concrete dome kit | AiDomes

The American Ingenuity Dome Kits
are DIY Prefab Dome Homes for Owner Builders or for a Contractor

The prefab dome kit can be a Do It Yourself Project with the owner builder utilizing family and friends or hiring his own workers for kit assembly.  Or the home owner can hire a builder who hires the independent Kit Assembly Specialist who travels world-wide to supervise your kit assembly and the application of the first layer of fiber concrete into the panel seams and onto the entryways and dormers. Then either your workers or your builder’s workers complete the second layer of concrete in the seams & on the entryways and dormers. For interior finishing complete yourself or hire local subcontractors to complete the plumbing, electrical, framing, window/door installation, wall board finishing, kitchen cabinetry, bathroom fixtures, etc.  To view pictures of prefab concrete panel assembly, click on Dome Kit Assembly.

American Ingenuity’s (Ai’s)dome kit is affordable, strong and can be assembled by Do It Yourself individuals because the kit is engineered as a system of pre-finished prefabricated component panels. Each panel is cut at a computer-generated angle so that it fits flush with the adjacent panel. The edges are precisely beveled at the seams where steel and concrete will unite to complete the structure. All panel materials are noncombustible and contain no food source for mold growth.

Building an Ai dome from prefab concrete panels makes home construction easier than stick built construction and results in the dome exterior having a 225 mph wind and F4 tornado guarantee. The process of stacking the panels, overlapping/locking the steel mesh of adjacent panels and filling the seams with special fiber concrete, produces the structural components of the home, the finished concrete surface, installs the insulation and all the dome shell 1/2″ drywall.

This advanced building system makes it easier for an owner builder to construct an American Ingenuity dome than a conventional house or a wooden dome. No exterior walls, no roof trusses, no sheathing, tar paper, or shingles, no soffit, exterior trim, insulation or siding to install and no interior shell drywall to install.  During the dome kit assembly, owner builders or builders can email pictures of the kit assembly. At no cost to you, Ai will review the pictures and give feedback about rebar and cable installation, etc.  Due to large size of panels in 45′ and 48′ domes, considering hiring the consultant to assist in your assembly.

 

Nomenclature-top

Nomenclature Diagram for Downloading & Printing
Nomenclature Diagram
Nomenclature Diagram for Viewing in Browser
Nomenclature Diagram

The building plans contain blueprints for the installation of the foundation and installation and location for each panel. Within the plans is a nomenclature blueprint that shows lettering and numbering for each panel. An example of a nomenclature blueprint is above.

An Expanded Assembly Manual is now available with each dome kit order that explains step by step the panel assembly. (Once a deposit with signed order is received, the manual can be shipped). In the blueprints and Manual is the recipe for the concrete. Ai wants the concrete mixed on site to have the same properties as the concrete that is applied at our factory; as a result the same two liquid admixtures and fibers are shipped with each kit. In the manual is a list of tools and materials to have on site. To view a list, click on Materials and scroll down the page to view the list.

American Ingenuity’s prefabricated component panel consists of:

1.   7″ thick, rigid, nontoxic E.P.S. Insulation (not Styrofoam): The E.P.S. Ai utilizes is a closed cell with a 1 lb. per cubic foot density.  Seven inches of sturdy, rigid R-28 expanded polystyrene foam insulation forms the core of each component panel and is:

  •  Permanent
  • Chemically/thermally stable
  • Resistant to mildew and mold
  • Provides no nutritive value to animals/plants/microorganisms
  • Non-irritating to the skin
  • The insulation will not rot, shrink, absorb moisture, compact, or deteriorate due to age or the weather.
  • No CFC, no HBCD (hexabromocyclododecane), no TCPP (1-chloro-2-propyl) phosphate, no Chlorofluorocarbon (CFC) and no Formaldehyde

2.     Concrete: the concrete in your dome out performs other exteriors due to our specially developed formula. Because of this exceptional composition, it actually gains strength over the years. The special concrete formulation of fibers and admixtures improve concrete characteristics.

3.     Galvanized Steel: Galvanized steel wire mesh is encased in the concrete of each panel. As your dome is assembled the mesh of each panel overlaps and is locked to the mesh of  adjacent panels with C rings commonly called hog rings – resulting in your home being completely wrapped by steel mesh.

4.   Half inch (½” ) Georgia Pacific DensArmor Drywall: The DensArmor is not conventional sheet rock. Conventional sheet rock consists of conventional gypsum and paper backing. The paper backing can be a food source for mold growth. Sheet rock when it gets wet crumbles and molds. The DensArmor gypsum when it gets wet does not crumble due to fiberglass reinforced core. It has fiberglass backing on both sides. After the DensArmor dries out it goes back to its original firmness and consistency per the manufacturer.

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

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

 

45' dome - assembly of third row of panels

45′ dome – assembly of third row of panels

In this view of dome kit being assembled a side view of a component panel can be seen. The panel exterior is 3/4″ concrete reinforced with galvanized steel mesh. After the mesh is overlapped and locked between panels, special fiber concrete mixed on site is hand troweled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas are about 3″ deep by 5″ wide with average of 2″ thick concrete.  In this picture you see the first scratch coat applied to the exterior of the entryway panels and first layer of concrete in some of the seams between the panels.

Steps for American Ingenuity Concrete Building Kit Assembly:

  • Foundation installed. Standard foundation is monolithic slab; however Ai can design basement plans, pilings or columns, stem wall, etc.
  • Depending on size dome two to five workers are needed. Some with concrete experience.
  • Installing the first row of panels which are the 4’ vertical riser panels, base panels of the entryways and any first floor door dormer base panels
  • Erecting a temporary wooden rib system to support the triangle and riser panels during assembly using your locally cut, drilled and painted 2×4’s bolted to steel hubs borrowed from Ai.
  • Placing the panel’s one row at time using a hoisting mechanism (man lift) on to the rib system.
  • overlapping steel mesh from adjacent panels, locking mesh with C rings and pliers and depressing the steel mesh in the seam
  • mixing concrete with mortar mixer following concrete recipe in the manual (Portland Cement Type III, masonry or stucco sand, fibers, liquid admixtures)
  • installing cables per blueprints
  • installing rebar around back of entryway panels, back of first floor door dormer panels, top of entryway panels & around first floor window dormer panels per building plans
  • form up and install beams or troughs around lip edge of entryway panels, first & second floor door dormer panels, channels in top of the entryways
  • Concreting the seams between the panels (5″ wide and 3″ deep) with two separate layers of concrete using a bonding agent between the layers; and watering down all cured concrete before applying bonding agent or new concrete. Seam areas average 2” thick concrete.
  • Concreting the entryways, window dormers, door dormers, cupola and link with two layers of concrete. Sponge float finish the final layer of concrete to blend seam concrete to the panel concrete.
  • Framing in the entryways and dormers and installing your locally purchased exterior doors and windows.
  • Removing the temporary wooden rib system. Return the steel hubs to receive a full deposit refund if returned during five month rental period and if all hubs are intact.
  • Wash efflorescence off concrete, prime, paint the exterior concrete per waterproofing instructions in Assembly Manual.

Onsite concrete is only applied in the seam areas between the panels and on the entryways, dormers (or possible link or cupola). Concrete is not applied over the pre-concreted component panels. The interior shell drywall can be finished similar to conventional sheet rock with adhesive fiberlass and joint compound. To blend the seams joint compound can be skip troweled over the drywall before priming and painting.

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

If I am not ready to assemble my dome immediately, can the kit be stored outside? Yes, however if you expect to have your kit outside for more than two to three months, request that the E.P.S. edges be painted. On site if you need longer than 2-3 months prior to assembly, then on site the EPS edges can be painted again. (some boxed items & wooden 2×4 ribs if ordered should be stored inside.) The dome kit should not sit outside in the winter as freezing can harm the drywall.   Please call us for details at 321-639-8777 – Monday – Friday 9-5 eastern time.

American Ingenuity – 8777 Holiday Springs Rd. – Rockledge, Florida 32955   email: GlendaB.Aidmes@gmail.com

9th Step – Accept Delivery of Your Dome Kit. The Kit Buyer and American Ingenuity agree upon the month the dome kit will be shipped.  To receive the entire dome building kit discount, Ai determines the week and day of shipment in the agreed upon delivery month.  Buyer is given 6-8 week’s’ notice of the kit shipment date.

Your foundation does not need to be installed to accept delivery of your kit.  It is quite normal that foundations do not get installed when planned due to weather conditions, etc. Your dome kit can be stored outside for 2-3 months in nonfreezing weather waiting for your foundation installation (some boxes and items should be stored indoors.)  If more months of outside storage is needed, spray another layer of latex paint on the EPS edges.

Ai has a detailed truck unloading document which describe the kit unloading process.

 The dome kit can be stored outside (in nonfreezing months) for the following reasons:

  1. The steel reinforced concrete, noncombustible Expanded Polystyrene (EPS) insulation & drywall are not harmed by rain.
  2. American Ingenuity paints the EPS edges that extend out of the steel reinforced concrete with latex paint.  The paint prevents UV light from harming the EPS.
  3. The special 1/2″ Georgia Pacific DensArmor drywall on the interior of the dome panel is not conventional gypsum.  When conventional gypsum gets wet, the gypsum crumbles & the paper face is a food source for mold growth.  This special DensArmor drywall contains fiberglass face with special gypsum which allows it to be moisture resistant and mold resistant as there is no food source for mold growth.  Even if the drywall gets wet and is then allowed to dry out, per the manufacturer, the DensArmor goes back to its original consistency.

The following contains info about Ai Building Kit Summary

Top five Cupola Panels installed after concrete beam and concrete legs poured. (top of cupola consists of the five top dome panels lifted up to set on concrete legs.)

Fourth row of Prefab Panels being assembled on 34′ dome.  45′ dome in back ground.

To view a photo gallery of photos showing the Dome Kit Assembly Process, view Dome Kit Assembly. The dome kit can be assembled by owner builders or hire a contractor. Either the home owner or the contractor can hire the independent kit assembly consultant to supervise the kit assembly.

The view sale pricing on American Ingenuity dome kits and building plans, view Sale.

Housing technology has changed very little since framing replaced the log cabin. Modifications that were made to improve a concrete home or future home also increased its cost. We applied some American Ingenuity to the geodesic dome home, designed an all new component building system utilizing advanced kit home construction technology and developed a home plan without increasing the kit home’s prices.

American Ingenuity’s concrete dome kit includes all the triangular and riser panels needed for the dome shell and one entryway. The first floor of the 30′ thru 48′ dome homes can have up to five entryways. The second floor of the 36′ thru 48′ can have up to five single window or door dormers. As a result each floor plan varies as to the number and location of entryways and dormers. Underneath the entryway or dormer “eye brow” you or your contractor builds a conventional 2×4 framed wall and installs your locally purchased windows and doors.

Because we do not know which stock floor plan you will select, Ai does not know the type or quantity of entryways or dormers that you will need. View  Building Options to learn more about entryways, dormers, link, cupola, etc. Once you determine the floor plan, Ai can provide the Building Kit with Option Pricing.

You can view and print out Ai’s stock plans for each of the ten dome kit sizes, by clicking on Stock Plans

Houses and garages are built from the Dome Building Kits. The dome homes are available in ten sizes from one bedroom/one bath to four or five bedroom/four baths. The garage domes are typically one car or two car. In the back of the Stock Floor Plan Booklet are garage dome plans. The dome homes are built on conventional concrete slabs or raised wood floors. If needed, the dome can be built on a basement or pilings and a platform. American Ingenuity does not manufacture a basement wall kit, but does design the basement plans.  To learn about possible foundations, view Foundations.

The regular pricing for the Dome Shell Kit which includes one entryway ranges from $21,300 to $55,915 depending on your square footage needs. View Pricing for a complete listing of kit sizes and regular pricing.

Wherever an “opening” is left for doors and windows, Ai does not ship triangles or riser panels. The entryway and dormer panels “eye brows” are therefore structural and are required to maintain the dome’s integrity. The 2×4 or 2×6 wall that is build under the entryways or dormers is built to frame in your locally purchased doors and windows..

The component panel for the 15′ thru 48′ domes includes seven inch thick R-28 insulation. On the exterior of the insulation is ¾” thick fiber concrete reinforced with galvanized steel mesh and on the interior of the insulation is 1/2″ Georgia-Pacific wall board. Onsite the kit is assembled one row at a time, by concreting the entryways, dormers, cupola, link and seams between the panels. Do not concrete over the entire dome. The concrete on the panels does not need to be thick because the seam concrete averages two inches.

Once all the panel seams and entryways, dormers, etc. are concreted, the temporary wooden rib system is removed. The dome shell is self supporting. No interior walls are needed to support the shell. However, normally there is a bedroom and bathroom on the first floor. So those interior walls are used to support part of the second floor. The exact locations of the suspension rods is noted on the shell geometry sheet in the Building Plans. The suspension rods and top and bottom plates can be purchased from American Ingenuity.  We use the AutoCAD program to design and calculate the load on the second floor. So just let us know if you will have an Aquarian, water bed, library, exercise room, etc. on the second floor and Ai can calculate the load accordingly. The average load calculated is 55 lbs. per square foot.

The component panels do not come with any paint on them. Ai does not add any color to the concrete. The concrete shell is painted after the entire kit is assembled. The paint should include a concrete primer and two coats of good quality exterior concrete paint. The dome can be painted any color, tan, green, blue, etc. preferably a light to medium color to reflect the sunlight. The dome exterior is repainted every four to six years depending upon your area’s pollution and UV light. If you rub your hand over the paint and get any “chalk” on your hand, that is when the dome should be repainted. As needed remove algae with a mixture of chlorine and water or pressure washing.

Ai’s dome building kit does not include doors and windows. There is such a variety and varying price points,Ai  leaves the selection of the doors and windows up to each client to purchase locally. The floor plan you select will determine how many entryways or dormers you will have. Within the entryways and dormers {eye brows}, your framing subcontractor installs a 2×4 or 2×6 wall to frame in what ever standard doors or windows that were purchased locally.

No interior items are included in the building kit other than the shell wall drywall. Ai believes you should not pay shipping on items you can purchase locally such as plumbing, electrical, framing, flooring, kitchen cabinets, bathroom fixtures, lighting fixtures, etc. To learn about the panel composition, view Component Panel.

Dome Finished Costs: The finished costs on the domes depends so much on where you live, what the labor costs are in your area and what price points you select for your windows, doors, cabinetry, flooring, lighting fixtures, etc. You can ask at your local hardware store or ask a local contractor what the finished price per square foot is running for a conventional house in the neighborhood you plan to build in. That is approximately what it will cost to finish the domes (if you do no labor yourselves), because everything in the interior is standard whether it is a conventional house or dome home….plumbing, electrical, lighting fixtures, bathroom fixtures, flooring, kitchen cabinets, windows and doors, etc. are all the same. Basically you end up with a super-energy efficient, super-strong home for about the same price as a conventional house. To learn more, view Finished Cost.

Items in the Dome Shell Kit include: Triangular Panels, 4′ Riser Wall Panels, panels for one Entryway, Galvanized Steel Mesh, Concrete Fibers, Two Concrete Admixtures, Reinforcing galvanized cable, Concrete Bonding Agent, Connecting C-Rings, C-Ring Pliers and Assembly Manual. To learn more, view Kit Contents.  To learn what is not in the Dome Kit, view Items not included in the Kit

Depending upon your floor plan selection there will be various building options. The Options include: Additional Entryway Panels (standard, high profile, garage), Window Dormer Panels, Door Dormer Panels, Cupola Panels and Link Panels. view Building Options to learn more.