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 Testimonials American Ingenuity dome owner quotes and pictures 

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15 year old – 34′ Dome on full basement in Colorado

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Colorado 34′ Dome’s kitchen & partial view of second floor

34′ Dome on full basement in Colorado which is 15 years old:  Toni told us: “I built the American Ingenuity dome for my retirement home and now that I am retired I am so glad that did. I love my dome.  In 2014 we experienced a hail storm that beat the paint off part of their dome & damaged a vent. There was no damage to the concreted panels. To warm the dome in the winter I designed the windows to face south to let the sun in, I installed baseboard heaters that are heated with hot water and I use propane to heat the water in the boiler.  For back up I have a small gas stove.”  Above are two pictures of her dome.

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Twenty-five year old Florida AiDome Home Built in 1992

Three dome complex consists of 40′ dome home linked to a 30 garage dome with separate 22′ work shop dome (not visible on the right).  In an 8/2/17 Florida Today article, the reporter wrote:

But perhaps one the best selling points, the couple added, is the home’s safety features. Terry explained that the geodesic home is built to endure up to 225 mph winds, and is energy efficient. The couple said they have not paid more than an $80 electric bill since living in the home. 

“We’ve never had to evacuate (during a hurricane),” said Terry. “And we’ve never had any hurricane damage.”

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Pictures below are of this 45' dome on full basement.

Oliver 45′ Dome on full basement in Missouri – 21 year old dome

Dome Sold in 2011

Building the dome was a labor of love. We had visited your offices and researched every model and floor plans of every kit manufacturer in the US and, as you know, chose American Ingenuity’s kit. It was a wonderful experience constructing it. We appreciate all the guidance and support we received from you folks. We are available for testimonials and recommendations to any and all interested parties. Ralph Oliver. To view more pictures of their dome, please click on Oliver dome.

 

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Charles exterior

Charles 40ft Dome

Charles living pic1Charles 40′ Dome in Pennsylvania

One of American Ingenuity’s Pennsylvania Dome Owners Roger & Jeanne Charles installed radiant floor system in their basement and dome first floor.   To view pictures of their dome, please click on Charles Dome

This a quote from them and above are two pictures.

“We live in the mountains of PA. The winters up here can be brutal. Our Ai Dome is a 40ft with Link on a 9” livable basement. {Den, Office/Computer room, Kitchenette} The entire interior, to include the mechanical room, is heated and cooled by a GeoThermal, Water furnace, Radiant floor system.

Our zone controllers are set on 74 degrees winter and summer. Our sole power source, at present, is the grid. Our costs per month range from $99 to a high of $120. We were amazed that our cost now are less than when we lived in a 14 by 73 ft mobile home while building the Dome.

Our decision to build an American Ingenuity Dome home was the best decision we have ever made.”

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Whaley 34′ dome kitchen view. 

From R. Whaley, Florida: “Once the dome is initially heated or cooled, the temperature remains constant. Just think of when you take your soda pop to the beach on the hottest day of the year in an inch thick foam cooler. Once the house gets cool or hot as desired, it retains that temperature and stays constant.” In 2004 their dome went through two hurricanes. The following is their comments on the storms: “We live in a 34′ dome one block from the ocean. Our domes went through Hurricane Frances and the exit winds of Hurricane Charley. During the hurricane we could hear things hitting the domes. In the morning we walked around the yard and picked up shingles and soffits from other people’s houses and washed off our driveway. It was as if nothing had happened at all.” (34′ dome home and 27′ dome garage)

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From the Mathes, Florida: Their 34′ dome home with 30′ garage dome utilize a solar water heater and photovoltaic panels to power their lights and refrigerator. Although, their A/C, washer, well pump and TV are still connected to the meter, their total electric bill was less than $150.00 for the year. The owner/builder also states, “This has been a wonderful experience that I would not trade for ANYTHING!”

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Exterior solar Pineapple garage

34′ dome linked to 22′ one car garage dome – 12 year old domes.

Interior kitchen island 34' Pineapple

34′ dome kitchen built on entryway wall

From G. Busick, Florida: “During the hot summer months (May thru August), we can cool a 1,075 sq.ft. dome for less than $27 a month. We maintain an interior temperature of 76 degrees when home and 79 degrees when not.  To view electric bills & other 34 dome pics, click on Energy Efficient.

During Hurricane Jeanne, our neighborhood had 80 mph winds. The Ai domes had no damage, but a neighbor across the street lost her roof.. The entire interior of her house had to be replaced due to water damage.” (34′ dome home and 22′ garage dome) See info on Hurricanes.

 

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Exterior harlock showing both domes cor gb

 40′ dome linked to 30′ Garage Dome – 30 year old domes.

Interior dining room screen dome patio

From M. Ferral, Florida:  dining room in 40′ dome.  All electric home.  Three bedroom two bath 40′ dome average summer AC costs is less than $50.  I-95 abuts the back of this property.  When sliding doors are closed cannot hear traffic.  These domes won the award for “Most Energy Efficient Residence in the Southeastern USA.”

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Front

48 foot diameter (48 Delta 22 floor plan) approximately 2,600 sq. ft.

three bedroom, two bath American Ingenuity two story,

steel reinforced concrete dome home in Edgewater Florida.

Per Eric, “The Dome is very efficient and strong. It has been hit by several hurricanes and tropical storms with no damage at all. My neighbor’s conventional house was severely damaged by the storms. I keep the house at 72 degrees in the summer and warmer in winter. My electric bill is around $100 a month with no water/sewer bill because I’m on well/septic. The house is designed for very little maintenance.”

Features of the dome:
1. 3 ton 13 seer central AC system.
2. All windows are 7/8 low e argon filled dual pane glass.
3. The 10 foot sliding door is 1 inch low e argon filled.
4. The concrete exterior is painted with elastomeric paint.
5. Has 4 skylights and a transom window…all low e.

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From the Sparrows, Florida Keys: “We call our home ‘Sparrows’ Nest’…it’s pretty strong. It may look small from the outside, but…there’s a lot of room. The house is a rock.” (30′)

From the Clarks and Sayles, Ft Pierce Florida: “The eye wall of Hurricane Frances sat on us for two hours so the category 2 hurricane did category 3 damage. We experienced 120 to 130 mph winds with no dome damage while the house across the street lost most of its shingles.”

From the Woods,  Florida: “We were in the direct path of Hurricane Charley. We had winds greater than 145 mph and our dome had no problems. One widow got a crack from debris. Most of our town was destroyed and all three area hospitals had roof damage. Thank you for our dome.” (40′ dome and 27′ garage dome)

From the Vandebergs and Delongs, North Ft. Meyers Florida: “Thank you for our dome. The eye of Hurricane Charley passed only 15 miles from our dome. We had 117 mph sustained winds. Our domes stood strong. The only vulnerable part was our garage door. We used 2×4’s, plywood and sandbags to keep it from blowing in.” (34′ dome and 27′ garage dome)

From the Drybolas, Milton Florida: “Our neighborhood looked like a war zone. We were in the direct path of Hurricane Ivan and had the full blast of the winds plus there was a tornado in our area. Our concrete domes were wonderful and suffered no damage, despite winds of over 135 mph. Pine trees were stripped of bark and needles and many were lying on a 45 degree angle. Firefighters came by our dome and told us ‘You have the right house for this storm.’ We’ve had over 200 people stop by and see our dome. Believe me your product has never been shown off as good! Wish more people by the beaches, who lost everything would come by, sure wouldn’t have to worry anymore.” (45′ and 30′ with 34′ screen dome)

From the Hendersons, Santa Rosa Beach Florida: “We had over 135 mph winds from Hurricane Ivan and our domes suffered no damage. Our domes are close to the Gulf and sit about 56′ above sea level. This is higher than the surrounding houses so we received the maximum of any wind force, yet we received no damage. (48′ and 34′)

From L. Sawh, Florida: “It’s hard to believe, but we finally finished this house of ours! It’s taken us a good year and a half but its all been worth the hard work and challenges. We began with some designs on paper, added some features of our own, took a few suggestions from other dome owners and with a lot of sweat and pain, not forgetting our subs and the folks at the bank, here we are!!!” (40′ and 27′ Garage dome)

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From R. Napolitan, Idaho: “The dome is snug and warm. We heat it mostly with a woodstove that’s in the basement. Our staircases are open so the heat rises. It stays about 68 degrees without much effort, with our lowest outside temp…5-6 degrees. (2,000+ sq.ft. with basement, 34′)

From B. Gates, Illinois: “I’ve never been too much of a conventional person. I thought this was a pretty neat design, very energy-efficient. I like to keep things environmentally nice. It’s almost an organic feeling, being surrounded by curves instead of by rectangles. It seems to be a more relaxing environment to be in.” (48′)

From D. Partlow, Indiana: “The dome is ‘awesome’, ‘beautiful’ and ‘breathtaking’. At least that’s what visitors say. It is and it’s also a very comfortable home to live in. Our June electric bill was $107, we are total electric! We still love the house and the great savings on energy!!!” (2,400+ sq.ft.; 48′)

From S. Mumphrey, Louisiana: “We’re three years in our dome…we still pinch ourselves every morning thinking its a dream. But, it’s REAL and we love it.” (45′)

From L. Gillis, Michigan: “I don’t see how a city can ignore one of the great architectural breakthroughs of the 20th Century. A city without geodesic domes, is not thinking about progress. It’s thinking about replicating the past. A city cannot be a world-class city, unless it has some geodesic domes.” (45′)

From H. Willis, Mississippi: “I like the openness. You can see the kitchen, dining room, living room and bedroom loft when you walk in the front door.” (34′ with 25′ screen dome)

From L. Covington, North Carolina: “Doing everything on my own, not too bad when I think that it will save me $25,000 in labor costs for doing everything outside and inside….The folks that ride by are trying to break their necks gawking at the dome. A curiosity for folks I guess and a few have stopped for more info and a lot come back from time to time to check the progress….” (30′)

From J. Chang: “Thank you again for being the great company that you are! Keep us in the loop with information on finishing touches.” (48′)

From K. Millar, South Carolina: “What this house is about is alternatives.  We decorated it with an Oriental theme, even painting the floor with an Asian motif and we surrounded the house with a Japanese garden.” (40′)

From R. Scripps, Texas: “I like to thank you again for the advice you have given me and Dale.” (Two 45′ domes on full basements)

From J. Holden, Texas: “We just love our four domes, even after 15 years!” (40′)

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RayMesa Snow-4

Utah 45′ Dome Home linked to 30′ Garage Dome

 

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Utah 45′ Dome Home Living Room

From J. Collar, Utah: “My wife, Mary, devoured articles and books about straw bale, rammed earth, poured adobe, earthships, log, and any other unconventional building systems. Finally, Mary announced to me that she had found our house; a precast concrete and eps geodesic dome kit! Although I wasn’t wild about the look of a dome house, as an engineer I was excited about the sheer practicality. I quickly ran some heat loss calculations and found that at -20 degrees F, we could expect to keep the 2700 sq.ft. of living space at 70 degrees F using little more than 30,000 btuh, about 1/3 the size of a conventional home furnace. With judicious use of a large solar window and a masonry heater fireplace, we could limit our use of propane for backup heating.” (45′ and 30′ Garage dome)  

Jim Collar’s Utah Ai concrete dome buildings operate off the grid by using photovoltaic’s, masonry heater fireplace and passive solar water tubes. To learn more, click on Off the Grid.

This article covers Cisterns & Rain Barrels. Rainwater coming off the dome can be caught in troughs and carried to your cistern. One of American Ingenuity’s clients in Tortola British Virgin Islands installed a cistern.

The following information came from the web site www.oas.org

The application of an appropriate rainwater harvesting technology can make possible the utilization of rainwater as a valuable and, in many cases, necessary water resource. Rainwater harvesting has been practiced for more than 4,000 years, and, in most developing countries, is becoming essential owing to the temporal and spatial variability of rainfall. Rainwater harvesting is necessary in areas having significant rainfall but lacking any kind of conventional, centralized government supply system, and also in areas where good quality fresh surface water or groundwater is lacking.

Annual rainfall ranging from less than 500 to more than 1,500 mm can be found in most Latin American countries and the Caribbean. Very frequently most of the rain falls during a few months of the year, with little or no precipitation during the remaining months. There are countries in which the annual and regional distribution of rainfall also differ significantly.

For more than three centuries, rooftop catchments and cistern storage have been the basis of domestic water supply on many small islands in the Caribbean. During World War II, several airfields were also turned into catchments. Although the use of rooftop catchment systems has declined in some countries, it is estimated that more than 500 000 people in the Caribbean islands depend at least in part on such supplies. Further, large areas of some countries in Central and South America, such as Honduras, Brazil, and Paraguay, use rainwater harvesting as an important source of water supply for domestic purposes, especially in rural areas.

Technical Description

A rainwater harvesting system consists of three basic elements: a collection area, a conveyance system, and storage facilities. The collection area in most cases is the roof of a house or a building. The effective roof area and the material used in constructing the roof influence the efficiency of collection and the water quality.

A conveyance system usually consists of gutters or pipes that deliver rainwater falling on the rooftop to cisterns or other storage vessels. Both drainpipes and roof surfaces should be constructed of chemically inert materials such as wood, plastic, aluminum, or fiberglass, in order to avoid adverse effects on water quality.

The water ultimately is stored in a storage tank or cistern, which should also be constructed of an inert material. Reinforced concrete, fiberglass, or stainless steel are suitable materials. Storage tanks may be constructed as part of the building, or may be built as a separate unit located some distance away from the building. Figure 1 shows a schematic of a rooftop catchment system in the Dominican Republic.

All rainwater tank designs (see Figures 2a and 2b) should include as a minimum requirement:

  • A solid secure cover
  • A coarse inlet filter
  • An overflow pipe
  • A manhole, sump, and drain to facilitate cleaning
  • An extraction system that does not contaminate the water; e.g., a tap or pump
  • A soakaway to prevent spilled water from forming puddles near the tank

Additional features might include:

  • A device to indicate the amount of water in the tank
  • A sediment trap, tipping bucket, or other “foul flush” mechanism
  • A lock on the tap
  • A second sub-surface tank to provide water for livestock, etc.

The following questions need to be considered in areas where a rainwater cistern system project is being considered, to establish whether or not rainwater catchment warrants further investigation:

  • Is there a real need for an improved water supply?
  • Are present water supplies either distant or contaminated, or both?
  • Do suitable roofs and/or other catchment surfaces exist in the community?
  • Does rainfall exceed 400 mm per year?
  • Does an improved water supply figure prominently in the community’s list of development priorities?

If the answer to these five questions is yes, it is a clear indication that rainwater collection might be a feasible water supply option. Further questions, however, also need to be considered:

  • What alternative water sources are available in the community and how do these compare with the rooftop catchment system? – What are the economic, social, and environmental implications of the various water supply alternatives (e.g., how able is the community to pay for water obtained from other sources; what is the potential within the community for income generating activities that can be used to develop alternative water sources; does the project threaten the livelihood of any community members, such as water vendors?)
  • What efforts have been made, by either the community or an outside agency, to implement an improved water supply system in the past? (Lessons may be learned from the experiences of the previous projects.)·
  • All catchment surfaces must be made of nontoxic material. Painted surfaces should be avoided if possible, or, if the use of paint is unavoidable, only nontoxic paint should be used (e.g., no lead-, chromium-, or zinc-based paints). Overhanging vegetation should also be avoided.

Water Barrels

The following information came from Aaron’s Rain Barrels web site http://www.ne-design.net/

A rain barrel is a rainwater harvesting system that is connected to a down spout tube from a house or building. We make quality rain water barrels that collect, store and divert rooftop runoff during a rain shower.

An Aaron’s Rain Barrels is a better designed rain barrel. We offer you our #1 selling recycled plastic barrel or a traditional whiskey barrel. Our preferred rain collection barrel connects directly to your rain gutters down spout tube, has an overflow valve and is only made from the best quality parts so they last a lifetime.

There is more to making rain barrels then just adding a spigot to a barrel. If things are not done just right your rain barrel will leak within a few weeks.

 

Wood Star on exterior Dome Wall.

Wood Star on exterior Dome Wall

The American Ingenuity dome owner is conscious of what materials are used to finish

the interior of their dome. Natural sold oak was used for the stair case

and wood star.  Very warm and cozy.

 

Healthy Dome Living Questions & Their Answers

Q: Does the interior shell wall board that American Ingenuity utilizes support the growth of mold and mildew?

A: No. The 1/2″ Georgia Pacific Dens-Armor Plus drywall that Ai utilizes showed no mold or mildew growth when tested per ASTM D 3273. The drywall is adhered to the E.P.S. insulation with wallboard adhesive. The Dens-Armor employs fiberglass mat facing instead of paper on both sides of the board. The inorganic core provides excellent moisture resistance, fire resistance and adhesion properties. It doesn’t provide fuel for an accidental fire. It isn’t even damaged by multiple immersions in water. It won’t harbor spores that create sick homes.

The glass mats embedded into the core on both faces, results in dimensional stability and prevents warping. The glass mat is encapsulated with a coating which reduces skin irritation from exposed glass fibers. The moisture-resistant inorganic core has superior mold, mildew and fire resistance.

The following info was taken from Georgia Pacific’s 1/2” Dens-Armor Wall board data sheets:

Dens-Armor wall board features an inorganic glass mat embedded into a water-resistant treated gypsum core. The combination of glass mat surfacing and a treated core renders Dens-Armor wall board more resistant to delamination from water than paper-faced gypsum products. Comparative testing has demonstrated Dens-Armor wall board’s supremacy over such alternatives as perlite and fiberboard. Its engineered features make Dens-Armor wall board the obvious substrate for housing membranes. Resists delamination, deterioration and warping, puncturing and other job site damage and resists rot.

Fire Protection: Because of its noncombustible core and surface, Dens-Armor wall board offers greater fire protection than other conventional products. Dens-Armor wall board, when tested to ASTM E 84, has achieved a rating of 0 flame spread and 0 smoke developed. Noncombustible when tested in accordance with ASTN E 136.

Properties of Dens-Armor: Noncombustible, Water Resistance, Dimensional Stability, Decay Resistance, Resistant to Warping, Rodent and Fungus Resistance, Torch Safe, High Compressive Strength.

Fire Classification: UL Class A, ULC S-102; UL 1256, ULC S-126; UL 790; ULC S-107.

Flame Spread/Smoke Developed: per ASTM E 84 – 0

R-Value: as tested in accordance with ASTM C 518 (heat flow meter) -.28

Surface Water Absorption, grams: per ASTM C 473- 2.5

Mold & Mildew Resistance: per ASTM D 3273- No growth

The wallboard finishing includes applying joint compound and tape on the seams and painting the wall board. To blend the seams, mix some vermiculite into your paint.

You can purchase the building kit without the interior wall board. If you do not purchase the optional interior wall board, on site you can trowell either plaster or stucco directly to the E.P.S.

Q: Do any of the materials utilized in your panel – EPS (Expanded Polystyrene insulation), Galvanized Steel Mesh, Fiber Concrete or Georgia Pacific DensArmor – contain any food source for mold growth?

A: No. The materials are not a food source for mold growth.  Algae can sometimes be mistaken for mold.  It contains no spores and is not mold. Algae will grow on materials if exposed to water and sunlight. Algae is removed with combination of bleach and water or oxygen/bleach and water.

Q: I have allergies. Does your product promote allergic reactions?
A:
We have had a individuals contact us who are allergic to chemicals, etc. Feel free to us at 321-639-8777 Monday thru Friday 9 to 5 eastern time with your questions or click on Contact Us and email your questions. One of our clients has had to live in a stainless steel trailer due to reactions to conventional building materials. She investigated our dome and  built two of Ai’s small domes for her permanent residence.

The best way to see if you would be allergic to our shell materials is to purchase a small sample of a panel. Then ask someone to place the sample in a brown paper bag and without you knowing when, have them put it under your bed. Let them remove it at a later date and put back an empty paper bag and see if you have any reaction at any time during the test period.

The E.P.S. insulation Ai uses was expanded with steam, no chemicals. The quality of your indoor air will be determined by your interior materials such as flooring, upholstery, cabinet composition and whether an energy recovery ventilator or heat recovery ventilator and exhaust fans have been installed in your dome.  Please ask your local HVAC subcontractor for his recommendations for how to bring in fresh air for your area.

American Ingenuity has been manufacturing dome housing kits since 1976, during that time we have not heard of any of our domes having “sick building syndrome” due the following:

  1. Dome Homes always have doors and windows. Double paned windows are only an R-4 so air moves back and forth through the glass and or the windows are opened to let in fresh air.
  2. Dome owners have central air conditioners, furnaces or dehumidifiers or energy recovery ventilators or heat recovery ventilators that serve the purpose of removing the moisture within the dome.
  3. To exhaust the moisture out of the top of the dome, exhaust fans are installed in top center of the dome, in each bathroom, above stove and microwave, in the laundry room.

Q: Does the insulation Ai manufacturers with support the growth of mold and mildew?
A:
Based upon a FHA test, expanded bead polystyrene insulation, E.P.S. ,will not support bacterial growth or fungus growth. It also contains no food value to any living organism. Its lack of food value means that although termites, ants and rodents could tunnel through it, there is no other attraction. The following is other information taken from the E.P.S. data sheets.

  • OUTGAS: The E.P.S. is made from expandable polystyrene beads. These spherical beads contain a blowing agent such as pentane, which causes the beads to expand up to 40 times their original volume in the presence of steam. After the expansion and long before the panels are shipped, virtually the entire blowing agent has escaped.
  • DEGRADING INSULATION VALUE: This rigid foam insulation does not compress, absorb moisture, deteriorate or degrade like fiberglass and many other forms of insulation.
  • Water Absorption: The E.P.S. insulation American Ingenuity uses is closed cell and will not absorb more than 2.5% of water based on volume. It is often used as flotation for docks because it will not absorb water. Insulation materials that absorb water have a significant loss of performance because water is a good conductor of heat. This is particularly true with fibrous materials, which must be positively protected by an efficient vapor barrier. There are two ways in which, moisture can effect insulation materials: water absorption from contact with damp surfaces or from condensation of water vapor. EPS is a closed cell material that has minimal water absorption and low water vapor transmission.
  • BREATHABILITY: The amount that a material will breathe or the amount of water vapor that will pass through the material is measured in “Perms” or sometimes “Perm inches”. EPS will breathe enough to allow moisture trapped inside of it to dry out but at the same time it is tight enough to also serve as a good vapor barrier.
  • In the American Ingenuity dome, the inside of the rigid insulation is covered with wallboard. Wallboard does not interfere with the drying process but will offer protection from fire. If the E.P.S. gets hot enough it will burn.
  • EPS will dissolve in gasoline or similar solvents
  • EPS does not become brittle at sub-zero temperatures.
  • EPS – HEALTH HAZARDS:
  •   Ingestion: May act as an obstruction if swallowed
    • Inhalation: Minor respirator irritation possible from dust particles
    • Skin Contact: No hazard is known
    • Eye Contact: Minor eye irritation possible from dust particles
    • Carcinogenicity: NTP: No IARC: No OSHA: No
    • Symptoms of Overexposure: Respiratory irritation may occur from dust particles
    • Medical Conditions Aggravated by Exposure: None known.

Q: Is there a web site that recommends building materials for sensitive individuals?
A:
Yes, we have learned of a site called Healthy Home Designs. It has a listing of “Recommended Healthy Building Resources.” Their web site is www.healthyhomedesigns.com The following info came from the healthy home designs web site:

  • What makes a home healthy? A healthy home is one that incorporates healthy design elements, non-toxic building materials, and proper construction techniques. It “breathes”, emits no toxic gasses, and is resistant to mold.
  • Our criteria for a healthy home include the following attributes:
  • Reduction of exposure to chemicals (such as formaldehyde in insulation and particleboard; volatile organic compounds in adhesives, sealants and paints; and pesticides, fungicides and heavy metals used to treat wood) through use of non-toxic building materials and products.
  • Mitigation of mold and rot by employing proper building techniques and materials from foundation to roof.
  • Utilization of passive airflow, day lighting, and fresh air exchange through proper placement of windows and doors.
  • Location of areas of high toxicity and combustible materials (such as the garage and utility room) away from bedrooms and primary living spaces.

The benefits are homes that are safer, quieter, more comfortable, and require less maintenance. A healthy home is also more energy efficient, and therefore incurs lower monthly operating costs.

Building a Concrete Home – Panel Composition.  Because of fires, super storms, hurricanes and tornadoes, home owners are researching concrete home construction and finding the American Ingenuity concrete dome kit. Building an Ai dome from prefabricated concrete panels makes home construction easier and results in the dome exterior having a 225 mph wind and F4 tornado guarantee. The process of stacking the panels, overlapping/locking the steel mesh of adjacent panels and filling the seams with special fiber concrete, produces the structural components of the home, the finished concrete surface, installs the insulation and all the dome shell 1/2″ drywall.    To learn about Building Kit Assembly click on Assembly.  An Expanded Assembly Manual is now available with each dome kit order.

How long does it take to assemble the dome kit if I use the Kit Assembly Specialist? Depending on the size dome, and if your building kit has two entryways and four dormers with dome built on concrete slab, the shell assembly with one layer of concrete in the panel seams and on the entryways and dormers can take about 9 to 16 days. Assembly time depends on the number of workers in your team, your foundation type, weather and the type of hoisting mechanism. Click on Kit Assembly Specialist to learn more.

Side of view of panel being installed. The panel exterior is 3/4″ concrete reinforced with galvanized steel mesh. After the mesh is overlapped and locked between panels, on site special fiber concrete is mixed and hand trowelled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas are about 3″ deep by 5″ wide with average of 2″ thick concrete.

Side of view of panel being installed. The panel exterior is 3/4″ concrete reinforced with galvanized steel mesh. After the mesh is overlapped and locked between panels, on site special fiber concrete is mixed and hand trowelled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas are about 3″ deep by 5″ wide with average of 2″ thick concrete.

 

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

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

In this view of dome kit being assembled a side view of a component panel can be seen. The panel exterior is 3/4″ concrete reinforced with fibers & galvanized steel mesh. After the mesh is overlapped and locked between panels, special fiber concrete mixed on site is hand troweled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas average of 2″ thick concrete.

What are the American Ingenuity triangular and rectangular shaped panels made from? Center core of 7″ Expanded Polystyrene R-28 Insulation (not Styrofoam!), exterior is ¾” thick concrete reinforced with fibers & galvanized steel mesh with interior of 1/2″ Georgia-Pacific DensArmor Plus High-Performance gypsum drywall board (which is moisture resistant, mold resistant gypsum and noncombustible).  None of the materials in the panel are combustible or contain a food source for mold growth.

Superior Insulating Technology The core of each panel consists of a seven inch block of R-28 rigid modified expanded polystyrene (E.P.S.) insulation. The E.P.S. Insulation that Ai utilizes contains NO HBCD, NO TCPP, NO CFCs and NO formaldehyde and is not Styrofoam.   The EPS that Ai utilizes has a flame retardant added to it, therefore the EPS is noncombustible and is protected by the 1/2″ DensArmor wallboard which is non-combustible and provides the Code required 15 minute thermal barrier.   The EPS that Ai utilizes does not out gas poisonous chemicals.

Your American Ingenuity concrete home kit is affordable and strong because it is engineered as a system of prefinished component panels. Each panel is cut at a computer-generated angle so that it fits flush with the adjacent panel. The edges are precisely beveled at the seams where steel mesh and concrete will unite to complete the structure.

Q: Do you have an engineering statement about your dome panels that can be reviewed?

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

After the foundation is installed, the dome shell assembly consists of:

  • Erecting a temporary wooden rib system with supports under each hub.
  • Using some type of hoisting mechanism place the component panels one row at a time upon the rib system.
  • Overlapping the steel mesh from adjacent panels. Locking the steel mesh with “C” rings and pliers. Depressing the mesh into the seams.
  • Installing rebar, cables, hardware, (headers, king studs for doors and windows)  and suspension rods in appropriate seams per the building plans.
  • Watering down prefab concrete in the areas where new concrete will be applied. Applying one layer of fiber concrete in the seams and on the entryway/dormer panels one row at a time. Depending upon the dome size, there are four to five rows of panels.
  • Once the last row is installed then the second layer of concrete is applied in the seams between the panels and on the entryways and dormers. Bonding agent is applied between the two layers.  Cured concrete in the seams and around the area where new concrete is being applied is watered down prior to bonding agent and new concrete being installed.  The new concrete is misted per the Assembly Manual.
  • Only the seam areas between the panels and the entryways/dormers/cupola/link are concreted. Do not concrete over the finished prefab concrete on each panel.
  • Finishing exterior framed walls and Installing your locally purchased doors and windows.
  • Removing the temporary wooden rib system. Most of the wood can be recycled into interior framing and second floor perimeter knee wall framing.
  • Watering down the concrete exterior 3-4 weeks to remove efflorescence prior to priming and painting the concrete exterior.
  • Hiring conventional subcontractors: framer, electrician, plumber, drywall finisher, cabinet installer, HVAC, etc. to finish the interior of the dome.
  • Priming and painting the exterior of the dome.
  • Finishing the seams between the interior shell wall board with joint compound, fiberglass tape and applying joint compound in a skip trowel method over all the shell drywall.  Ask Ai for latest interior shell finishing document.
  • Priming and painting the shell wallboard.

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

For special discounts, click on Sale.   For Building Option Pricing click on Basic Kit Prices and then scroll down the page for the building options chart.  

American Ingenuity’s Component Panel’s steel mesh, concrete, EPS insulation and DensArmor wallboard contain no food source for mold growth and are therefore mold resistant.  The Georgia Pacific wallboard is not conventional sheet rock. Conventional sheet rock consists of  conventional gypsum and paper backing.  Sheet rock when it gets wet crumbles and molds with the paper matting as a food source for mold growth.  The DensArmor gypsum when it gets wet does not crumble.  It has fiberglass backing on both sides is no food source for mold growth. 

Tell us more about American Ingenuity’s panel materials.

Concrete: The panel concrete is a special formulation containing synthetic fibers and liquid admixtures. Locally purchase bags of Portland cement and masonry sand.  After the mesh is overlapped and locked between panels, special fiber concrete mixed on site is hand troweled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas are about 3″ deep by 5″ wide with average of 2″ thick concrete.  Prior to applying new concrete, water down all concrete around areas where work will be done. 

Mix the ingredients with a Mortar Mixer NOT a cement mixer!  Ai ships with your building kit the same fibers and admixtures that are used in the panel concrete so the seam concrete which is mixed on site will have the same properties as the panel concrete. These ingredients improve the concrete’s characteristics, create super toughness, extend durability, give higher tensile and compressive strength, provide elasticity for expansion and improve freeze protection.  The first layer of seam concrete contains two liquid admixtures and synthetic fibers.  The second layer does not require fibers; however now due to advances in fiber technology there are small 1/4″ fibers which can now be added to the second layer.  These smaller fibers for the second layer can be purchased from Ai.

The concrete in your concrete home out performs other exteriors because of its specially developed formula. Because of its exceptional composition, it actually gains strength over the years.

The exterior panel concrete, which is 3/4 inch thick, adheres directly to the steel mesh and E.P.S. insulation without the need of a bonding agent.  The panel concrete is hand applied, hand troweled, and hand sponged at American Ingenuity’s Rockledge Florida factory.  During the on site process of concreting the seams, entryways, dormers, etc., a bonding agent is applied on the first layer of concrete before the second layer is applied.  Bonding Agent is supplied with the kit with additional bonding agent being purchased from Ai. This bonding agent is not diluted onsite.  It is used full strength and must rest 30 minutes before new concrete can be applied over it.  Prior to applying bonding agent, water down cured concrete.  Before applying second layer of concrete, water down all cured concrete in the seams and around where the new concrete will be applied.  The final layer of concrete is sponge float finished on site.

Steel: Galvanized steel wire mesh is encased in the concrete of each component panel and extends out over the insulation’s beveled edges. As your dome panels are assembled, the mesh of each panel overlaps minimum 2″ and is hooked to that of the adjacent panels with C-rings (commonly called “hog rings”). The dome then becomes encircled by steel mesh.

E.P.S. Insulation that Ai utilizes contains NO HBCD, NO TCPP, NO CFCs, NO formaldehyde.  The EPS thickness is 7″ (R28).  The seven inches of sturdy, rigid, nontoxic R-28 expanded polystyrene (E.P.S.) insulation forms the core of each component panel. This is NOT Styrofoam!  The E.P.S. Ai uses is a closed cell with a 1 lb. per cubic foot density. The insulation is permanent, chemically and thermally stable; resistant to mildew; provides no nutritive value to animals, plants, microorganisms; non-irritating to skin.  The insulation will not rot, shrink, absorb moisture, compact, or deteriorate due to age or the weather. It also acts as a vapor barrier for your home, providing stable performance year after year. To learn more about E.P.S. as a Vapor Barrier click on Vapor Barrier.

ANALYSIS OF EXPANDED BEAD POLYSTYRENE

The Expanded Polystyrene (E.P.S.) Insulation that American Ingenuity utilizes is seven inches of sturdy, rigid R-28 modified E.P.S. insulation, which forms the core of each component panel. The E.P.S is one pound per cubic foot density (pcf).  EPS is NOT Styrofoam.

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. that American Ingenuity utilizes in its prefabricated panels:

  • is permanent
  • is chemically and thermally stable
  • is resistant to mildew
  • provides no nutritive value to animals, plants, microorganisms
  • is non-irritating to skin
  • contains NO Chlorofluorocarbon (CFCs) and is formaldehyde free
  •       Contains NO HBCD (hexabromocyclododecane) and NO TCPP (1-chloro-2-propyl) phosphate

What kind of vapor barrier will American Ingenuity dome have?  Approximately one quarter of the energy consumed by an air conditioner is used to extract water vapor from inside the house. Water vapor easily passes through most building materials and is readily swept into homes through joints, seams and through the attic. The E.P.S. insulation that Ai uses provides a good vapor barrier.   And the Ai building system provides for an air tight house.

During the US Dept of Energy Study on energy efficiency in  housing designs, the blower door test showed the American Ingenuity dome to be 56% tighter than the conventional test structure and 29% tighter than the Dow house.  To see if air was passing through walls of the dome, tests using infrared were performed. Thermal irregularities in the dome were shown to be insignificant.

Per the manufacturer of the E.P.S. which American Ingenuity uses, “the E.P.S. is closed cell and will not absorb more than 2.5% of water based on volume”.  E.P.S. is often used as flotation for docks because it will not absorb water. 

Per E.P.S. manufacturer’s data sheets the following description was given to explain how the E.P.S. is affected by Moisture:  “To retain their original insulation value, all insulation materials must remain dry.  Water is a good conductor of heat so a high moisture content in the insulation results in a significant loss of performance.  This is particularly so with fibrous materials which must be positively protected by an efficient vapor barrier.  Two ways in which moisture can affect insulation materials are; water absorption from contact with damp surfaces or rain penetration or from interstitial condensation of water vapor.  E.P.S. is a closed cell material and has minimal water absorption and low water vapor transmission.  Both of these properties are to a large extent, density related, but also to the degree of fusion of the material.  Tables 4 and 5 show typical performance figures for good quality E.P.S. boards manufactured to Arco Polymers recommendations.”           

Table 4  Water Absorption

Density (pcf)                                  1.0 lb                            1.5 lb                             2.0 lb
(pounds per cubic foot)

Water absorption (% vol)        less than 2.5                  less than 2.0                  less than 2.0

Table 5 Water Vapor Transmission (WVT)

Density (pcf)                                                     Grains (hr/sqft) In/Hg (Perm inch)

1.0                                                                                            1.2-2.2

2.0                                                                                            0.6-0.8

2.5                                                                                            0.5-0.7

3.0                                                                                            0.5-0.7

The amount that a material will breathe is measured in perms or sometimes perm inches.

 “Note: FHA requirements for perimeter insulation are that the original K value of the material must not increase by more than 15% after repeated wetting and drying cycles.  Tests have been carried out on nominal 1.0 pcf density E.P.S. with an original K value (at 75 degrees F) of 0.26.  After submersion the K value was found to be 0.28–an increase of only 7.7%.”

 Climatic Changes:  E.P.S. board has been used as an insulation material in various types of building structures for over 35 years in climatic conditions ranging from Arctic cold to desert heat and has performed satisfactorily.  E.P.S. does not become brittle at sub-zero temperatures (in fact its K value improves) and suffers no loss of impact resistance at -100 degrees F compared with 73 degrees F.  The maximum recommended continuous operating temperature is 175 degrees F.  Roof surface temperatures in Southern States may reach this temperature for short periods, but with suitably designed roof systems E.P.S. can be used under these conditions.”

In Ai’s building system the water is stopped on the outside surface because the concrete is rich and dense enough to inhibit significant absorption and it is coated with a primer and two coats of good quality exterior concrete paint which further insures against leaks.  If a leak occurs the remedy is to check the area for hair line crack that gets repaired with elastomeric patching compound and another coat of paint.  If and when any water gets past the concrete very little will be absorbed by the E.P.S.

Now this brings up breathability of the E.P.S.  The amount that a material will breathe is measured in perms or sometimes perm inches.  E.P.S. will breathe enough to allow it to dry out inside our walls.  At the same time it is tight enough to also serve as a good vapor barrier. Ai’s insulating concrete panel (ICF) is made from expanded polystyrene (E.P.S.) molded into lightweight foam blocks. The foam itself provides excellent insulation with an R value of R-28. The R-value of E.P.S. remains constant. (R-values of traditional fiberglass insulation decreases when the material is wet or damaged.)  Ai chose to manufacture its dome component panels with Modified Expanded Polystyrene (E.P.S.) foam because of its fire performance, structural performance, and environmental advantages. Modified E.P.S. contains no formaldehydes, no CFCs, no HBCD, no TCPP or toxic chemicals, and uses fewer resources to manufacture than other insulation products.  E.P.S. provides you with superior thermal performance to better insulate your buildings, and no harmful CFC’s have ever been used to manufacture it.

You can now recycle your jobsite scrap through a network of manufacturers, re-processors, and retailers across the country. E.P.S. is a valuable resource than can be remanufactured into foam packaging or made into an amazing array of polystyrene products from office supplies to video cassette cartridges.  To locate your nearest E.P.S. collection site, call the RECYCLING HOTLINE at 1-800-944-8448.  Please recycle jobsite scrap.

Expanded Polystyrene (E.P.S.) Facts

The E.P.S. that American Ingenuity utilizes is manufactured from expandable polystyrene beads containing a hydrocarbon blowing agent and a flame-retardant additive that contains NO HBCD (hexabromocyclododecane) and NO TCPP (1-chloro-2-propyl) phosphate. Ai’s insulation is made from Nova Chemicals M-77 E.P.S. product.

The EPS Ai utilizes is a closed cell, lightweight, resilient, foamed plastic composed of hydrogen and carbon atoms. There are two common types of polystyrene foam, Extruded Polystyrene or X.E.P.S. (Popularly known by its Dow trademark, Styrofoam) and Expanded Polystyrene (E.P.S.). American Ingenuity utilizes only Expanded Bead Polystyrene that contains NO HBCD, NO TCPP, NO CFC’s and NO formaldehyde. Ai does not use Styrofoam.

During the processing of E.P.S., steam heat softens the beads and causes the blowing agent to expand to produce moisture-resistant multi-cellular particles, which increase in size up to 40 times their original volume.  Following a period of stabilization, during which time the beads lose their moisture, the blowing agent condenses out and air diffuses into their cellular structure, the pre-expanded beads are molded into blocks of insulation.

The benefits of E.P.S. thermal insulation products are its lightweight, has stable long-term thermal resistance, no R-value loss over time (Source: 1985 Study conducted by Structural Research, Inc. for NRCA, MRCA, and SPI), and cost effectiveness when compared to other rigid board insulations on the basis of R-value.

Is E.P.S. a water, vapor or air barrier?

E.P.S. is considered water resistant and vapor permeable and at the density and thickness that American Ingenuity utilizes, the material acts as both a vapor retarder and an air barrier. This characteristic essentially moves the dew point to the exterior side of the concrete wall, minimizing interior humidity in the summer, and at the same time eliminates air infiltration in all seasons which is recognized as a major cause of R-value loss in fiberglass insulation. Air exchangers or heat recovery ventilation systems are highly recommended!

Is E.P.S. foam toxic?

E.P.S. is an inert, non-biodegradable organic plastic foam which will not rot and is highly resistant to mildew. According to National Bureau of Standards Combustion Tests, data collected from seven labs concluded that under the worst case fire scenario, fumes from E.P.S. are no more toxic than those from wood (Douglas Fir).  

Is E.P.S. Flammable?

Due to the flame retardant added to the EPS during expansion, the EPS is not combustible but will melt and draw back from a heat source.  Tests have shown that the smoke and soot produced from the melting EPS is less than is produced by burning Douglas Fir wood.  Of course no one wants to breathe smoke or soot…that is why there are smoke detectors to alert occupants to fire.  The requirements of all the major code organizations for foam plastics is that they have a flame spread of not more than 75 and a smoke development rating of not more than 450. The foam used in Ai’s component panels has a flame spread rating of 15 and a smoke development rating of 125 based on ASTME84-87 tests, well below the code requirements.

If you are in an extremely cold climate (Vermont, South Dakota, Canada) you may want to purchase 9″ EPS R36 insulation.  Just remember if you purchase the thicker insulation, this will increase the size of the panels, which will cause a 45′ r 48′ kit to require two trucks for delivery. To learn more about the properties of the E.P.S. click on E.P.S. data and then scroll down the page to Analysis of Expanded Bead Polystyrene.

1/2″ Georgia Pacific DensArmor Plus Gypsum Wall Board

Drywall/WallBoard: Consists of Georgia Pacific 1/2″ DensArmor Plus High Performance Gypsum Panels adhered to the E.P.S. insulation with a wallboard adhesive  with moisture treated core.  DensArmor Plus High-Performance Interior Panels are noncombustible (as defined and tested in accordance with ASTM E136 or CAN/ULC S114) interior panels that consist of a moisture-resistant gypsum core with coated fiberglass mats. The fiberglass mats provide superior protection from incidental moisture.  The treated core and the coated facings made with fiberglass offer greater moisture resistance and improved dimensional stability than regular gypsum board. The product resists warping, rippling and buckling.

The DensArmor has zero flame spread and zero smoke development and complies with the 15 minute thermal barrier test as described in 2010 Florida State IRC Section R316.4.

Georgia Pacific’s Dens-Deck roof board is a patented nonstructural glass mat-faced, noncombustible, water-resistant, gypsum core panel.  Georgia Pacific does not add any flame retardant to its gypsum products.  The DensArmor contains no HBCD and no TCPP.

Q: Does the interior shell wall board that American Ingenuity uses support the growth of mold?
A:
. DensArmor Plus Panels are highly resistant to the growth of mold, and have scored a 10, the highest level of performance for mold resistance under ASTM D3273 test method. DensArmor Plus Interior Panels are the first drywall panels to be GREENGUARD indoor Air Quality Certified and GREENGUARD Children & Schools Certified for low emissions of volatile organic compounds (VOCs) by a leading third-party organization, GREENGUARD Environmental Institute.  In addition, DensArmor Plus interior Panels are the first drywall panels listed as GREENGUARD microbial resistant.  This listing means Dens-Armor Plus Panels, which feature fiberglass mats instead of paper facings used on the surface of traditional gypsum board products, resist mold growth.  The microbial resistant test is based on ASTM D6329, a testing standard set by ASTM International, which develops testing guidelines and procedures for building materials, products, systems, and services.

Green, brown or black algae can appear on the wallboard. Algae just needs water and sunlight to grow.  Algae can be removed with a combination of chlorine and water or oxygenated bleach and water.

The wallboard is adhered to the EPS with a wallboard adhesive.  The glass mats embedded into the core on both faces, results in dimensional stability and prevents warping. The glass mat is encapsulated with a coating which reduces skin irritation from exposed glass fibers. Please use a mask when cutting the DensArmor.

Fire Protection: Per Georgia Pacific:

  • 1/2″ Dens Armor Plus High Performance Gypsum Panels are gypsum panel products, designed for interior use, are manufactured to meet the temperature rise criteria of a thermal barrier as described in Section R316.4 of the 2010 Florida Residential Building Code.
  • In addition to having a non-combustible core per ASTM E 136, Dens Armor Plus has been evaluated by Underwriters Laboratories LLC per UL 723 Standard for Test for Surface Burning Characteristics of Building Materials. DensArmor Plus has a Flame spread/Smoke Development of 0/0.
  • The Finish Rating Thermocouple Temperatures obtained during the evaluation (WFCI Project No. 06047A) was conducted at Western Fire Center (WFCi) in Kelso, WA. WFCI is a recognized testing facility per the Gypsum Association (GA-600).
  • The Finish or Membrane Protection Rating was determined to be 0.15:40 for 1/2″ DAP. Please note the average ambient temperture was 21.0 degrees C for the 5 Finish Rating Thermocouples.
  • Properties of Dens-Armor: Noncombustible, Water Resistance, Dimensional Stability, Decay Resistance, Resistant to Warping, Rodent and Fungus Resistance, Torch Safe, High Compressive Strength.

The wallboard seams can be finished similar to drywall by applying joint compound and adhesive backed mesh tape on the seams. To blend the taped seams to the drywall finish, apply joint compound in a skip trowel fashion over the dome shell drywall.  Please call Ai for latest drywall finishing document.  Prime and paint the drywall.

 If I am not ready to assemble my dome immediately, can it be stored outside? Yes, but not in freezing weather. If you expect to have your kit outside for more than two to three months, when you order your kit request that the E.P.S. edges be painted.   Call us for details at 321-639-8777.

What do the component panels weight?

Dome Diameters 22′ 27′ 30′ 34′ 40′ 45′ 48′
Triangular (lbs)

155-180

245-295

120-150

160-200

230-275

275-355

315-400

Riser (lbs)

255

315

230

260

315

350

380

How are the panels supported during assembly?  Ai recommends using the temporary “wooden rib system.” The rib system consists of your own 2×4’s (cut to length and holes drilled to our specs) and steel hubs on loan from American Ingenuity to erect a free standing geodesic framework. The 2×4’s can be purchased from Ai (precut, holes drilled with ends painted) and shipped on the truck with your kit. The deposit on the hubs is $1,600 for a 5 month rental time…$20 a month rental thereafter, with the client paying to ship the hubs back to Ai to receive their deposit back less any additional months rental and any cost for any missing or damaged hubs. The bolts/nuts/washers are purchased for $128 and are not returned to Ai.  An Expanded Assembly Manual is now available with each new dome order.

The “Rib System” dictates the exact panel placement. Once all the seams/options have been concreted and entryways/dormers framed in the “Rib System” is removed and recycled into the interior framing and the hubs returned to us.  Click on Rib to learn more.

How are the panels hoisted into place? And what equipment is attached to the panels to make lifting easier?

  • The typical method for lifting the panels is by man lift, crane or transverse fork lift.
  • Monthly rentals on transverse lifts also called Boom Lifts, Horizontal Boom Fork Lifts, Roofing Lifts, Shooters are available from National Rental Chains.
  • Four Panel Lifting Spikes are purchased from Ai for $120 and attached to your locally purchased chain and couplers.  To learn more about the spikes click on Lifting Spikes.  Please scroll down the page to find the spikes info.