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American Ingenuity Concrete Dome Home Kit
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7 report

1. Why concrete is the absolute best way to build a dome.

2. What you need to know about local building codes.

3. What can be done locally and when to call in an expert.

4. The ins and out of bank loans on dome homes.

5. What you need to know about the land. 

6. When is the best time of year to build a dome for certain locations.

7. Why AiDome exterior can have 225 mph wind and F4 tornado warranty

Also from time to time you will be receiving Ai’s Newsletter

 

Benefits to signing up for (Ai’sNewsletter:
1. Receive notices on Unadvertised Dome Kit Sales
2. Receive notices about new Advertised Dome Kit Discounts
3. Receive updates on additions or changes to our web site
4. Receive updates on new Stock Floor Plan layouts






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Staff at American Ingenuity

GlendaB.Aidomes@gmail.com

American Ingenuity Inc, 8777 Holiday Springs Rd.  Rockledge, Florida 32955
Telephone 321-639-8777. Office Hours Mon-Fri 9-5 Eastern Time

How Can I View Ai Domes?

American Ingenuity’s Florida office domes (45′ & 34′ of 3,700 sq.ft.) are open for viewing by appointment on Tuesday and Thursday.  And once a month  a Saturday tour is available. Call 321-639-8777 for details. Click on Tour for info. View pictures of beautiful dome interior designed by international artist Electros, To view pictures of a 45′ dome on full basement review Stroupe page. For other dome pictures, check out the left menu bar on this home page for fourteen picture files and view pics.  American Ingenuity has sold over 800 dome kits into 47 USA states and 13 foreign areas.

The dome kits American Ingenuity sell become private homes. Ai would like to have model homes throughout the country but it is not economically possible. If Ai did have models, we would need to double the price of the building kit to pay for the model construction, the staff to man them and the annual costs to run, pay property taxes, etc. Ai has sold over 800 dome kits throughout the country. The assembled domes don’t belong to us and we can’t extend invitations to see them. However we are very happy that a few dome owners allow us to give out their name and number. So a referral could be a few states away from you.

Our referrals love their domes and are very happy to speak with potential owners. However, since they are not dome sales associates, we promise them that we will speak with each perspective buyer to answer their basic questions and walk them through significant pages on our web site. Ai tries to answer the multitude of potential buyer questions so as to not take up hours of the referral’s time with basic and in depth questions. As a result, please call our office and our friendly staff will be happy to talk with you and later provide a referral.To view free info, click on Info.  To view pictures of different America Ingenuity dome homes, look at the left side Menu Bar and scroll down to category pictures and click on the picture submenu items.

To view the DVD, click on New DVD.  To view stock floor plans, click on Stock Plans and scroll down the page to click on the hyperlinks. At no cost to you, Ai will email other stock plans that are not on our web site.  If stock plans are mailed, call Ai at  321-639-8777 for printing costs and mailing costs.

To view a Youtube video showing the interior and exterior of an Ai two dome complex for sale in Albuquerque New Mexico, click on Domes.  To view photo gallery of domes in Tornado Alley, click on Oklahoma

The two photo galleries & YouTube Video below are of concrete home on block basement
built in North Carolina. Three bedrooms & two bath dome home.
Above Photo Gallery is of Completed 45′ Dome Photos
Please click on arrows to view all photos.
 
The above photo gallery shows Construction Photos of the 45′ Stroupe Dome.
Please scroll down this page to view a YouTube Video of the Stroupe Dome.

45′ Dome on Full Basement in North Carolina.
Dome first floor square footage is 1,490.
Second floor is 540 for total dome sq.ft. of 2,030.
Basement garage and work shop is 1,492 sq.ft.
For total home sq.ft. of 3,522.

Floor Plans in PDF format.  Open by clicking on the PDF below or

download to your computer by right clicking and saving to your computer.

First Floor Plan
Second Floor Plan
Basement Floor Plan

(your browser may allow you to rotate the picture
by right clicking in the picture after it’s open and selecting.)

Below is YouTube Video of North Carolina 45′ Geodesic Dome Home

 

10% Discount Concrete Geodesic Dome Kits.
Please scroll down page to see dome kit discount chart &
25% discount on geodesic dome plans. For commercial plans call for pricing.
Above is 15 year old Ai Assembled Dome Kit in Colorado
on Custom Built On Site Basement
After the prefabricated panels are assembled
the exterior concrete is primed & painted. 
The Dome appearance does not age.

New Coat of paint and the Dome looks brand new!

 10% Discount: Dome Home Kits – Concrete Home
Savings of $1,608 up to $6,011
25% Discount on Geodesic Dome House Plans. Call for Commercial Plan Pricing.

It is Ai’s philosophy that each customer pays for only what they need. Ai does not burden the price of the prefabricated home dome kit with plan’s pricing, engineer seal cost or energy report cost. Dome Floor plans are purchased 3 months to 1 1/2 years prior to kit shipment.  About 50% of the building departments require engineer sealed dome home plans and an energy report to issue a permit. Sometimes structural calculations are required.  As a result each customer pays for their plans separately from the dome kit and pays for a seal, energy report and structural calculations only if their building department requires them.  This link shows stunning dome pics.  To view Engineering Statements about Ai’s dome click on outside the box.


Save 10% off kit with one entryway pricing*, place kit deposit by January 15, 2018 and accept delivery by June 15, 2018 with Buyer & Ai selecting month of shipment (March, April or May or by June 15, 2018) & Ai selecting the week/day of shipment in the agreed upon shipment month.  Place deposit with order by January 15, 2018 to take advantage of this offer.

**Dome Outside Diameter – includes wall thickness (if two entryways on each side add 5′ 5″. to the above diameter).

To view a chart listing each stock plan & its kit sale pricing, click on Stock Plans & Kit Sale

The prefab home dome kit includes all the prefabricated component panels for the dome shell and one entryway. Once the panels are assembled the finished dome can look similar to above. Above dome was built on a custom on site basement. Basements can be built from concrete block, ICF or poured concrete. Ai does not sell basement kits – only basement building plans.  To view Kit Assembly Process, view Dome Kit Assembly and Construction Overview. Check out left hand menu bar on our home page for fourteen picture files.  One of which is Kaufman.

Due to spam filters your email requests may not make it to American Ingenuity and our email replies may not make it back to you.  If you email Ai and do not receive a reply in one to two days, please call us at 321-639-8777.  While you are on the phone, we will send you a test email and have you send your email to us.

Each floor plan varies as to number of entryways and dormers. Additional entryways and dormers are added on to the kit sale price at current pricing. Entryway and dormer pricing can be viewed at Building Options. The prefab panels consist of  center core of R28 – seven inch rigid expanded polystyrene (EPS) insulation with 3/4″ concrete reinforced with galvanized steel mesh and 1/2″ Georgia Pacific DensArmor gypsum wallboard adhered to the interior of the EPS. The insulation is not styrofoam.  The seam areas between the panels are about 3″ deep by 5″ wide and is filled with fiber concrete on site.  The seam concrete averages two inches thick. To learn about panel contents, click on Composition.  To learn about Kit Contents, click on Kit.

Save 25% on stock, modified or custom Residential Building Plans if plans are ordered prior to January 15, 2018.  To determine which floor plan layout is best for you, click on Geodesic Dome Home Plans to view stock plans. If you do not see a stock plan that fits your needs even modified or custom plans are discounted 25%.  Please scroll down to view Plan’s Sale Chart. 

What are the Advantages of American Ingenuity’s prefabricated home dome kit? 

To review info on why build a geodesic dome versus conventional shaped house, click on Why?

Super-strong Concrete Exterior, super-energy efficient, low exterior maintenance, fire resistant concrete exterior, tree impact resistant concrete exterior, noncombustible exterior wall materials and environmentally friendly.   To view Advantages Summary with photos, click on Summary.

To acquire a building permit, building departments can require the building plans to be engineer sealed by an engineer licensed for that state and an Energy Report.  The building plans, engineer seal and energy report can be purchased through Ai.  Stock or Custom plans take 2-10 weeks for delivery. Time depends on number of plan orders in queue when you place your plans order.  It is Ai’s philosophy that each customer pay for only what they need. Ai does not burden the price of the building kit with plan’s pricing, engineer seal cost or energy report cost. Building plans are purchased 3 months to 1 1/2 years prior to kit shipment. 

If you give Ai your property address, at no cost to you we will call your building department, show them our web site, email generic building plans and ask what is required to obtain a building permit on Ai’s dome kit.  About 50% of the building departments require engineer sealed plans and an energy report to issue a permit. As a result each customer pays for their plans separately from the building kit and pays for a seal and energy report only if their building department requires them.

A great way to save on building your prefabricated home dome kit is to take advantage of Ai’s sale pricing on the dome kit and the dome building plans. By placing a deposit and ordering your dome kit,  American Ingenuity can schedule your kit for manufacturing and ship your kit prior to May 15, 2018.  While Ai is designing your dome plans, you can be completing all the other paperwork that is required to obtain a building permit. With building plans in hand, obtain bids for your foundation installation.  Your foundation does not need to be installed to take delivery of your dome kit.  The 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.)

The dome kit can be stored outside (in nonfreezing months) for the following reasons: 1) the steel reinforced concrete, EPS insulation & drywall are not harmed by rain; 2) American Ingenuity paints the EPS edges that extend out of the steel reinforced concrete.  The paint stops UV light from harming the EPS.  3) The special ½” Georgia Pacific DensArmor drywall on the interior of the dome panel is not conventional gypsum.  When conventional gypsum gets wet, the gypsum crumbles & paper face molds.  This special DensArmor drywall contains fiberglass face with special gypsum which allows it to be moisture resistant and mold resistant as there is no paper for food source for mold growth.  Even if the drywall gets wet and then allowed to dry out, per the manufacturer the DensArmor goes back to its original consistency.

  • Submit Plans Order & full payment by January 15, 2018 to receive 25% discount.
  • The stock floor plans for each size dome can be viewed by clicking on dome home plans. If floor plan layouts are mailed, please call for printing and mailing costs.  321-639-8777 Mon-Fri 9-5 ET.
  • If a stock plan doesn’t fit your needs, Ai has flexible plans which can be modified or customized to fit your life style at a 25% discount as well.  Plans Quote completed after custom sketch & description are reviewed.
  • Building plan pdfs are emailed so sets can be printed locally.
  • Pricing does not include printing costs or mailing/Fedexing cost.
  • Residential Building Plan sets contain all the blueprints typically provided with any type of housing and include floor plans, exterior elevations, dome shell section view, top view showing panel placement, floor joist framing plans, joist/edge beam dimensions, foundation dimensions and angles, structural details and locations of plumbing and electrical fixtures.
  • Engineer seal, Structural Calculations, Rescheck Energy Report & Local Site Specific Product Approval can be purchased through Ai if required by your building department to issue a building permit.  Florida Energy Reports are completed by local companies with Ai providing dome dimension info. 
  • Standard foundation is Concrete Slab. The design of other types of foundations; i.e. basements, stem wall, pilings, etc. require the hiring of an independent engineer.  Call for engineer pricing.
  • Plans may be purchased with Visa, Master Card, Discover, check or money order.
  • Stock plans utilize a concrete slab foundation and are delivered in 2 weeks.  Allow at least 5 weeks for modified plans and 8 -10 to 12 weeks for custom plans. (time frame depends on time of the year and orders in queue when Ai receives your order.)
  • Commercial Plans are custom plans. Call for pricing.  Independent Engineer is hired to assist in Commercial Plan Design.  Engineer seal and energy report costs are quoted after seeing plan’s layout.

AMERICAN INGENUITY, 8777 Holiday Springs Road, Rockledge, FL 32955 – 321-639-8777 – eastern time zone.  

General FAQ on American Ingenuity’s Prefab Home Dome Kit.

Exterior Office lots of green

American Ingenuity’s Office Domes – 45′ linked to 34′ – 3,700 sq.ft.

Domes were built in 1993

Q: How long has American Ingenuity been designing and manufacturing domes?

A: Established in 1976, Ai has continually been under the same ownership. Ai has sold domes into 47 states and 14 foreign countries.  The only states that Ai currently has no domes in are: Rhode Island, New Hampshire and North Dakota.

Ai domes have been exported outside the continental USA to: Hawaii, Puerto Rico, Trinidad, the Virgin Islands-St. Kitts and St. Croix, the British Virgin Islands-Tortola, West Indies-Nieves, Canada, Israel, Jamaica, Bahrain and the Faroe Islands (between Iceland/Scotland/Norway).

The first American Ingenuity dome was built in 1976 after two years of design research. Founder Mr. Busick employed the talents of the Director of the Florida Solar Energy Center, University engineering students and an architectural professor to design the very first Expanded Polystyrene (E.P.S.), concrete and steel geodesic dome.

Normally American Ingenuity does not assemble the dome kits but because this was our prototype, the dome was built by propping up the precut E.P.S. insulation panels, hand tying steel mesh to the exterior of the insulation and spraying concrete over the entire dome exterior. This first dome became the office and model of American Ingenuity and by our standards was a primitive design. There were no riser walls or performed entryways or dormers at that time.

Countless designs and construction techniques were analyzed in the early years as we developed a new generation in housing and designed our special component panel. American Ingenuity received a patent on its panel in the early 80’s. These pre-concreted panels produce a better quality home and eliminate the need for costly concrete pumping equipment.

Ai has progressed from a prototype structure to a home that has received a design competition award and three energy awards along with exposure through numerous articles in national magazines, on Inside Edition, on Film and Garden, front cover of Popular Science and other media. Ai outgrew two previous locations as we progressed to our current five-dome complex. Ai’s Building Plans have progressed from simple hand drawings to a detailed computer designed set of blueprints.  American Ingenuity’s Building Plans are new and improved. An Expanded Assembly Manual is now available with each new dome order.  Ai was the first to offer second floor door dormers/balconies on a dome.

Q: Can I view an American Ingenuity dome?

A: Ai’s offices are in a 45′ dome connected to a 34′ dome.

  • You can visit our office domes here in Rockledge, Florida Tuesday and Thursday after 1 pm by appointment only.  And once a month there is a Saturday tour, where we tour not just our office domes but a 34′ dome linked to 22′ dome home.  Please call 321-639-8777 for an appointment or click on Contact Us.
  • Although the domes are set up as offices, you can easily see how spacious and livable the domes are.
  • Sorry due to insurance reasons, Ai’s factory domes cannot be toured.
  • Once a month Ai has a Saturday Office Tour starting at 11 am for those individuals who cannot visit during the week. Click on Office Domes to learn more and obtain directions.

The dome kits American Ingenuity sell become private homes. Ai would like to have model homes throughout the country but it is not economically possible. If Ai did have models, we would need to double the price of the building kit to pay for the model construction, the staff to man them and the annual costs to run, pay property taxes, etc. There are over 800 American Ingenuity domes throughout the country but they don’t belong to us and we can’t extend invitations to see them. However we are very happy that a few dome owners allow us to give out their name and number. So a referral could be a few states away from you.

Our referrals love their domes and are very happy to speak with potential owners. However, since they are not dome sales associates, we promise them that we will speak with each perspective buyer to answer their basic questions and walk them through significant pages on our web site. Ai tries to answer the multitude of potential buyer questions so as to not take up hours of the referral’s time with basic and in depth questions. As a result, please call our office and our friendly staff will be happy to talk with you and later provide a referral.To view free info, click on Info.  To view pictures of different America Ingenuity dome homes, look at the left side Menu Bar and scroll down to category pictures and click on the picture submenu items.

To view a Youtube video showing the interior and exterior of an Ai two dome complex for sale in Albuquerque New Mexico, click on Domes.   On the left hand side of the Home Page are fourteen links to click on to view dome photos.

Q: Does your customer service staff work on commission?
A:
No. What we have found best is to offer good customer service and not twisting anyone’s arm to purchase a dome. Just call or email your questions. We stay in contact with our clients with a newsletter. If you would like to receive the newsletter go to our web site’s home page and enter your name and email address under Newsletter.

Q:  I hear that American Ingenuity recommends solar tubes instead of skylights  – please explain why?

A:  Ai no longer manufacturers skylight panels. For additional light max out the number of second floor window dormers and door dormers. In the door dormer install a tall window instead of a door. Or on site install Solar tube in the panel NOT skylight. Skylights allow too much hot or cold air into the dome. Solar tubes unlike traditional skylights, are designed to control the problematic aspects of sunlight. They reduce glare and inconsistent light patterns. They also screen infrared rays that can overheat interiors as well as ultraviolet rays that can fade furniture and fabrics.  Solar tubes have the following names:  tubular day lighting devices, or TDDs for short are also called “tubular skylights,” “light tubes,” “sun pipes,” and even “light tunnels.”

Q: What does frequency mean in relation to domes?
A:
Frequency is simply the number of segments between the centers of pentagons in a geodesic dome. To best visualize this, first note the five panels that make a pentagon at the top of the dome. Follow any of the seams that radiate from this pentagon center to the center of another pentagon. There will be three segments in a three frequency dome; in a four frequency it will be four; in a two frequency, two. A soccer ball exemplifies a three-frequency icosahedron. A typical golf ball utilizes dimples in a six-frequency design. If you are a contestant on a quiz show, or become a proud dome owner, this bit of trivia may be of help to you.

Ai’s 15′ & 18′ domes are two frequency, 1/2 spheres on a 4′ vertical riser wall with an additional 2′ riser.

Ai’s 22′ and 27′ domes are two frequency, 1/2 sphere on a 4′ vertical riser wall.  Or the 22′ kit can have a custom 5′ riser instead of the 4′ riser.  An additional 2′ riser can be ordered for the 27′ dome. 

The 30′, 34′, 40′, 45′ and 48′ domes are three frequency, 3/8 spheres on a 4′ vertical riser wall. An additional 2′ riser can be ordered.

American Ingenuity has developed a dome that is approximately a one-half sphere with a four foot tall riser wall. All of Ai’s building plans and manufacturing specifications are for 3/8 domes on a four foot riser.

5/8 Domes:

  • Ai finds it more practical to use a vertical 4′ riser wall on all of its domes instead of designing its domes with the 5/8 geometry.
  • Ai’s 30′ dome turns out to be almost the same height as a 5/8 dome.
  • Also the 4′ riser wall makes for a better shaped entryway and allows the dome to link with all of our other size domes.
  • Ai can manufacture a 5/8 dome but none of our predesigned entryways will fit. And the location of the second floor will be different and difficult for us to design because our predetermined supports will no longer work. As a result the framing design will cost more than we normally charge. Call our office for more information.

Q: What is the largest American Ingenuity dome available?
A:
Prompted by requests for a large, single dome for commercial uses, we developed a 60′ dome in 1988. It can be built for a warehouse or storage building  All the 60′ building plans are custom plans. The 60′ dome will cost more per square foot to assemble than the smaller domes because of the greater number of panels and the height of the dome. The 60′ dome requires two trucks for delivery.
If you need a larger dome than this, contact Monolithic Dome in Italy Texas. 

Q: What is the shipping cost?
A:
Because Ai’s Building Kits are reasonably priced, even with the addition of the shipping cost, your dome home kit will be more affordable than you think. Having our manufacturing plant located in Florida is advantageous for shipping since more is shipped into than out of the state, leaving many trucks headed out empty.

Using an independent trucking agency, Ai contracts to have these trucks carry the building kits for a low cost of approximately $2.70 to $2.90 per mile or a minimum of $800 for Florida sites north of our factory.  Call for shipping costs to Florida sites south of Ai’s factory.  This is less than we could do with our own trucks. Most of the time each flatbed truck can carry one large building kit or two 22’s.  Per mile shipping costs can vary at any time due to fuel costs, fuel surcharges and travel distances.The small 15′ and 18′ dome kits can be picked up with a trailer and 3/4 ton pick up truck. Call us for details. 321-639-8777.

The number of multiple kits that one truck can carry varies depending upon the number of entryways, dormers, size of insulation, etc. with each kit. The entryways and dormers take up more room than triangles or riser panels. Once your floor plan has been finalized, Ai can determine the number of trucks that will be needed for your shipment.

Florida sales tax and surtax are not paid on building kits shipped out of the state of Florida.

Each trucking company has cargo insurance. Ai communicates with you and gives you the name/cell number of the truck driver so you can also communicate with him. Shipping is paid with the kit balance two weeks prior to the kit shipment date in the form of a bank check.  The truck is unloaded an all-terrain forklift (2,000 to 3,000 pound lift capacity) that you rent locally. Please have an experienced forklift driver and at least two to three people to assist the fork lift driver. Click on Shipping to learn detailed information on the unloading of the semi-truck.  Ai emails the Truck Unloading document which contains precise details for kit unloading.

Two of the main reasons Ai’s Dome Building Kits are reasonable in price are first: labor costs are less in Florida than out west or up north where most housing kits are manufactured. Second: because of Ai’s component panel design, your building kit contains all the R-28 insulation & 1/2″ DensArmor and 80% of the finished concrete exterior already installed.

In comparison with other building kits besides purchasing the building kit

  1.  the insulation is usually purchased separately and installed separately
  2.  roofing is usually purchased separately and installed separately
  3. the drywall is usually purchased separately and installed separately  

Please click on Panel Composition to learn about Ai’s panel.  As a result of Ai’s prefabricated panel’s contents, normally Ai’s Building Kit is about one third to one half the cost of other housing kits. So even, when you add the shipping cost to the American Ingenuity Kit pricing, the total is still less than other housing kit’s pricing.

Q: How does the weight of these domes compare to other houses?
A:
Because of the reduced surface area of a dome and its thin shell construction, American Ingenuity domes weigh less than the average house, but are remarkably stronger than other types of structures. Domes are considerably lighter than a concrete block house.

The Ai dome foundation does not require anything more than 2000 lbs. per sq.ft. soil bearing capacity.  If there is any doubt about your soil, please hire a soil report. To complete this report, the company will bore test holes in your soil and evaluate your soil. A soil engineer with the company will review the data and make a recommendation of what type foundation your new home should be built on. Because you are building a super-strong American Ingenuity dome you want to assure your foundation is built on correct foundation.

Q: Are American Ingenuity concrete domes manufactured in any other location?
A:
No. Our manufacturing costs here in Florida are well below the national average, which offsets any long distance shipping expense. We can actually manufacture a kit here in Florida and ship it cheaper than we could manufacture it elsewhere.

Q: What are the advantages of the dome shape?
A:
The dome, or partial sphere, is a geometric form that encloses the greatest amount of volume with the least amount of surface area. Historically, massive domes constructed of stones, brick or concrete were common in ancient Greece and Rome. In modern times, Buckminster Fuller was the first to formulate geodesic principles for constructing a spherical surface by triangular subdivision.

During the past decade the home buying public has experienced a substantial increase in the cost of construction, the cost of energy and the cost of borrowing. As a result, there has been increased interest in the use of technology to help address these concerns. In the last decade, many people have discovered that the dome home design offers a viable solution.

As a residential building concept, geodesic dome home construction translates into a highly comfortable and livable home that has a maximum of floor area enclosed by a minimum of materials. These features combine superior strength and cost-effectiveness in a single structure. In short, the building concept of a dome home expands the range of simple and economic housing options.

Manufactured dome homes are constructed using a triangular network to form a spherical shape. This method provides for a free span, self-supporting structure requiring no internal supports such as roof load bearing partition walls. This allows for maximum flexibility of floor plan design and utilization of interior space.

As an architectural form, the dome is one of the strongest structural forms devised and built by man. Domes that were built centuries ago enclose many of the great cathedrals of Europe. Domes are structurally superior to rectilinear enclosures. The partial sphere is an aerodynamic shape that is very stable in high winds and can withstand heavy snow loads. For these reasons, residential domes greatly exceed the structural requirements of the major building codes in the United States.

One of the most exciting architectural environments ever designed, a dome brings its best attributes to your home. It delivers a rewarding living experience filled with warmth, light and open space to those who accept the challenge to build and live in their own dome. To learn more:

Q: Do you have any pricing comparisons?
A:   We have a few.  Please call and Ai will email those comparisons. 
 At least once a month perspective clients visit our office domes and inform us that our kit is at least one third to one half-less in cost than the shell materials for a conventional house or wooden dome or gunited concrete dome.  We believe when you do your own research that you will agree with our visitor’s conclusion.

The reasons why our kits have a better price is not magic.

  • The primary reason is the design concept. It is far more practical to build a dome with concrete than wood. Applying the concrete to rigid foam insulation produces a component panel that provides structure, exterior finish and the insulation.
  • Our philosophy of each person paying for only what they need results in a lower kit price as we do not have an 800 number, our literature prices are based on their printing costs, only our clients who need an engineering seal pay for one, etc.
  • Also we maintain a lower advertising cost; by marketing our dome on line.
  • None of our staff is on commission.
  • Due to lower labor costs in Florida, we can manufacture in Florida and ship to other locations cheaper than it would cost to manufacture there.

Remember to compare apples to apples when pricing each company’s kit. Ai’s component panel includes 80% of the steel reinforced concrete exterior, all the shell’s seven-inch thick R-28 insulation and all of the interior shell’s wall board. In wooden domes you will likely have to purchase the insulation, wall board, exterior finish and roofing at extra costs. Click on Stick Built to read more.

Q: What do the panels weight?
A:
On the left side of our Home Page click on Dome Kit Sizes and Prices, then click on Specifications. Scroll down the page and you will find a category, Panel Weights. Depending upon the size dome, the panel’s weight from 155 to 400 lbs.

Q: What size land do I need?
A:
The size property you would need for a dome depends upon the following items:

  1. What are the front, back and side setbacks for your property. Meaning how many feet does your building department require you to leave vacant along the front, back and sides of your property lines, well, septic tank and drain field?
  2. Do you want to drive a vehicle around each side of your house? When you know these answers you can add the distances up to determine the minimum width (dome diameter plus side set backs and any other space needed to drive a vehicle around the sides of your dome). The minimum length of land needed would equal front and back setbacks, lawn plus diameter of dome(s).
  3. To learn more click on Planning Process.

Q: What should I consider before purchasing land?
A:
Call or email us, and request our latest buying land document that lists items to obtain answers before purchasing property.  Some of the biggest concerns are:

  • Does muck have to be removed and truck loads of fill brought in?
  • Are there any minimum house square footage requirements or garage requirements?
  • Are there any impact fees in order to build?
  • Are there any height restrictions?
  • Is there wetlands, or running water on the site causing environmental concerns?
  •  Are there any endangered plants or animals on your property?
  • Would you have to build your house on concrete pilings?
  • Are there any deed restrictions or homeowner associations governing what can be built on the land?
  • If you use a septic tank, will the soil perk?  Did your neighbors install a septic tank near your property line which will limit where you can install your septic tank?
  • If you do not have access to city water, what is the average number of feet your neighbors had to drill down to find water? What is the cost per foot to drill a well?
  • If there is no electricity to the site, will your neighbors sign easements so you can get electric lines to your site?
  • Do you have egress to the property via a road that is county or state maintained?
  • Are there front, back and side set back requirements which limit your building area, etc.?
  • Is there a county maintained road to give access to the property for emergency vehicles?

Q: Explain about painting the American Ingenuity Dome
A:
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 primed and painted after the entire kit is assembled.

  • In the Assembly Manual is a section on waterproofing that gives the latest info on primer and paint.
  • Stain is not used because stain will not seal the concrete.
  • The painting of the dome includes 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.

It is not difficult to paint the dome….there are no soffits or gutters to have to deal with. Repaint the dome when you rub your hand on the paint and it chalks. Prior to painting, remove any algae with combination of chlorine/water or oxygen bleach and water and pressure wash.  Best to roll the paint on so there is a good mill thickness per the painting guidelines.

Typically, the American Ingenuity dome is repainted every 4-5-6 years, it depends on your personal preference.

  • During construction, install five stainless steel eye bolts in the top of the dome around the exhaust pipe. One in each of the five top seams  A rope is tied thru one eye bolt and fastened to the worker’s harness.  Each eye bolt is installed 6″ from a top center pipe with vent cap. The pipe is installed during construction to later install exhaust fan which will remove water vapor out of top of dome.  The eye bolts keep the rope away from the pipe with vent cap…so no rubbing on pipe to harm it.  There is a document in the Assembly Manual that describes this pipe and eye bolt installation.  The vent pipe, vent cap, exhaust fan and eye bolts are purchased locally.
  • The sides of the dome can be painted using a cherry picker or an extension ladder and paint roller on a pole. To paint the top of the dome stand on the dome with the rope tied to harness or stand in a cherry picker.
  • Yes you can walk on top of the domes.
  • To access the top of the dome put an extension ladder to a second floor dormer and then walk onto the top of the dome from top of dormer. Tie rope thru eye bolt and attach rope to harness. A person can sit in the harness and use pole with roller to apply paint or stand in a cherry picker. Current technology allows for a plastic tube connecting paint in bucket on the ground to painting pole. 
  • Do not use a sprayer to paint the dome as the spray is too thin a layer. The paint should be applied to the mil thickness noted on the paint can. Ai has found it is more efficient and quicker to paint the dome using a power roller attached to a paint sprayer to get this correct thickness. If the paint is applied in too thin a layer then UV light deteriorates it sooner thus causing the need to paint sooner.
  • Prior to priming and painting the newly concreted dome allow the concrete to be rained on for three weeks to one month to remove efflorescence. If not raining, then water down the concrete weekly with garden hose.

Paints and Primers

American Ingenuity is continually reviewing primer, sealant and paint info from the market place and from our dome owners. Paints recommended by dome owners:

  1. Ames Research Labs Maximum Stretch: At participating Ace & True Value Stores. If using Ames there are specific sealants and primer to be used.
  2. Sherwin Williams: Loxon XP Paint, Loxon Primer and Conditioner
  3. Richards Paint: Rich Flex 245 and  Rich Flex Alkali Resistant 100% Acrylic Masonry Primer
  4. Behr’s Premium Elastomeric Masonry, Stucco & Brick Paint –Home Depot
  5. Seal Krete Paint (pigmented) –Home Depot

Ames products are available at comparable or less costs than paint from Lowes or Sherman Williams or Home Depot and can be purchased at participating ACE and True Value Hardware Stores (does not have to be purchased out of Oregon).  Only negative is the paint coverage of Ames is less than the other paints described above.

To speak with Ames representative call 888-345-0809 and ask for Gene (direct line in Oregon).  To test the product purchase pints or single gallons from Gene and then purchase your 20 – 50 gallons in 5 gallon buckets from local ACE or True Value Hardware Stores.  Ames Products can be researched and videos viewed at AmesResearch.com when on their web site click on Products to view info about their Super-Primer, Peel & Stick Contouring Tape and Maximum Stretch Paint.

The main reasons American Ingenuity selected exterior concrete paint is because it is readily available, economical and easy for the beginner. Specialty paints like epoxy are unable to stretch and the epoxy paint can “in some areas” crack and allow water to pass through. In addition, any paint that would have a high gloss would highlight flaws in the seam finish. A paint that would withstand UV light or last longer would be advantageous but keep in mind that it is much easier to paint a dome than a conventional house.

Does the dome’s steel mesh ground out electrical line waves?
Yes. The entire dome except for the widows and nonmetallic doors is completely wrapped with steel. The steel mesh would block or ground electromagnetic radiation with the exception of high frequency in the order of what cell phones use. Radio and TV will possibly be blocked and the 60 cycle of power lines being very low frequency would definitely be grounded.

How resistant is Ai’s dome shell to termites? Based upon a FHA test, E.P.S. will not support bacterial growth or fungus growth. It also contains no food value to any living organism. Its lack of food value means that although termites, ants and rodents can tunnel through it, there is no other attraction.

Prior to when the slab is poured, the foundation area is treated for termites. After the dome is assembled, treat an area around the slab to stop the termites. In the USA, use termite stacks, etc. In addition, Ai has learned to keep mulch away from the sides of the foundation as mulch holds moisture for the termites.

There are no openings or cracks in the dome shell that would provide a path for insects. The windows, doors etc. could provide a path. Ask the window and door supplier how to seal them from bugs and termites. Concrete that is applied in the bottom riser wall seam overlaps the foundation concrete and is primed and painted.

 

 

This page covers importing geodesic dome home kits.  The Kits can be shipped in containers to any destination in the world.  International Buyers purchase the American Ingenuity dome and pay USA inland trucking costs & ocean shipping costs, because they know they cannot build or buy any conventional home as strong or fire resistant or energy efficient as an American Ingenuity concrete dome. Below are answers to our most frequently asked importing questions and info on what size containers are needed to ship each dome kit size.   To view the dome kit sizes converted to meters, click on Sizes in Meters.

importing Faroe Island Dome

American Ingenuity Dome Being Built on Basement – North Of England

To date Ai has sold dome kits into 47 U.S.A states and fourteen foreign areas. American Ingenuity has exported domes into Hawaii, Puerto Rico, the Virgin Islands-St. Kitts and St. Croix, West Indies-Nieves, Canada, Israel, Jamaica, Trinidad, Bahrain, the Faroe Islands (between Iceland/Scotland/Norway) and Tasmania (near Australia). 

Please note the wooden 2×4 rib system is temporary, once all the panel seams/entryways/dormers receive two layers of on site fiber concrete and the entryways and dormers are framed in, the dome is self supporting and the wooden rib system is removed. Some of the wood can be used for interior framing & framing of second floor perimeter knee wall.  There is no wood in or on the American Ingenuity dome exterior walls to rot or to be eaten by termites or to burn.  There are no shingles to blow off in high winds.  No shingles to burn in a forest fire.  The exterior concrete is primed and painted.  The entryways and dormers are framed in with pressure treated wood to accept your locally purchased doors and windows.  To view our web site page that lists what comes in a kit, click on Kit Contents.  To view dome home plans for each size dome, click on Dome Home Plans.

 

Container shipping

Container With 34′ Dome Kit Inside –
ready for semi-truck to pick up and take to USA port for shipment to Tasmania

The following is a list of our most commonly asked importing questions with their answers. 

Q: Do you export the concrete dome kits?

A: Yes. Ai. domes have been exported outside the continental USA. Requests for shipment into your area are best handled by freight forwarders located at your local ports.  Call Ai and give us the receiving port name and names of freight forwarders you want Ai to call about shipping costs and Ai will call for quote.  The freight forwarder will give costs for inland trucking company to bring the container(s) to our factory to be loaded and returned to USA port and ocean shipping costs to your port.

To work with your freight forwarder and assist them with the international paperwork, there is a fee of $200.

Q: What is the most shipping cost paid by dome buyer to receive their Dome Building Kit?

A:  Ai had a buyer in Tasmania (near Australia) who paid $18,000 to ship one 34’ Dome kit with 7” EPS insulation in one 40′ high cube container.  He paid this shipping cost because he knew he could not build or buy any conventional home as strong or fire resistant or energy efficient as an American Ingenuity concrete dome.

The Ai dome is more energy efficient than a conventional house, because of the thick insulation, the reduced exterior surface area and because the exterior walls of Ai dome contain no wood to interrupt the insulation.

Q: Does American Ingenuity have an engineering statement about your dome panels?

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

Q: Please explain about the temporary wooden rib system which supports the panels during kit assembly:

A: American Ingenuity’s Dome Building Kits are erected using a wood rib system to temporarily hold the panels in place until the seam concrete, concrete on the entryways, dormers, cupola and link has cured and the entryways and dormers are framed in. The system is dismantled upon completion of the dome and the 2x4s are recycled as part of the interior framing. Shorter 2×4’s can be used to frame the second floor perimeter knee wall. Behind this knee wall, electrical, plumbing or ducting can be run or the second floor perimeter space can be used for storage.

The Rib System consists of using your own 2x4s, bolts/nuts/washers purchased from Ai and steel hubs purchased from America Ingenuity to assemble a free standing framework which matches the geometry of the dome.  Or Ai can cut, drill and paint the ribs and ship them in the container with your building kit.

Q: Due to high shipping cost to return steel hubs to American Ingenuity from out of country, can the steel hubs be purchased from American Ingenuity? 

A: Yes for three frequency domes (30′ – 48′) the 46 Hubs are purchased from Ai for approx. price of $2,070.  For two frequency domes (15′,18′, 22′ & 27′) the 26 steel hubs are purchased for approx. price of $1,170.

Q: A container has all sides enclosed except for the end versus a kit shipped within the USA is shipped on a semi- truck that has all sides open. How do you load the dome kit into the container?

A: For loading a container Ai has to rent a telescoping forklift which allows the forks to extend into the container to place stacks of panels 39 feet back into the container to load the container. As a result Ai’s forklift cannot be used to load the kit into the container. The rental cost on the telescoping fork lift is $800 for one day rental. If your order includes two or more containers, the telescoping forklift will need to be rented for two days or more. Two day rental cost is approximately $1,235.

Onsite the panels are unloaded by hand one at a time. 

Q: Besides the dome kit and the misc. parts that I can order from American Ingenuity, can I purchase cut, drilled, painted 2×4’s to erect the temporary wooden rib system?

A: Yes the 2×4’s can be purchased from Ai with Ai cutting them to specific lengths, drilling holes and painting the ends. The steel hubs have each leg painted a specific color to match the same color 2×4.  Due to fluctuating 2×4 prices we cannot list exact price. Pricing will be based on current 2×4 costs at the time of shipment.  Ai does not add overhead costs to the labor to cut the 2×4’s. Only the labor costs to cut the 2×4’s plus the actual 2×4 cost determines the pricing.

For two freq domes (15′, 18′, 22’ or 27’) there are 75 – 2×4’s for approx. price of $605. For three freq domes (30′ – 48’)  135 – 2×4’s can be purchased for approx.price of $1,088.  The temporary support system needs 2×4’s cut to a precise length, holes drilled in both ends of the 2×4’s that make the triangles and one hole drilled in the 2×4 leg for the riser wall, and ends painted red, white or blue to match the steel hub leg color. Ai can email the cutting & drilling specs for the 2×4’s to be cut, drilled & painted on site. We realize this cutting, drilling and painting is difficult and time consuming for our clients; therefore, the 2×4’s can be purchased from Ai.

Q: Isn’t shipping expensive to export your kit into my country?
A:
Yes, but if you look at the low cost of the Ai building kits….usually the kits are one third to one half less in cost than the cost for materials to build the exterior walls and roof of a conventional house in your area….that savings can typically cover your shipping costs and more…hoisting mechanism,etc.  Plus you receive more from the Ai Dome, greater strength (225 mph & F4 tornado guarantee) and greater energy efficiency (insulation comparable to 11″ of fiberglass batting) than a conventional house can offer.

American Ingenuity’s manufacturing costs in Florida are well below the national average, which offsets any long distance shipping expenses. Ai can actually manufacture a kit in Florida and ship it to countries cheaper than we could manufacture it there.

PRICING COMPARISONS: When you research other building kit pricing, generally you will find that Ai’s kit pricing is about one third to one half less than conventional building kits. The reason Ai’s kits have a better price is not magic.

  • The primary reason is the design concept. It is far more practical to build a dome with concrete than wood and applying the concrete to rigid foam insulation produces a component panel that provides structure, exterior finish, the insulation and the shell wall board.
  • Our philosophy of each person paying for only what they need; results in a lower kit price as our literature prices are based on their printing costs and only our clients who need an engineering seal, energy report, engineering calculations, etc. pay for those items.
  • Ai’s staff is not on commission.
  • Due to lower labor costs in Florida, Ai can manufacture in Florida and ship to any other location cheaper than it would cost to manufacture in that area.

Remember to compare apples to apples when pricing each company’s building kit. Ai’s panels include all the R-28 insulation already installed, 80% of the dome’s prefinished concrete exterior reinforced with fibers and galvanized steel mesh and all the interior 1/2″ DensArmor shell drywall. In conventional houses you will likely have to purchase the roof trusses, exterior walls, insulation, roofing and ceiling wall drywall and pay for the installation of the trusses, exterior walls, insulation, roofing and drywall. With Ai’s kit the assembly process is placing panels on a temporary wooden rib system, cementing entryways, dormers and the seams between the panels and filling the shell interior wall board seams with joint compound and tape.

Q: What size containers are required to ship American Ingenuity Dome Building Kits?
A:
Until we see the floor plan that you select for your dome(s) we cannot quote the exact number of 20′ high cube container or 40′ high cube container(s) or 45′ high cube container(s) that will be needed.   Your floor plan selection determines the type and number of building options (entryways, dormers, link, cupola, additional risers, etc.) that will be included with your Building Kit.  The following number of containers could increase if all the building options for that size dome are purchased.

To save space Ai usually ships most of the same size items together. So until we can add up each size panel for your floor plan, we do not know the number of containers that will be needed for your order.  Due to the large size triangles of a 40′, 45′ and 48′ domes, the triangle shaped H panels will not fit in the container.  American Ingenuity trims the EPS/wallboard tips off the H panels so that the remaining H panel will fit in the container.  On site during assembly, the tips are reattached with expanding foam supplied with the kit at no cost.

The following info about riser height is explained, because the height of the riser panels effects how many containers are needed for shipment.

Q:  Please explain about the Riser Panels that come with each kit.

A: American Ingenuity includes a four foot tall riser panels in the building kit at no extra cost.

The four foot tall riser panels allow for more vertical space near the perimeter of the first floor.  Because of the spherical dome shape, usually 30% to 50% of the first floor is left open so that the living room and dining room are located under high vaulted ceilings.  This allows for a partial second floor to be installed.  The first floor ceiling height in the 22′, 27′, 30′, 34′  & 36′ domes that have a second floor above them is 7 1/2 feet.  The first floor ceiling height in the 40′ and larger domes that have a second floor built above them is 8′.

Q: Can the first floor ceiling height in rooms that have a second floor built above them be taller than 7 1/2′ or 8′?

A:  Yes.  Custom Two Foot Tall Riser Panels can be  installed above standard four foot tall risers. To achieve a taller ceiling height in first floor rooms not under high vaulted ceilings purchase a 2′ tall riser to be installed above the standard 4′ riser.  This results in the first floor ceiling height of rooms not under high vaulted areas

  • 9’6″ for 27′, 30, 34, 36′ (with second floor door dormer)
  • 10′ for 36′ dome with out second floor door dormer
  • 10′ for 40′, 45′ and 48′ domes.

Possible Containers needed to ship American Ingenuity dome building kits.  Because a container has sides, Ai has to rent a telescopic forklift boom to load the container.  Call for current equipment rental costs.

The Ai dome building kits 30′ thru 48′ come with a standard 4′ tall vertical riser panels.  The 15′ & 18′ kits come with 4′ riser panels & 2′ riser panels. The 15′ & 18′ kits can be purchased with 3 1/2″ EPS instead of standard 7″ EPS.  The 22′ & 27′ kits come with either four foot riser or five foot riser panels.  Ai cannot manufacture kits larger than 18′ with 3 1/2″ because the thinner insulation makes the larger panels too flexible causing the concrete to crack.

  • One 15’ – kit with 7″ EPS (4’ risers plus 2’ risers) (with 2×4’s) and cupola panels will fit in one standard 20′ container. H panel tips are not trimmed.
  • One 15’ – kit with 3 ½” EPS (4’ risers plus 2’ risers) (with 2×4’s) and one 22’ with 7” EPS, ½” drywall (4’ risers) (with 2×4’s) can fit in one 40’ high cube container. H panel tips are not trimmed.
  • One 15’ kit with 3 ½” EPS (4’ risers plus 2’ risers) (with 2×4’s) (no link) (can have ½” drywall) can fit in one 20’ standard container
  • Two 15’ kits with 3 ½” EPS with one entryway on each kit (4’ risers plus 2’ risers) (can have ½” drywall) (no 2×4’s) (no link) will fit in one 20’ standard container.
  • One 15’ kit and one 18’ kit each with 3 ½” EPS with one entryway on each kit (4’ risers plus 2’ risers) (no ½” drywall) (no 2×4’s) (no link) is a real tight fit in one 20’ standard container.
  • Four 15′ kits with 7″ EPS, 1/2″ drywall, standard 4′ risers & 2′ risers & two sets of 2×4 ribs can fit in one 45′ high cube container.
  • Eight 15′ kits with 3 1/2″ EPS, no drywall, standard 4′ risers & 2′ risers & two sets of 2×4 ribs can fit in one 45′ high cube container.
  • One 18’ kit with the panels having 7” eps, ¾” concrete reinforced with galvanized steel mesh and fibers and ½” DensArmor Drywall with one entryway and one window dormer will fit in one 20’ standard container. The kit has 4’ risers and additional 2’ risers made from 7” eps/concrete/drywall.
  • Two 18′ kits with 7″ EPS, 1/2″ drywall, standard 4′ risers & 2′ risers & one set of 2×4 ribs can fit in one 45′ high cube container.
  • One 18’ kit with 3 1/2 “ EPS (4’ risers plus 2’ risers) (with 2×4’s) (no link) (can have ½” drywall) will fit in one 20’ standard container.
  • Two 18’ kits with 3 ½” EPS WITH NO DRYWALL AND NO STEEL REINFORCED CONCRETE will fit in one 20’ standard container.   The kit has 4’ risers and additional 2’ risers made from 3 ½” eps.   On site after the panels are assembled, hand tie galvanized steel mesh on the exterior and apply fiber concrete over the entire exterior.  1,000 sq.ft. of 1”x1” galvanized steel mesh is needed.
  • Four 18′ kits with 3 1/2″ EPS, no drywall, standard 4′ risers & 2′ risers & one set of 2×4 ribs can fit in one 45′ high cube container.
  • One 22′ kit w’ 7″ EPS with standard 4′ risers will fit into one 20′ high cube container.  However it is a very tight fit.  2×4’s for temporary rib system will not fit.   Link will not fit.  
  • One 22′ kit with 7″ EPS with 5′ risers, 2×4’s for temporary rib system and link panels will fit in two 20′ high cube containers.
  • Two 22′ kits w’ 7″ EPS with 4′ or 5′ risers can fit in one 40′ high cube container. 2×4’s for rib system will fit. Link will not fit.
  • One 27′ kit w’ 7″ EPS with 4′ or 5′ risers can fit in one 40′ high cube container.  Link and 2×4’s for rib system will fit.
  • One 22′ kit w’ 7″ EPS with  4′ risers and one 27′ kit with 4′ risers require one 45′ high cube container.
  • Two 27′ kits with 7″ EPS will not fit in one container or on one semi truck.
  • One 22′ kit w’ 7″ EPS with 4′ risers and one 27′ kit with 4′ risers can possibly fit in one 40′ high cube container and possibly one 20′ container.
  • One 30′ kit w’ 7″ EPS with 4′ risers requires one 40′ high cube container or two 20′ high cube containers. Link will not fit. 2×4’s for rib system will fit.
  • One 34′ kit w’ 7″EPS with 4′ risers  requires one 40′ high cube container or three 20′ high cube containers.
  • One 36′ kit w’ 7″ EPS with 4′ risers requires one 40′ high cube container.  2×4’s for rib system will fit. Link will not fit.
  • One 36′ kit w’ 9″ EPS w’ 4′ risers requires one 45′ high cube container.
  • One 40′ kit w’ 7″ EPS with 4′ risers requires  one 45′ high cube container. 2×4’s for rib system will fit. Link will not fit. H panel tips may need to be trimmed.
  • One 40′ kit w’ 9″ EPS with 4′ risers requires one 45′ high cube container. 
  • One 40′ kit w’ 7″ EPS with 4′ risers can be shipped in one 45′ high cube container or  three 20′ high cube containers. H panel tips may need to be trimmed.  2×4’s for rib system will fit.  If a link is included may need one other 20′ high cube container. (due to shape of triangles and size of 20′ container there is wasted space in the 20′ container versus shipping in 40′ high cube containers)
  • One 45’ kit W’ 7″ EPS with 4′ riser requires one 45′ high cube container and one 20′ high cube container.  H panels will need to be trimmed. A link will fit.  2×4’s for rib system will fit.
  • One 48′ kit w’ 7″ EPS with 4′ risers requires one 45′ high cube containers and one 20′ container. H panel tips will need to be trimmed to fit in the container.

Q: Do you have freight forwarder who can estimate the shipping cost on the containers?
A: Yes. 
SR International Logistics, Inc. is a full service international freight forwarder.  David Ross at SR International Logistics Inc. info is www.SRInternational.com 2525 16th Street #208 Denver CO Tel: 1-720-855-3115 Fax: 1-720-855-6464  email: dross@srinternational.com  

Q: Do you have any information on shipping one 40′ high cube container to Port of Spain, Trinidad Tobago?
A: Yes, here is container trucking info and ocean shipping quote to Port of Spain Trinidad as of October 2015.  One 40′ kit can fit in one 40′ high cube container. (H panel tips are cut off to fit in the container and reattached with Enerfoam on site.)

MSC– William Diaz 1 305-477-9277 Ext 75042 email: wdiaz@msn.us
Trucking Cost – 1,496.00 (drop container at Ai factory and pick up next day & delivery to port)
Ocean Shipping – $2,935.00 from Port Everglades, Florida to Port of Spain, Trinidad
Hazardous fee – $100.00 (cans of Enerfoam (adhesive) and cans of cleaner for enerfoam metal dispensing gun cause container to be labelled Hazardous. Results in $100 fee)
Total Trucking & shipping on one Hazardous 40’ High Cube Container  – $ 4,531.00

Q: Do you have any information on shipping to Hawaii?
A:
Yes, shipping to Hawaii involves: containers being delivered to our factory to be loaded; once loaded the containers are transported by truck to a port in California. Then the containers are loaded onto a ship. The company that delivered the containers to our factory was Falcon Transport, Inc. at POBox 411 , Bird-In-Hand, Penna 17505-0411; their phone number is 717-687-0471.

A past rate to have a 40 foot container spotted at our factory here in Rockledge, Fl 32955 and shipped through to Port Hilo, Hi was $14,618. Matson Navigation jhorbaczewski@matson.com at 415-957-4000 handled the boat shipping to Hawaii.

A 45’ kit  requires two containers. A 34’ kit requires one 40′ High Cube container for a shipping of about $14,618.

For example a 45′ kit and a 27′ kit requires two 40′ high cube containers and one 20′ high cube container.

Q: Do you have any information on shipping to Nieves in the West Indies?
A:
Yes, a past rate to have a 40 foot container spotted at our factory here in Rockledge, Fl 32955 and shipped through to Nieves was $8,812.

Q: Do you have any information on shipping to Puerto Rico?
A:
Yes, one of our clients in Puerto Rico purchased two domes, a 34′ and a 45′. Our client used two flat racks and one container that were shipped on Sea Star from the Jacksonville port to San Juan. The shipping was $2,612 for each 40′ flat rack or $5,224. The shipping on the 40′ Standard Container was $2,412, plus the following fees: delivery fee to Aguas Buenas $585, paperwork $140 for a total shipping cost of $8,361 for a 34′ and a 45′ dome.

The Sea Star contact was Jim Stoshak at 904-751-2110.

A Trucking Company that deliveries containers and flat racks to factories to be loaded for export to Puerto Rico: is Magic Transport Miami Fl 305-887-2424 or 888-693-7312, fax 305-887-0320.

Q: Have you exported into Europe?
A:
No but Ai can ship to Europe. We have exported into the Middle East but not into any European countries.

Q: Do you export to the Virgin Islands?

A: Yes. We have shipped two 40′ domes to St. Kitts. MVC Transportation Corporation brought the two 40′ Standard Containers and 40′ flat rack to our factory to be loaded. MVC’s mailing address is POBox 653808, Miami Fl 33265 phone 305-888-4MVC, fax 305-888-8011. The Consignor was Crowley Port Everglades Ft Lauderdale Fl. The Freight Forwarder was Caribbean Freight Systems, Inc. The Port of Loading was the Port Everglades. Port of unloading was St Kitts. Each container cost $5,200 for inland trucking costs and shipping from Port Everglades to Virgin Islands.

Q: Do you export to Mexico?
A:
We can.  Contact a Mexican importing person who can answer your border questions, such as “What are the duties? What paperwork is involved.” The kit is shipped on a semi truck from our Rockledge Florida factory. Your border person may know of Mexican trucking companies that carry loads into Florida. Once that truck’s Florida merchandise is unloaded, it would drive to our factory and be loaded with your kit. Brownsville Texas is about 1,200 miles from our factory. Shipping to that point would be about $2,650 US Dollars at $2.20 per mile estimated shipping costs
.

Q: Do you export to the Middle East?
A:
Yes. In 2004 we got an approximate shipping quote from Transgroup Worldwide Logistics on two 40’ containers being trucked from Miami to our factory, then delivered back to Miami and then shipped to Dubai, UAE for about $5,225. 42 days transit time. This pricing included two hours no charge for each container to be loaded and an additional loading time of two hours per container at $45 per hour ($180). Two drivers at $725 each to bring the container to our factory and take it back to Miami after loading ($1,450). Ocean freight of $1,750 per container from Miami to Dubai UAE ($3,500). And $95 for Documents and forwarding. This does not include any duties or documents for the Dubai port. This quote was from Transgroup Worldwide Logistics/Stephen Brown in Ocean Quoting at 321-868-2230.

Q: Do you export to Canada?
A: Yes. We have shipped domes into
Canada.  But none of our clients allow us to give out their name and numbers for referrals.  

The Canadian broker for L.M. Clark Broker is Steve Martonino, (905-673-8650 ext 224) who did the customs work for Donkers Harris LTD for one of our clients.

In Canada the building department will require the building plans to be engineer sealed prior to giving you a building permit. Ai knows of an engineer licensed to seal our building plans for most areas of Canada. A Canadian seal could cost from $900 to $1,500 to $3,000….depends on the size dome and the foundation type.

Please scroll down the page to find chart showing specifications for Geodesic Dome Home, square footage by floor,  first floor ceiling height if a second floor is installed above first floor, dome interior height, etc.   To view  15′ & 18′ dome specs, click on Tiny Home Specs. 

To view Dome Diameters in Meters and floor plan square footages in square meters, select page 2.

American Ingenuity manufacturers ten different prefab home kit sizes also called Modular Home.  Domes are measured by diameter in feet.  The 15′ & 18′ & 22′ domes can have a first floor only with optional attic/loft while the 27′, 30′, 34′, 36′, 40′, 45′ and 48′ domes can have a second floor framed with wood 2×10 joists.  If a cupola is installed on top of a 40′, 45′ or 48′ dome there is enough interior height to install a small loft area under the cupola.

The floor plan selected determines how much of the second floor is installed. Where a second floor is not installed there will be high vaulted ceilings over first floor areas.   It is typical that one half to two thirds of the second floor is installed.  However any of the domes can be  built with no second floor.   Below are pictures of some of the dome sizes.

Ai’s Tiny Home Kits 15′ & 18′ come with 4′ risers and additional 2′ risers.  A’s 22′ – 48′ dome kits include four foot tall riser panels before the triangle geometry.  Ceiling Heights in first floor rooms that have second floor installed above them is either 7′ 6″ or 8′.   22′, 27′, 30′, 34′ & 36′  kits – 7’6″.   40′, 45′ & 48′ – 8′.

How to have 8’6″ or ten feet first floor ceiling heights in rooms with a second floor installed above them:  In 22′ & 27′ domes custom order five foot tall risers instead of the standard four foot tall risers which results in eight foot six inch ceiling height.  In 30′, 34′, 36′, 40′, 45′ & 48′ domes order taller entryway panels and custom  2′ risers to install above the standard risers to result in either 9’6″ or ten foot first floor ceiling height in areas where a second floor is installed above the rooms.

Hamilton Dome Ext DSCN7883 - 1

40′ Garage Dome on the left linked to a 45′ Dome Home

 

Henderson domes flash 2a

40′ Garage Dome on the left linked to a 48′ Dome Home

 

Dome with two standard entryways on basement

40′ Dome with two standard entryways on basement

Exterior basement NC from up the hill

34′ Dome on full basement

 

 

27' garage dome with garage door up.....can park two medium size vehicles.

27′ garage dome with garage door up…..can park two medium size vehicles.

Or 27′ dome can be built as a two bedroom/two bath dome home. 

Dome on the right is 40′ in diameter.

22' dome with two entryways.

22′ dome with two entryways

  •  To learn more about entryway widths, panel weights, etc., scroll down.
  • To view sample stock plans, click on dome home plans.
  • To learn more about entryways, cupolas, etc., view Building Options.
  • To learn what is included in the Dome Building Kit, view Building Kit Contents.
  • To learn about dome kit sale prices, view Sale.
  • To view pictures of the Kit Assembly Process, view Kit Assembly.
  • To view info about Construction Overview, view Overview.
  • To learn about the regular pricing for each stock plan and the corresponding regular pricing on the building kit for that stock plan, click on Stock Plans & Kit Regular Prices.
  • To learn more about interior finishing click on Finishing.
  • To view  15′ & 18′ dome specs, click on Tiny Home Specs.

DOME GEOMETRY: Frequency is the number of intersections from the center of one pentagon grouping to the next pentagon grouping.

  • Ai’s 15′, 18, 22’ and 27′ domes are 2-frequency, 1/2 spheres on a 4′ vertical riser.  The 15′ & 18′ kits come with 4′ riser and additional 2′ risers. Instead of the standard four foot riser panel, a five foot riser panel with taller entryway panels can be ordered for the 22′ & 27′ kits.
  • Ai’s 30’, 34’, 36′, 40’, 45’, and 48′ domes are 3-frequency, 3/8 spheres on a 4′ vertical riser.  On site a one foot or two foot tall wall can be built to install the risers on which increases first floor ceiling height (where 2nd floor built above first floor) to 9′ or 10′.  Or additional 2′ risers can be ordered and installed on the standard 4′ riser panels.

American Ingenuity’s 30′ through 48′ in diameter domes are approximately a one half sphere with a four foot tall riser wall.

5/8 Domes:

  • Ai. finds it more practical to use a vertical 4′ riser wall on all of its domes instead of designing its domes with the 5/8 geometry.
  • Ai’s 30′ dome turns out to be almost the same height as a 5/8 dome.
  • Also the 4′ riser wall makes for a better shaped entryway and allows the dome to link with all of our other size domes.

(Click on chart below to enlarge)

 

Panel Composition: To learn more about the panel composition, view Composition.

To view Dome Diameters in Meters and floor plan square footages in square meters, CLICK HERE

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,  Ai knows of a licensed Florida Builder, Randy Dixon, who will travel to some USA areas with 1 associate to assemble the kit using your local workers 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 associate cannot travel to your area, Randy 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

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

To view an article which covers why build a geodesic dome for your new home that summarizes the major info about the Aidome building system and component panel, please click on Why Build a Geodesic Dome.

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

Kit Assembly time for 27′ linked to 22′ – 9 1/2 days:   A dome owner hired a Florida Builder by the name of Gary Cook who hired the independent Kit Assembly, Randy Dixon, to supervise the builder’s workers during the assembly of his 27’ Aidome linked to a 22’ garage dome.  Here is direct quote from the Dome Owner: “Randy Dixon and a crew of five and sometimes six people, brought the project from a basic slab with a few standing riser panels to this state in 9 1/2, eight hour working days.”

The state the dome owner is referring to is that all the panels for the two domes and link are installed, with some seams having a first layer of concrete.  At this phase of assembly, the builder’s concrete workers can complete the exterior concrete work without the consultant being on site and can call him when any questions arise.   The exterior work left to be done involves concreting the seams, framing in locally purchased doors and windows, concreting the entryway and dormer panels, priming, sealing and painting the exterior concrete.  Then the dome is considered weather tight and interior finishing can occur without weather concerns; i.e. framing, plumbing, electrical, kitchen and bathroom fixture and cabinet installation, HVAC, drywall finishing, etc.

*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

Kit Assembly time for 27′ linked to 22′ – 9 1/2 days:   A dome owner hired a Florida Builder by the name of Gary Cook who hired the independent Kit Assembly, Randy Dixon, to supervise the builder’s workers during the assembly of his 27’ Aidome linked to a 22’ garage dome.  Here is direct quote from the Dome Owner: “Randy Dixon and a crew of five and sometimes six people, brought the project from a basic slab with a few standing riser panels to this state in 9 1/2, eight hour working days.”

The state the dome owner is referring to is that all the panels for the two domes and link are installed, with some seams having a first layer of concrete.  At this phase of assembly, the builder’s concrete workers can complete the exterior concrete work without the consultant being on site and can call him when any questions arise.   The exterior work left to be done involves concreting the seams, framing in locally purchased doors and windows, concreting the entryway and dormer panels, priming, sealing and painting the exterior concrete.  Then the dome is considered weather tight and interior finishing can occur without weather concerns; i.e. framing, plumbing, electrical, kitchen and bathroom fixture and cabinet installation, HVAC, drywall finishing, etc.

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* $13,248
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: $23,864 – $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.