formaldehyde | AiDomes

The standard seven inch thick (R-28) expanded polystyrene insulation (E.P.S.)  in the American Ingenuity 22′ thru 48′ dome building kits can be upgraded to nine inch thick (R-36) E.P.S.  See below for pricing.  To view the detailed data and characteristics of E.P.S. insulation, please click on Panel Composition and scroll down the page to view the EPS data.

Cold northern climates like Vermont and Wisconsin, etc. are appropriate areas to build Ai dome kits with the thicker 9″ (R-36) insulation. If a 45′ or 48′ dome’s insulation is upgraded, your shipment will require two semi-trucks for delivery.  The Ai dome with 7″ E.P.S. will easily outperform conventional housing with 11″ thick fiberglass insulation. Instead of purchasing thicker insulation from American Ingenuity consider applying the money you would have spent for the thicker insulation to purchase thermal coverings for windows, triple paned windows and insulated doors.

E.P.S.- Expanded Polystyrene Insulation

E.P.S. is frequently mistakenly referred to as “Styrofoam”. Although they both come from the same “base” material, polystyrene, the two products differ in many respects. “Styrofoam” is the registered name of Dow Chemical Co. and refers to the extruded polystyrene insulation product produced and marketed solely by that company. “Styrofoam” is generally blue in color and has a minimum density of about 1.80 pounds per cubic foot. It has a different cell structure (like hollow bubbles) and has a marginally lower better R value, but is considerably more expensive, not only per board foot but even more so on a “cost per R” basis. E.P.S. is available from more than 100 manufacturers throughout the country in a variety of sizes, densities and forms. “Styrofoam” is only available from one company in a more limited range of sizes.

Seven inches of sturdy, rigid R-28 expanded polystyrene (E.P.S.) insulation forms the core of each American Ingenuity component panel. This insulation is permanent, chemically and thermally stable, and resistant to mildew, provides no nutritive value to animals, plants, microorganisms, is non-irritating to skin, and is Chlorofluorocarbon (CFC) and formaldehyde free. This 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 Ai uses is sometimes referred to as bead board and sometimes incorrectly referred to as Styrofoam (Styrofoam is the trade name for extruded polystyrene manufactured by Dow Chemical Co). Ai does not use Styrofoam.

American Ingenuity uses the one pound per cubic foot density, closed cell E.P.S. which has a thermal resistance (R-value) of 4.17 per inch of insulation at near freezing temperatures. This also explains why it is a very common insulation used in housing and sold at hardware stores. Ai uses the 7” thick E.P.S. which has an R-value of about 28.

Ai chose the expanded polystyrene over the extruded polystyrene because the extruded polystyrene is almost twice the cost with only a slightly better R-value.

When should you purchase the 9″ thick E.P.S.? If you have five or more days a year where the temperature reaches zero degrees then you may want to purchase the thicker 9″ insulation. If you have hotter days than most climates, we leave it up to you whether you need the 9″ thick E.P.S.. On the price list go to the Building Options and look down the list for 9″ Insulation.

Ai does not recommend that you purchase the 11″ E.P.S. insulation unless you live in a severe climate like the Northwest Territory of Canada.

Insulation Comparisons:

  • 2×4 solid wood with 3 1/2″ fiberglass is about R-8.
  • 8″ Concrete Block, with 3/4″ air, 3/4″ Celotex is about R-9.
  • 2×6 Solid wood construction with 5 1/2″ fiberglass is about R-11.
  • 2×4 solid wood with 3″ urethane is about R-13.
  • 7″ E.P.S. insulation is R-28 and is comparable to 11″ of fiberglass insulation.
  • 9″ E.P.S. insulation is R-36.
  • 11″ E.P.S. insulation is R-44.

American Ingenuity’s component panels for the 22′  thru 48′ domes includes the R-28 insulation and most of the steel reinforced concrete exterior finish and all the interior shell wallboard. Typically, in wooden domes you will likely have to purchase the insulation, wallboard and roofing materials for extra costs.

2015 Pricing For Thicker 9″  E.P.S. Insulation
22′
27′
30′
34′
40′
45′
48′
call for pricing
call for pricing
$2,650
$3,090
$3,715
$4,305
$4,795

 

If you upgrade your 40′, 45′ or 48′ dome with 9″ EPS more semi-trucks will be needed for delivery.  The 40′ or 45 ‘ & the 48’ kit will require two trucks for delivery. All Kits whose insulation is upgraded are considered Specialized Orders and are custom made for that Buyer.  These orders require a 50% deposit to start manufacturing.  If the specialized order is cancelled any payments made are non-refundable.

Q: Why are your dome homes so energy efficient?
A:
You can save 50-70% on heating and air-conditioning costs with your American Ingenuity dome over a conventionally built home. Some of the reasons for this superb energy efficiency are:

  • Super insulation that does not degrade with time, moisture, or compaction.
  • Spherical shape means reduced exposed surface.
  • Airtight exterior virtually eliminates energy leakage.
  • Solid thermal envelope.
  • Uniform R-value. The insulation is not interrupted with structural members (e.g. 2X4’s roof trusses). The only breaks are for doors and windows.
  • Downsized heating and cooling equipment.

Your kit comes with lifetime R-28 E.P.S. insulation or if you choose, thicker R-36 E.P.S. insulation is available. Even in cold climates, you may find that a single ventilating wood stove can heat a smaller dome (22′, 27′ or 30′) will provide all the heat your home will need. Larger domes need a centralized ducting system or mini-split ductless unites to disperse the heated or cooled air throughout your dome.

 ANALYSIS OF EXPANDED POLYSTYRENE INSULATION (EPS)

The Expanded Bead Polystyrene (E.P.S.) Insulation that American Ingenuity utilizes is seven inches of sturdy, rigid R-28 modified E.P.S. insulation that forms the core of each component panel. The E.P.S is one pound per cubic foot density (pcf).

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. is:

·         permanent

·         chemically and thermally stable

·         resistant to mildew

·         provides no nutritive value to animals, plants, microorganisms

·         non-irritating to skin

·         Chlorofluorocarbon (CFC) and formaldehyde free.

 

 

16.15 un loading truckKaufman picture assembly 121

45′ dome kit being offloaded from semi-truck using lull. 

Or an all terrain fork lift can be used.

All panels are lettered per the Building Plan Nomenclature blueprint.

 

45' dome kit off loaded from semi-truck.

45′ dome kit off loaded from semi-truck.

 

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 view of triangle 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.

The above wooden rib system is temporary and supports the panels until all the seam areas between panels are concreted and the entryways and dormers are concreted.  Then the dome is self supporting and the system is disassembled.  Steel hubs are returned to Ai for a deposit refund. Some of the 2×4’s can be used for interior framing or the framing of the second floor perimeter knee wall.   The dome shell contains no wood to rot, no wood to burn, no wood for termites to eat and no shingles to blow off in high winds. The exterior concrete is primed and painted with two coats of paint. Dome owners seem to prefer Ames primer and paint which can be purchased at Ace, True Value, Handy Hardware, Orgill, Do It Best or Wallace Hardware.  Info about painting is in the Kit Assembly Manual which is shipped to each dome buyer.

Q: What does my American Ingenuity dome kit include?

A: The American Ingenuity dome building kit contains all of the component panels needed to build the basic dome shell and panels for one entryway. These panels consist of triangular panels, the four foot high vertical riser panels and one set of entryway panels. Each floor plan varies as to type and number of additional entryways, window dormers, door dormers, etc.  Within the entryways and dormers {structural awnings}, your framing subcontractor installs a vertical framed wall and installs your locally purchased standard exterior doors and windows.  Click on Building Kit Contents to learn more.  To learn what is not included in the Kit, click on Not Included.

The Building Options include: Additional entryway panels, window dormer panels, door dormer panels, cupola panels and thicker insulation.are available Click on Building Options to learn more. Once you select a floor plan, Ai can give more specific pricing for your building kit with building options.

The component panel includes: the seven inch thick R-28 expanded polystyrene (EPS) 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 adhered a 1/2″ Georgia-Pacific DensArmor gypsum drywall. Onsite the kit is assembled by concreting the entryways, dormers, cupola, link and seams between the panels. The entire dome is not concreted over….only the seams between the panels and the entryway and dormers are concreted.  For the interior shell finish, fill the wall board seams with tape and joint compound. Apply primer and two coats of paint to the exterior.

The component panels do not come with any paint on them. Ai does not add any color to the concrete. On site the seams are concreted, if Ai painted the panels or added color to the concrete it would not match your painted seam concrete. The concrete shell is painted after the entire kit is assembled. The painting should include a concrete primer and two coats of good quality exterior concrete paint. The dome can be painted any color, tan, blue, green, etc. preferably a light to medium color to reflect the sunlight.  Ai’s dome owners have successfully sealed their domes using Ames Research Laboratories primer and paint which can be purchased at Ace or True Value Hardware for about the same price as Lowes and Home Depot paint.

The American Ingenuity (Ai) dome building kit does not include doors and windows. There is such a variety and varying price points, Ai leaves that up to each client to purchase locally. The floor plan selection will determine how many entryways or dormers your dome will have.

No interior items are included. Ai believes you should not pay shipping on items you can purchase locally such as: plumbing, electrical, framing, flooring, kitchen cabinets, kitchen appliances, bathroom fixtures, lighting fixtures, etc. Purchase at local building supply stores: Lowes, Home Depot or from eBay and Craigs List.

Q: What determines the type and number of Building Kit Options I need for my Building Kit?
A:
Your floor plan selection determines the type and number of Building Kit Options. On the first floor of Ai’s 30- 48′ residential house domes there can be as many as five entryways. On the second floor of the 27′ dome and the 34′ – 48′ domes there can be as many as five window or door dormer in our house domes. On our web site we have displayed a few of our stock floor plans which illustrate different numbers of first floor and second floor options. If you do not see a plan to fit your life style, Ai can email other stock plans for your review.  Ai can customize any plan or start from scratch with your sketches and develop a custom floor plan layout.  Click on Plans.to learn more.

Q: Does the Building Kit contain any interior items?
A:
No interior item is supplied except each triangle panel and riser panel has 1/2″ gypsum drywall adhered to it.

Q: What size windows and doors will fit in the Window Dormers and the Door Dormers?
A:
Click on Window Sizes to see this answer.

Q: What is the component panel’s composition?
A:
The component panel consists of steel reinforced concrete adhered to one side of the rigid expanded polystyrene (E.P.S.) insulation and 1/2″ Georgia Pacific DensArmor drywall adhered to the under side with wallboard adhesive.  Your American Ingenuity dome kit is affordable, strong and assembles quickly 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.

Concrete: The panel concrete is a special formulation containing synthetic fibers and liquid admixtures. The homeowner purchases bags of Portland cement and masonry or stucco sand locally. Ai ships these same fibers and admixtures with your building kit so the seam concrete 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 concrete in your dome 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 is 3/4″ thick and reinforced with galvanized steel mesh.

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 and is locked to that of the adjacent panels with C-rings (commonly called “hog rings”). The dome panels then become completely encircled by steel mesh.

E.P.S. Insulation:

E.P.S. Insulation in Ai domes:  standard insulation is seven inches of sturdy, rigid R-28 expanded polystyrene (E.P.S.) insulation forms the core of each component panel. The E.P.S. Ai utilizes is 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, Chlorofluorocarbon (CFC) and formaldehyde free. The EPS 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.  Click on Insulation to learn more.

Wall Board: Consists of Georgia Pacific 1/2″ DensArmor adhered to the E.P.S. insulation with a wallboard adhesive.

Q: If I am not ready to assemble my dome, can it be stored outside?
A:
Yes. However if you expect to have your kit outside for more than two months, when you order your kit,  request that the E.P.S. edges be painted. Do not allow the kit to sit outside during the freezing rain or winter.