to wood.

Aluminum windows have a stronger frame but poorer insulation than wood or vinyl. They’re fine in areas with a mild climate, and are also used for commercial applications.

Fiberglass combines the higher strength and stability of aluminum with the insulating properties of wood and vinyl. Fewer options are available at this time, as fiberglass is just beginning to show up in the window market.

Combination windows are available with wood on the interior and vinyl or aluminum on the exterior, combining the look of wood with a low-maintenance exterior material. This is known as “cladding” (as in vinyl-clad or aluminum-clad).

Features to consider when purchasing windows:

Energy efficiency. Almost any good-quality window available today incorporates two pieces of glass with a sealed airspace between then as a buffer between indoors and out. Some windows are even triple-paned. You may have the option of argon gas instead of air between the glass to further the window’s insulating abilities. Most window manufacturers also offer such options as low-E glass, which reflects heat and screens out the sun’s rays.

Design. Windows are available in shapes ranging from quarter rounds to ovals. Consider an arrangement of smaller windows instead of one large one, or vice versa.

Ease of installation. The easiest type of replacement window is a frame-within-a-frame design that can be installed in an existing frame without disturbing walls or trim work. Some are sold in kit form, complete with hardware, for standard sizes. If your original windows have divided lights or panes, look for multipane replacements or snap-in grilles that match glass dividers on the old units as closely as possible. If your windowsills are rotting or damaged, however, you’ll need to replace the old frame as well.

Ease of maintenance. Weather-resistant materials will reduce your regular maintenance; vinyl or aluminum-clad exteriors need no painting. For ease of cleaning, choose windows that tilt in or open from the side. Many double-hung windows now come with tilting sashes so both interior and exterior glass surfaces can be cleaned from inside the house.

Function. Tempered glass is required by code for certain applications, such as glass doors and some window installations with low sill height. For more extreme conditions, such as coastal environments, consider laminated impact-resistant glass designed to withstand hurricane-force winds and the impact of airborne debris.

Hardware. Some manufacturers offer improved hardware for crank-out windows such as casements and awnings — specifically, collapsible or low-profile handles that don’t interfere with blinds or other window coverings. Others offer a variety of style options for latches and locks. To be safe, ask about these and any other convenience features before the units end up in your walls. Also, try the hardware in the showroom. Does the window lock, unlock, and open easily? This test gives you a feel for the window’s usability and its overall quality as well.

Cost guidelines:
Broadly, vinyl and wood are the least expensive, fiberglass costs more, and clad windows are even more. That said, a general price range for an average size (30-inch by 48-inch) window is $100 to $200, which will be higher in urban areas.

More features like tilting versions and higher E-ratings increase the cost, although sometimes as the price and quality increase, more options are included. Differences in the up-front purchase price of a window may eventually be offset by other factors. Energy efficiency and a no-maintenance exterior will offset the up-front cost difference over time. Second, installation and labor costs could actually be higher for an “economy-grade” all-wood window, if you factor in charges for painting, and how much sooner you may have to replace it than a window made from more durable material.

One way to keep your window costs from rising is to avoid special orders. Try to work with standard sizes from a manufacturer, and select from the standard styles and features that your local retailer stocks.

 

 

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 as of May 2017,  Ai knows of a licensed Florida Builder, Randy Dixon, who will travel to some USA areas with 2-3 men to assemble the kit 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 crew does not travel to your area, he 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

In Texas, builder Don Simons with NewTech Builders, Inc. states he will bid the dome kit assembly and the finishing of the dome for Texas and surrounding states.  He has a superintendent who will travel to your site, interview subs and hire subs for the site clearing, driveway installation, foundation installation, dome kit assembly, electrical, framing, plumbing and finishing of the interior and exterior of the Aidome.  His number is 979-212-6000.

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

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

*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

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* $6,720
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: $17,336 – $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.