dome kit | AiDomes

Wood House burns in CA Silver Fire – home owner rebuilds with Ai concrete dome home kit.

The California Silver fire started on August 12, 2013 in southern California just south of Banning. By the time firefighters had contained the blaze, it had burned about 20,000 acres, forced thousands to evacuate their homes, injured eight people, and destroyed 46 structures.

One of the homes destroyed was a wood dome owned by the Berres’s. Because they loved the advantages of living in a dome home, strength, energy efficiency, etc. they chose to rebuild another dome; but this time instead of a wood dome with shingles they chose to rebuild utilizing an American Ingenuity dome building kit because its exterior is noncombustible steel reinforced concrete.

Below the photo gallery of the Berres dome under construction is an image of the burn scar left from the Silver fire and a YouTube video of the fire.

Photo Gallery of Berres 48′ Concrete Dome Kit Under Assembly

(Click the arrows or dots to change pics)

 Silver Fire Area

silverfire_oli_2013222Dark red color shows the burn scar when the California Silver Fire of 2013 burned about 20,000 acres,

forced thousands to evacuate their homes, injured eight people and destroyed 46 structures. 

On August 10, 2013, the Operational Land Imager (OLI) on Landsat 8 captured this false-color image of the burn scar left by the Silver fire, which burned in southern California, just south of Banning.

The image was made with a combination of shortwave infrared, near infrared, and green light collected by OLI. Shortwave infrared is between near infrared (seen in infrared photography) and thermal infrared light (used by temperature sensors) on the electromagnetic spectrum. Shortwave infrared light is reflected by some surfaces (like bare soil), and emitted by very hot objects (lava or fires). Burned areas appear dark red. The lighter red area in the upper left of the image is a burn scar from a previous fire. Dark green areas are forests; light green areas are grasslands, golf courses, or yards.

Over the last decades, California fires had charred an average 5.7 million acres by August 22, according to statistics published by the National Interagency Fire Center.


 

 

Kitchens, Cabinets, Islands, Appliance Garages

Almost any of American Ingenuity’s stock floor plans can be modified to increase the counter and cabinet space. To view sample stock plans showing kitchen arrangements for each of the ten dome kit sizes, click on Stock Plans.  If you do not see a stock plan to fit your lifestyle, Ai can modify or customize the plans from your descriptions or notes.   We would love to answer your questions about floor plan design within a dome home.  Please call us Monday – Friday 9-5 eastern time.

  1. American Ingenuity can move the bottom cabinets about 17″ away from the curved dome wall, add overhead cabinets to a 7 ft. partition wall and create appliance garages by extending the counter top to the dome shell.
  2. Kitchen cabinets can also be installed on an entryway wall. This will allow for a above counter cabinets and a window above the sink to be installed in framed entryway wall.
  3. If kitchen is designed along dome wall, a window dormer can be installed above the kitchen sink to allow for an opening window above the sink.
  4. Or kitchen cabinets can be hung on interior walls within the dome.

 

These two photos are of a kitchen in a 40′ dome with the sink and cabinets installed on an outside dome shell wall. A 2×4 wall is attached to the dome shell to make a vertical wall for the installation of the cabinets.

 

 

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This center kitchen has a counter 

 

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Kitchen in a 45′ Dome Kitchen in a 40′ Dome

 

Appliance Garages in American Ingenuity Dome Kitchens

To install kitchen cabinets along an outside dome shell, a vertical 2×4 framed wall is built. This results in a deep area behind the counter top which can be used to park appliances…keeping clutter off your counters.  Here the dome owner constructed vertical sliding doors to hide the appliances.

 

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This dome owner built their kitchen on an interior wall. Because they wanted appliance garages, they built deeper walls. The appliance garages are hidden behind the blue glass panels.

 

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Kitchen/dining area in a 40′ Dome
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Kitchen in a 40′ Dome

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

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

Above American Ingenuity Dome Kit   Assembled and Finished on Basement

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

 15% DISCOUNT* OFF AMERICAN INGENUITY’S

DOME KIT WITH ONE ENTRYWAY PRICING 

 IF ORDER PLACED BY  August 16, 2017

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

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

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

If ordered prior to  August 16, 2017

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

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

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

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

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

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

Within the Sale Pricing Chart Below Ai uses Abbreviations

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

These are the Definitions.

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

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

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

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

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

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

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

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

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

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

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

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

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

Diameter in feet converted to Meters:

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

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

 First Floor Square Footage converted to square meters:

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

Second Floor Square Footage converted to square meters

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

Optional Third Floor Loft Square Footage converted to square meters

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

All Domes Can Be Designed Without a Second Floor

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

 

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

 

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

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

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

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

Diagram Identifying

3domes

 

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

The building plan’s pricing listed below does not include an engineer seal on the plans or energy report or fee for an engineer to design basement/stem wall/ columns, pilings, etc.  It is Ai’s philosophy that each Buyer pays for only what they need. Ai does not burden the price of the building kit with plan’s pricing, engineer seal cost, structural calculations or energy report cost. Building plans are purchased three months  to two years prior to kit shipment.  About 50% of the building departments require engineer sealed plans and an energy report to issue a permit. As a result each buyer pays for their plans separately from the building kit and pays for a seal, calculations and energy report only if their building department requires them.  If you give us your property address or tax ID number & building department name, at no cost to you, Ai will call the plans examiner and inquire what is needed to obtain a building permit on the American Ingenuity dome kit.

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

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

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

15′ kit: 

1/2 ton truck minimum (Ai recommends 3/4 ton truck )
13 ea.  2″ x 30′  straps Working Load Limit 3000 lbs.
Trailer specifications
7′ wide 20′ long minimum
tandem axle 3000 lbs. each axle
axles with brakes
bed height of 48″ max

18′ kit: 

1/2 ton truck minimum  (Ai recommends 3/4 ton truck )
13 ea.  2″ x 30′  straps Working Load Limit 3000 lbs.
Trailer specifications
7′ wide 22′ long trailer minimum
tandem axle 3000 lbs. each axle
axles with brakes
bed height of 36″ max

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

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

 

 

 

Continued…

Building Plan Composition 

 

This article contains Construction Cost Estimate Blank Form

Bob applying final layer of concrete in the seams.

Fiber concrete being applied in the seams between the prefabricated panels of a 22′ dome.

The following blank form is provided for you to fill out as you determine your material and labor costs for your dome kit assembly and finishing. Because labor costs and materials cost vary in the USA, Ai cannot estimate your costs. However the web site link below can be used to estimate finishing costs for your area.

Free Web Site To Calculate Finishing Costs For Your Area

To view information on a free web site where you can look up finishing costs for a conventional home in your state and area, click on Calculating Square Footage Costs. This article also includes  a Construction Cost Estimate Report from building-cost  for a 1200 sq.ft. home in Melbourne, Florida.

If you build an American Ingenuity dome using one of our stock plans, click on Plans & Kit Sale Prices to view regular and sale pricing on the building plans and the kit  w’ building options pricing or each stock plan.

The American Ingenuity dome kits can be assembled by owner builders.  If you choose to use the Kit Assembly Consultant to supervise the assembly of your dome kit, click on Kit Consultant/Specialist for approximately labor costs to assemble the dome shell kit. The rest of the categories are generally the same costs whether it is a dome or a conventional house. To learn about Kit Assembly & see pictures, view Assembly and Construction Overview.

The finished costs on American Ingenuity concrete domes depends so much on where you live and what labor costs are for your area. 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 what it will cost to finish the domes (if you do no labor yourselves), because everything in the interior is the same whether it is a conventional box house or a round house: foundation, plumbing, electrical, second floor joists, framing, lighting fixtures, bath room fixtures, kitchen appliances, flooring, kitchen cabinets, windows and doors, etc. To learn more click on Finished Cost.

To View three charts listing pricing for items purchased from Ai
for three dome kits Ai recently shipped, click on Pricing Charts

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

Ai thinks the only big bargain you will receive is its dome building kit, which costs about one third to one half less than other building kits or materials to build the exterior walls and roof of a conventional house, wooden dome or sprayed concrete dome. And with the American Ingenuity Dome you end up with more….super-energy efficiency, super-strength, noncombustible concrete exterior and  low exterior maintenance home.

To view floor plan layouts for each of American Ingenuity’s ten dome kit sizes, click on Stock Plans.   On each plan is a to-scale ruler. When you print out the plan, cut out the ruler and use it to measure length and width of rooms and compare those room dimensions to the rooms you currently live in. You know whether you want your kitchen, living room or bedroom to be larger or smaller than your current house or apartment.  This will help you figure out what size dome will fit your needs. The scale is 1/10″ equals one foot.

No question is too small,  please call our office at 321-639-8777.  Monday – Friday 9-5 eastern time. 

To view info about financing, please click on  Financing Booklet.

Domes are measured by feet in diameter. Refer to Specifications to see possible square footages by floor.

  • A 15′ and 18′ Tiny Kits are one bedroom one bath size.
  • A 22′ can be a one car garage or a one bedroom/one bath home.
  • A 27′ or 30′ can be a two car garage or a one bedroom/one bath home.
  • A 34′ is a two bedroom, two bath. (The 34′ was a little too small so Ai designed a 36′ dome.
  • A 36′ is a two bedroom, two bath.
  • A 40′ is a three bedroom, two bath.
  • A 45′ is a four bedroom, three bath.
  • A 48′ can be a four or five bedroom home with three to four baths.

Calculating Finished Cost

Please compare apples to apples when trying to calculate finished cost of an American Ingenuity dome.  A conventional house would need walls greater than 2×10 with exterior reinforced with rebar and super thick concrete and still not come close to the advantages of an American Ingenuity dome.  The Ai dome should cost about the same price per square foot to build as a conventional house but you receive more….greater energy efficiency, greater strength, noncombustible concrete exterior.  To view Ai dome advantages, click on Advantage Summary.

When you factor in the storm resistance and energy efficiency, a traditional home would need to have 11″ of insulation requiring over 10″ thick insulated walls (this is with our standard 7″ EPS R-28 value insulation) as well as additional roof strapping, rebar and concrete against storms, and still not be equal to one our structure’s insulation and strength. So please compare apples to apples! Our kit comes with all the interior shell 1/2″ gypsum drywall installed, all the R28 insulation installed and 80% of the finished roof….and no wood to interrupt the insulation to rot, burn or be eaten by termites.  No shingles to blow off in high winds. Exterior concrete is primed and painted.

Comparing Apples to Apples When Researching Types of Housing

Material cost is only half of the equation, labor costs often eat up a large chunk of a construction budget. American Ingenuity’s panelized system has proven to save our clients labor time, as well as a reduction in material waste and material costs. That is why when comparing geodesic companies, conventional construction, etc. it is important to compare apples to apples, not just kit cost. The process of stacking the American Ingenuity prefab 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 all the insulation and all the dome shell 1/2″ drywall. No need for material and labor costs to install exterior framing, plywood, tar paper, shingles or interior shell insulation and shell drywall.

Ai is committed to providing you with the best design, energy efficiency, and durability with our panelized system for geodesic concrete homes for an affordable price.

Q: What are the American Ingenuity triangular and rectangular shaped panels made from?

A: Center core of 7″ rigid, nontoxic Expanded Polystyrene R-28 Insulation (not Styrofoam), exterior is three quarter inch (¾”)  fiber concrete reinforced with galvanized steel mesh with interior of 1/2″ Georgia-Pacific DensArmor Plus High-Performance gypsum drywall (which is moisture resistant, mold resistant gypsum and noncombustible). The steel mesh extends out all sides of the prefab panels. When two panels are set side by side, the steel mesh overlaps the mesh of the adjacent panel and is locked with “C” rings. Special fiber concrete is mixed on site and hand troweled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas average 2″ thick concrete.

Ai wants the concrete that is mixed on site to have the same properties as the concrete we manufacture and apply to your prefab panels. As a result we ship the same  fibers, liquid admixtures and bonding agent with your kit and supply a concrete mix recipe in the building plans and in the Assembly Manual.

When you compare other companies dome kits, please consider the following items:

Q: Does the companies kit have a finished exterior, or do you need to finish with a vapor barrier and either shingles, siding or stucco?
A: Ai’s dome’s exterior is 3/4″ fiber concrete reinforced with galvanized steel mesh. Only the seams (about 3” deep by 5” wide) between the panels & the entryways & dormers are concreted on site. You do not concrete over the entire shell. After kit assembly the concrete gets primed and painted.

Q: Is the framing of the exterior walls wood or is the exterior of the kit wood, that eventually rots, or termites can eat, or can potentially burn?
A: Ai’s dome prefab panels contain no wood in them making the panels fire resistant. Our domes have survived forest fires. There is no wood in the dome exterior to rot or be eaten by termites. There is no roof or shingles to burn and no roofing to blow off in high winds.

Q:What maintenance is needed for the dome exterior?
A: The entire exterior of the Ai dome shell is covered with a continuous layer of concrete so there is nothing to rot, rust, shrink, warp, or be eaten by termites. Without shingles, gutters, or exterior trim to maintain. It only requires an occasional pressuring washing and painting.

Q: Does the kit contain insulation? What type, and what is the overall R-Value for energy efficiency?
A: Ai’s kit’s riser and triangle panels come with 7″ thick Expanded Polystyrene (EPS) insulation already installed producing an overall R-Value of 28. An option is available for 9″ insulation R-36 value. In addition, our exterior triangle and riser panels have no wood ribs interrupting the insulation resulting in continuous insulation. (Other companies suggest the use of spray foam insulation which is expensive to install, often covers wiring and piping making repairs difficult).

Q: Does the insulation recommended for the shell contain HBCD, TCPP, CFCs and formaldehyde?
A: The EPS insulation that Ai contains none of the above items. It 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 drywall which is also non-combustible and provides the Code required 15 minute thermal barrier. EPS when exposed to flame does not produce toxic gases such as Cyanide.

Q: How is the interior of the dome shell finished? Do you have to buy, cut, nail or glue drywall that you have purchased to the interior of the dome shell? Or do you need to spray foam insulation over the entire shell? (Very labor intensive and expensive)
A: Ai’s kits triangle and riser panels come with ½” thick DensArmor (by Georgia Pacific), fiberglass mat on both sides with gypsum that is moisture resistant and mold resistant. During kit assembly rain will not harm the drywall. The drywall is adhered to the EPS with wallboard adhesive. There is no cutting and adhering of the drywall needed for the shell interior. There is no need to spray foam insulation, saving you labor costs, and less product waste. When the kit shell is assembled tape the joints and finish like traditional wallboard. (To blend the seam areas to the drywall, apply joint compound in a skip trowel effect.)

Q: Do their kits come with standard vertical riser panels before the triangle panels slope inward?
A: Ai’s kits come standard with 4′ tall prefab riser panels. This allows for first floor vertical space (8′ headroom on first floor) before the dome panels start to slope in giving you more useable headroom on the second floor. We also offer an option to increase the riser panel height giving you up to 10′ of headroom on the first floor (dependent upon dome diameter size).

Q: Do they offer in house building plan design? Are the plans fully executable, and permit worthy? Do they use a knowledgeable licensed engineer, for design calculations and engineer seal if needed? Can they produce an Energy Report if needed? Is an Assembly Manual provided?
A: Ai’s cad designer works to create a home layout that is unique, whether using existing floor plans or one that is designed to your specifications. Our plans are in full detail (13- 17 sheets), fully executable, and permit worthy. We work with engineers who are knowledgeable about geodesic structures to do specialized load bearing designs and seal our plans (if needed). Ai can provide energy reports if required for permit. Our assembly manual covers in detail the construction process of the dome (the manual is available to view once a kit deposit and order is made.)

Q: Finally, does the other companies back up their product against high winds Tornadoes and Hurricanes?
A: American Ingenuity offers a limited warranty up to a 225 mile an hour hurricane winds, or an F4 tornado, see details on our website.

I hope that when finished comparing our concrete dome home kit against other housing types, you will see that our product is superior, and more cost effective. We look forward to speaking with you, and working with you to provide you a home kit that is safe, secure and energy efficient.

 

 

Dome Size 30′ 34′ 40′ 45′ 48′
Item
Material Labor Material Labor Material Labor Material Labor Material Labor
  • Dome Kit w/ Options
  • Dome Kit Assembly
  • Concrete Slab/Foundation
  • Windows: qty. – cost
  • Exterior doors: qty. – cost
  • Insulation: already installed
  • Rough plumbing
  • Rough electrical
  • AC/Heat & Ducting
  • Interior Faming/Joists
  • Stairway
  • Drywall & finish for interior walls
  • Shell Interior finish**
  • Dome Shell Wall Board: already installed
  • Interior doors, trim, finish
  • Painting: int. & ext.
  • Cabinets & vanities
  • Plumbing fixtures
  • Electrical fixtures
  • Carpet & flooring
  • Kitchen appliances
Total
Total Material & LaborCost per sq. ft.

** Finishing seams with joint compound and tape and painting a textured paint (paint with sand or vermiculite mixed in it) onto the dome shell wallboard. Or apply joint compound in a skip trowel fashion over the drywall to blend seam areas to the drywall.

These categories do not include costs of land, engineering and permit fees, Florida impact fees, building plans, site preparation, utilities such as water, septic/sewer, electric, etc.

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.