The following info gives a construction overview of the American Ingenuity Panelized Dome Kit
Workers sponge finishing final second layer in the seams between the panels.
Sponging produces a “sponge sand finish” which blends the seam fiber concrete to the prefabricated panel fiber concrete.
45′ dome home on the left linked to 34′ garage dome.
To view You Tube Videos about construction of Aidome, click on these videos:
Video 1: This video is part of a series of video detailing Aidomes 22ft in diameter dome when finished with local materials is one bedroom/one bath. Customer ordered 2 – 22′ kits, one to live in while visiting parents and one to rent out. Kit assembly and site prep is performed by Kevin Kirchmer with Infinite Improvements Construction.
Video 2: Construction Process Video 2. Prefab AiDome Home Kits – Shows Types of Foundations.
Video 3: Construction Process Video 3. The dome home is considered dried in if local workers have framed in exterior doors and windows & finished the exterior wall around the doors and windows. To make weather tight, after all concrete work is done, the exterior concrete is watered down at least once a week to remove efflorescence for 3-4 weeks. Remove any algae with combination of bleach water or oxygenated bleach water and then exterior concrete is pressure washed. Next step is to apply white primer, seal any hair line cracks with patching compound and then paint the exterior with two layers of elastomeric paint. The interior finishing is completed by the owner builder or his builder’s subcontractors; i.e. interior framing, plumbing, electrical, installation of kitchen cabinets, bathroom fixtures, drywall work, etc.
To view assembly pictures of 45′ dome home & 34′ dome garage, view Dome Kit Assembly.
Q: Do you have an engineering statement about your dome panels that can be submitted to my building department?
A: Yes, to view the statement click on Engineering.
The American Ingenuity geodesic dome shell kit is designed with unique and practical materials. Ai developed simplified, effective construction techniques, invented a component panel and created a home which offers the ultimate in energy efficiency, strength and practicality. Ai has been in business, with the same owners, since 1976 and has domes in 47 states and thirteen foreign areas.
Whatever size floor plan you seek, whether for a modest starter home or a grand estate, American Ingenuity domes are flexible enough to adapt to your conditions. The dome kit can be a Do It Yourself project with panels assembled by owner builders or the home owner can hire a contractor who hires the independent kit assembly consultant. To view info about DIY, click on owner builder.
To view stock plans for each diameter dome, click on Stock Plans Pdf. If you do not see a stock plan to fit your lifestyle, Ai can design modified or customized plans per your sketches and descriptions.
American Ingenuity’s new DVD is $7 includes mailing costs. To order please call our office at 321-639-8777 – Mon – Fri 9-5 eastern time. To view at no cost, click on Free DVD.
Building plans include the basic drawings for the dome that are needed when you acquire a building permit. The plans are composed on our computer aided drafting system as stock plans, or custom plans based on your individual requirements and design. Some of the pages are a 3-D elevation and a 3-D perspective view. These plans include all the structural drawings, show the placement of the electrical outlets, light fixtures, plumbing fixtures; however, they do not have the electrical, plumbing, HVAC layouts. We have found if the layouts are included, then the inspectors require the subcontractors to follow the diagrams when usually the subs like to do their own layouts.
Where can I see one of your finished domes? Ai has facilities in Florida where it manufactures the kits. Ai has sold domes into 47 USA states and fifteen foreign areas. We would like to have model homes throughout the country but it is not economically possible. If we had models throughout the country, Ai would need to triple the price of its building kit. There are over 800 American Ingenuity Domes throughout the country. We are thankful a few dome owners allow us to give out their name and number after we have answered the callers basic questions. To learn more view Visit our Dome Offices.
Dome Built on Basement w’ perimeter deck
Only a few of our dome owners allow us to give out their name and telephone number. Ai promises the dome owner that we will not take advantage of their courtesy and we will only give out their name to those who are serious and knowledgeable of the information on our web site. That way the dome owner is not answering basic questions that we can answer or is answered on our web site. After Ai answers your basic questions, we will review our dome referral listing for the dome owner closest to you who allows us to give out their name & phone number. Ai has also promised to not give out the dome owner’s address to assure that they will not have surprise visitors.
Dome Finished Costs:
The finished costs on the domes depends so much on where you live, what the labor costs are in your area and what price points you select for your windows, doors, cabinetry, flooring, bathroom fixtures, kitchen appliances, lighting fixtures, etc. You can ask at your local hardware store or ask a local contractor what the finished price per square foot is running for a conventional house. That is approximately what it will cost to finish the domes (if you do no labor yourselves), because everything in the interior is standard whether it is a conventional house or a dome house….plumbing, electrical, lighting fixtures, bathroom fixtures, flooring, kitchen cabinets, windows and doors, etc. are the same. Basically you end up with a super-energy efficient, super-strong home for about the same price as a conventional house. To learn more view Approx Finished Price Per Square Foot and Approx. Finished Cost.
About 40% of our clients assembly their kit while others hire a Builder who hires the independent kit assembly Consultant. The Component Panels and Building Plans come marked with panel nomenclature. If you do not want to manage the assemble of the dome kit, Ai knows of independent working consultants which travel around the country assembling the dome shell using your concrete workers or your contractor’s concrete workers. To view a list of possible Builders, click on builders. Best to hire a builder and pay him Cost Plus.
Using three to five good concrete workers and depending upon the size dome and type of hoisting mechanism used, shell assembly of 22′ – 48′ domes to the stage of having one layer of concrete in the seams and on the building options (Kit with one entryways and two dormers) can take from 14 to 26 days. To learn more about hiring the Specialist view Kit Assembly Specialist/Consultant.
You or your contractor hires local conventional subcontractors to perform the conventional jobs like forming and pouring the slab, plumbing, electrical, framing, etc. Ai believes you should not pay some one to come in from out of state to do work that your local subs can perform.
Prior to the Kit Assembly Consultant supervising the dome kit assembly, our clients had to hire a contractor who generally had never assembled an American Ingenuity Dome before. As a result the contractor would need to over-charge because he did not know how long it would take or what problems would arise. The Kit Assembly Consultant works directly for you as an independent subcontractor and can provide you with references for previous Ai domes built. Using this consultant will assure that the temporary wooden rib system and your building kit is assembled correctly and in a timely fashion. You or your builder hires concrete workers who mix the concrete to the special recipe and trowel the concrete into the panel seams and onto the entryways and dormers. The Consultant/Specialist does not apply concrete, he is there to supervise the job site workers.
Hiring the consultant for one week can save you two to three weeks or more of shell assembly time.
The consultant works for around $300 a day plus travel costs, motel, and car rental costs while at the job site. These costs include travel from his home base to the job site and a return to his home base at the completion of the job.
If you are interested in utilizing the Consultant, please call our office at 321-639-8777.
Contact your local Home Builder’s Association for the names of contractors and subcontractors in your area. American Ingenuity maintains a list of dome owners, contractors or subcontractors who have assembled Ai dome shell kits. To view this list view Builders & Assemblers.
A helpful web site is rsmeans.com They provide construction manuals, construction estimating CD’s, etc.
The following is a quick overview of Ai’s panelized kit contents and our building process to give you an idea of what is is required in building an American Ingenuity dome prior to the purchase of your personal dome. When you purchase a dome shell kit from us, the full “Assembly Manual” is included and is much more extensive and precise.
The American Ingenuity dome building kit includes one entryway and all the panels to assemble the dome shell. The triangular and riser panels are preconcreted, insulated and have wall board. The dome shell kit package includes: Triangular Panels, four foot tall Riser Wall Panels, Entryway Panels, Galvanized Steel Mesh, Concrete Fibers, Two Concrete Admixtures, Reinforcing Tension Wire, Concrete Bonding Agent, Connecting C-Rings, C-Ring Pliers, Cans of Expanding Foam, Metal Dispensing Gun for the expanding foam and the Assembly Manual. To learn more about the Kit Contents view Contents. To learn what is not included in the Kit view Not Included.
The interior wall board on the riser and triangle panels consists of Georgia Pacific 1/2″ DensArmor Plus Gypsum Wallboard adhered to the E.P.S. with wallboard adhesive. It employs fiberglass mat facing instead of paper on both sides of the board. The core is silicon treated gypsum providing excellent moisture resistance, fire resistance and adhesion properties. It won’t harbor spores that create sick homes. To learn more about this board view Panel Composition.and scroll down the page to the wallboard section or go to Georgia Pacific’s web site DensArmor and click on the its product specs.
For freedom and flexibility of design, you can select additional building kit options which are determined by your choice of floor plan. The options include: additional Entryway Panels (garage, high profile, or standard), Window Dormer Panels (first floor and or second floor), Door Dormer Panels (first floor and or second floor), Cupola Panels, Link Panels and R-36 Insulation. Within the entryways and dormers, on site a 2×4 or 2×6 PT wall is built and your locally purchased doors and windows are installed. To learn more about the Building Options view Options.
No interior items are included in the kit except for the interior shell wall board. Ai believes you should not pay shipping on items you can purchase locally such as; plumbing, electrical, framing, flooring, kitchen cabinets, bathroom fixtures, stairs, fireplaces, windows, doors, etc.
The basic building process consists of 1) placing the preconcreted insulated panels, entryway, door dormer and window dormer panels onto a temporary wooden rib system; 2) overlapping and locking the steel mesh with “C” rings and 3) concreting the seams and options. There is no need to concrete over the entire dome exterior. Only the panel seams and the building kit options are concreted on site. Prior to installing entryway, door dormer and window dormer panels, review your plans for any stud that needs to extend thru the EPS and for any anchoring hardware that needs to be installed; i.e. J bolts (top plate in door dormer & entryway framed wall), power studs (into sill plates), bolts,nuts, washers (into base entryway panels). The entryway, door dormer and window dormer panels are installed in the row of panels that they are in and receive a first layer of concrete when you apply the first layer of concrete in the seams. Prior to applying the scratch coat of concrete, the anchoring hardware or stud that extends thru the eps of the entryway or door dormer has to be installed. The next row of panels cannot be installed until the concrete on the entryways, dormers and seams has passed the scratch test.
The temporary wooden rib system and its bracing cannot be removed until 1) all panels (entryways, dormers, risers, triangles, link, cupola) are installed with two layers of concrete; 2) all framing is installed within the entryways and dormers and concrete has cured for two weeks.
Prior to priming and painting the concrete, tap on all seams to see if any sound hollow or the concrete shifts or vibrates. If this occurs then this concrete needs to be removed and new fiber concrete installed in that seam. Also allow the concrete to be rained on for one month to remove efflorescence. Examples of Paint which Aidome owners have had success with are:
- 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 Depot
- Ames Research Labs: Maximum – Stretch, at participating ACE & True Value Stores
- Sherwin Williams: Loxon XP Paint, Loxon Primer and Conditioner
- Richards Paint: Rich Flex 245; use Rich Flex Alkali Resistant 100% Acrylic Masonry Primer
- Behr’s Premium Elastomeric Masonry, Stucco & Brick Paint –Home Depot
- Seal Krete Paint (pigmented) –Home Depot
Once your kit is assembled, install framing and electrical. Then the wall board on the interior of the dome shell is ready to be finished similar to the method drywall board seams are finished. To accommodate some electrical wiring, grooves are cut through the wallboard and the EPS to allow for the insertion of electrical wiring. Grooves can be cut where baseboard will be installed to hide the grooves. To blend the taped electrical areas to the DensArmor finish, skip trowel joint compound over the DensArmor drywall. Call Ai at 321-639-8777 for further info.
A Brief Description of Ai’s Building Options and other items
Standard and High Profile Entryway panels for the 30-48 domes, utilize 3 1/2″ E.P.S. wrapped in steel mesh, are preconcreted on the underside surface and have a precast trough on the outer edge. You place rebar into the trough, fill the trough with concrete and concrete the outside surface and apply a second layer of concrete to the underside. The openings under the entryways are framed in on the site to fit your choice of locally purchased standard windows and doors.
G or Garage Type Entryways for the 15′, 18′, 22′ and 27′ domes, utilize 3 1/2″ EPS, but are not wrapped in steel mesh or concreted. You can purchase the steel mesh from Ai and at no cost to you Ai will install the mesh on the garage entryway panels.
Window and door dormer panels consist of 3 1/2″ E.P.S. wrapped with steel mesh ready for on site stucco. The openings under the dormers are framed in on site to fit your choice of standard windows and doors that you purchased locally.
To learn which domes come with which building options; i.e. second floor single opening window dormers or door dormers, standard entryways versus high profile entryways versus garage entryways, please view Building Options or call us or email us.
Link: Link panels consist of E.P.S. insulation and are not concreted or wrapped with steel mesh. Link panels are custom fit to the dome panels on site. Link prices vary depending upon the width and length of the link and whether you order the link panels with wallboard.
Domes are connected together with a Link made of the same materials as the dome panels; E.P.S. insulation. The Link connects to the adjacent domes in the same locations as an entryway or sometimes a door dormer. The thickness of the EPS in a Link is usually 7″ when it takes the place of an Entryway and 3 1/2″ when it connects like a door dormer. The width of the links depends on the size of domes and whether they are connected like an entryway or door dormer. The length of the Link varies from 2 ft. to 10 ft. Because the riser wall is a standard 4’ high, all domes will match each other despite a difference in diameters. Steel mesh can be purchased from Ai and on site the mesh is attached and then the link panels are concreted.
Cupola: Is the “cap like” item that can be installed on the top of the dome. Ai does not recommend a cupola due to the cost of installation and need to purchase five windows. The windows allow for hot or cold air to come in the dome, thus increasing your heating and AC costs.
Its purpose is to give additional headroom for a third floor loft in the 40′ or larger domes. The topside exterior of the five panels of the cupola and the underside exterior of the overhang (eave) are prefinished steel reinforced concrete, while the topside & edges of the eave are stuccoed onsite.
The top five insulated panels of the dome make up the cupola top with our overhang panels added on site. We recommend that you build the cupola only if you want a third floor loft. The cupola is a way to add height to the top center of the dome and another way to have opening windows. With the installation of a cupola, there is enough headroom in the 40′ and larger domes to have a third floor loft.
Hot air and moisture will rise to the top of the dome. If you build your dome without a cupola, we recommend installing a vent at the peak of your dome in within an interior second floor wall for ventilation. The electric fan vent has the added advantage of being easily controlled with a switch or timer. You can purchase vents used in sailboats that are quiet. The vent fan is installed in an interior wall near the top of the dome to exhaust the moisture and or hot air. The ducting for the vent fan runs through the interior walls and if need be in the floor joist to exit under a first floor entryway. That way there is no hole in the top of the dome to protect from leaking. Or you can install a Heat Recovery Ventilator in colder climates.
Does a copula change the structural integrity of the geodesic dome? In hurricane areas you would want to have shutters over the cupola windows. The cupola does not weaken the rest of the dome, but the cupola is more vulnerable to wind loads because it sticks up at the top. In high winds the overhang panels could come off; although in 30 years the eaves or overhang panels have never come off any of the Ai domes. Because the overhang panels are nonstructural if they did come off, they would simply be replaced after the storm.
Interior Framing: The interior framing of the dome is built much like conventional housing and can be either wood or metal. Some of the second floor can be hung from the dome concreted seams by suspension rods allowing for very “open” first floor plan designs. The American Ingenuity dome is capable of supporting a large amount of weight, including the 2nd floor, from the concrete dome shell. This weight is suspended by threaded steel rods which anchor into the concrete seams and extend vertically down into the dome. 3,000 lbs. can be supported by a 5/8″ threaded rod suspended in one of the concrete seams. To learn more view Interior Finishing and Framing.
Suspension Rods: The location of the suspension rods is determined by your floor plan selection. The Building Plans will show the suspension rod’s positioning. The suspension rod with nut sets on a 3″x 7″ steel plate, which is embedded in the concrete seam. The seam is reinforced with #4 rebar & two layers of galvanized steel mesh. The second floor can support at least 40 pounds per square foot, the same as other houses. We can easily design for a more demanding second floor load such as for waterbeds, whirlpool tubs, spas, libraries, etc.
Electrical and Plumbing: Almost all of the electrical and plumbing will be contained in the interior frame walls and installed in the same manner as conventional housing. To install electrical wiring in the exterior dome walls: simply cut a groove in the E.P.S insulation and wall board, insert the wire, use spray foam in a can to fill the groove and finish the wall like you would do conventional sheet rock with joint compound and tape. To install electrical boxes, conduit or plumbing pipes: cut the E.P.S. insulation and wall board slightly larger than needed, insert the box or pipe and fill in the opening with spray expanding foam. The spray foam will harden in about half an hour, holding the box or pipe secure. To learn more view Electrical and Plumbing.
AC/Heating Ducts: We leave the AC ducting diagram to your subcontractor, but generally the ducts run through interior walls, in the second floor joists and or behind the second floor knee wall. The vents are either in the interior walls or in the floor of the second floor. To learn more view AC/Heating and Fireplaces.
Click on picture below for a full size view
Foundations: Your dome can be built on your choice of foundation including: concrete slab, raised wood floor, stem wall or pier foundation, full or partial basement, stilts or pilings. To learn view Foundations.
Because of the reduced surface area of a dome and its thin shell construction, our domes weigh less than the average house, but are remarkably stronger. American Ingenuity domes are considerably lighter than a concrete block house. A finished 27′ dome shell weights about 25,000 lbs.; a finished 48′ in diameter dome weights about 42,000 lbs. Besides the weight of the dome, the load of your first floor and second floor will be calculated with load bearing walls designed into your foundation to support this load.
Prior to ordering building plans, determine your soil type and what type footing & foundation you need. Will it be normal footings under a concrete slab or will there need to be augured footings down to cap rock or wood pilings driven 40’ into the ground prior to the footing installation, etc.? To determine what type footing you need, you may need to hire a Soil’s Engineer and have a soil bore test. The soil under the footing and slab has to be compacted to 98% density for a minimum of 2,000 psf of bearing pressure. You cannot build on clay and you cannot back fill your basement walls with clay. Basically if you can build a regular house on your soil, you can certainly build a dome.
If three to five feet of fill needs to be brought in to reach the correct finished floor height, your foundation may need to be a stem wall with concrete slab or wood floor. If your property is in a flood zone, the building plans have to show the finished floor height. Contact your government department that handles Fema or flood zone info to find out if your property is in a flood zone. If you are in a flood zone, you will need to submit to Ai a letter stating the government official name that gave you the height and their phone number. Ai does not determine this height. If your home is not built at the correct finish floor height and you are in a flood zone, you will not be able to obtain insurance. And without insurance you cannot obtain a mortgage.
What is unusual about the foundation is the shape and rebars are designed to come out of the foundation and are concreted into the dome riser wall seams, into the front and back of entryway and first floor door dormer base panels and certain places under first floor window dormers. There are rebar hooks installed in the perimeter footing to come up under the horizontal riser wall seams. Check your entryway, door dormer and window dormer, link, cupola plans for anchoring hardware, etc. Always use a vapor barrier with your slab of 6 mil. plastic sheeting and 6″ x 6″ steel mesh or fibers.
Shipping: The above photo shows a building kit loaded onto a semi truck ready for shipment to the client. The domes behind the truck are two of our factory domes, a 48′ and a 45′ with the 60′ dome not pictured. For more info view Shipping.
Support Systems: Ai recommends the installation of a temporary wooden rib system to support the panels during the kit assembly. The rib system is illustrated by the photo on the right. The rib system consists of your own 2×4’s (cut and drilled to our specs), bolts/nuts/washers purchased from Ai and steel hubs on loan from American Ingenuity to erect a free standing geodesic framework. A deposit is placed on the hubs and is refunded to you when you mail or UPS the hubs back to Ai. The bolts/nuts/washers are not returned to Ai. Ai can purchase the 2×4’s, cut, drill and paint them and ship them on the truck with your dome kit. Pricing varies depending upon the 2×4 cost. Please call our office, 321-639-8777 Monday through Friday 9-5 eastern time for pricing.
During Assembly additional supports are used to brace the steel hubs, to brace panels, to brace both sides of the riser panels and to brace the entryway and door dormer panels. The “Rib System” dictates the exact panel placement. For more info view Rib.
Once all the seams and building options have been concreted with two layers of concrete, openings framed in with concrete curing two weeks, the “Rib System” is removed and recycled into the interior framing or second floor knee wall framing and the hubs returned to us.
Panel Assembly: The panel assembly process begins positioning of the four foot high riser panels on the floor and then assembling the rib system. Apply expanding foam under the riser panels to seal them to your foundation. Plumb the risers and fill any gaps between them with E.P.S. insulation wedges or expanding foam.
Then overlap the steel mesh from adjoining riser panels, lock the mesh with C-rings every 2″, apply the first layer of special formulated concrete following the concrete guidelines for watering down all the premade concrete around where you are working. Do not get concrete on the panel’s flat bonding ledges or the sloping bonding ledges…only partially cover the steel mesh. Your first layer of concrete is thrown through the steel mesh and fills the seam area behind the mesh. Two different tension cables are inserted on the locked mesh in two locations.
Once you apply one layer of concrete into the seams and onto the entryways, dormers, cupola, link, etc., you or your workers come down the dome from the top and apply a second layer into each of the seams using a bonding agent between the coats of concrete and on the flat bonding ledges and the sloping bonding ledges. (bonding agent comes with your Ai dome kit). The new concrete must be kept moist to allow for the concrete hydration. The Assembly Manual that is shipped with each kit gives specific guidelines for concrete application and mixing.
Panel Concrete: The panel concrete is a special formulation containing synthetic fibers and liquid admixtures. Ai ships these same fibers and admixtures with your building kit. These ingredients improve the concrete’s characteristics, create super toughness, extend durability, make concrete impervious to water, give higher tensile and compressive strength, provide elasticity for expansion, improve freeze protection.
The concrete in your dome out performs other exteriors because of its specially developed formula. Because of its exceptional composition, it actually gains strength over the years. Locally, you purchase bags of Portland Cement (type 1 or 111) and sand (masonry or stucco sand) and add in the fibers and admixtures per the recipe in the Assembly Manual. The concrete is mixed with a mortar mixer NOT a cement mixer. Do not use a cement mixer because it does not have paddles. Paddles are required to get a thorough mixing of the cement, sand, fibers and admixtures.
Hoisting Mechanisms: The typical method for lifting the panels is by a man lift or crane or transverse forklift. Monthly rentals on man lifts, transverse lifts also called Boom Lifts, Horizontal Boom Fork Lifts, Roofing Lifts, Shooters are available from National Rental Chains.
If you want to speed up the kit assembly, considering renting a scissor lift for inside personnel movement (instead of using ladders and scaffolding) and a Straight boom lift – man lift or cherry picker- for outside personnel work (instead of ladders, planks and scaffolding).
These photos illustrate the use of planks on the exterior for filling and finishing seams and concreting the options. You install the panels and trowel concrete into the seams. The first layer of concrete fills the seams up to the steel mesh. After all the seams are half filled with concrete, then a second layer of cement is troweled into the seams after bonding agent is applied. Seam concreting is done one row of panels at a time.
Most of fourth row of panels installed.
Seam Finish: The concreted seams are usually finished in one of two styles:
Start at the top of the dome and work down. This will allow you to practice on easier seams and ones that are less visible and any spills will not be on finished work. The concrete seams are usually finished in 1 of 2 styles:
1. Flat: The quickest, highlights the geometry, the least cost and least labor intensive. The concrete fills the seam up to the edges of the prefinished concrete of each panel and is troweled to a flat surface between those panel edges. When complete there will be two concrete edges along each seam where the panel concrete meets the concrete that fills the seam. The edges of the concrete panels can be used to screed the flat surface making this the quickest method of finish, the lowest cost with the least labor.
2. Rounded: requires the most skill to be consistent but like the flat seam it can be completed with two coats. The concrete is mounded in the seams and shaped to create a rounded transition between adjacent panels. This method should be used when a rounded appearance is desired.
Additional supports under the steel hubs are required to hold the weight until all the seams and options are concreted and framing is installed in the entryways and dormers. Then the extra supports and temporary wooden rib system are removed. The dome shell is self supporting. Interior walls and second floor joists are conventionally built.
The left photo illustrates a conventional interior wall covered with drywall. The photo on the right illustrates how the opening under the entryway was 2×4 framed and insulated with E.P.S.(waiting for plywood sheathing & either 1/4’x1/4″ or 1/2″ x 1/2″ steel mesh & stucco to be applied). Above the standard entryway is a door dormer.
Past Ai clients have found it difficult and expensive to purchase steel mesh locally; as a result the steel mesh used to frame in the entryways and dormers can be purchased from Ai and added to your Parts List. A Parts List is a page within American Ingenuity’s official Dome Building Kit Order Form…that lists the items that come with the Ai kit at no cost and lists items you can purchase from us….for example the suspension rods and top and bottom plates that help support the second floor, extra cans of expanding foam (20 ozs), steel mesh, Simpson joist hangers, additional Admixture A and B, additional C -rings, C- ring pliers, additional bonding agent, 1″ EPS in 4’x8′ sheets, 2×4’s cut, drilled and painted for the temporary wooden rib system, etc.
Ai’s building kits come with the interior wall board (Georgia Pacific 1/2″ DensArmor Plus gypsum wallboard that is moisture resistant and mold resistant) already adhered to the triangles and riser panels with drywall adhesive. On site apply joint compound and tape to finish the seams between the wall board. On site the wall board is primed with two coats of primer.
In summary, there is now no need to plaster or apply dry wall board to the shell interior because the triangular and riser panels come with 1/2″ DensArmor Plus drywall.
An owner/builder is finishing her concreted seams with a sponge. The seam sponge finish matches the panel texture.
A finished dome prior to painting. This is a 34′ dome home connected to a 22′ dome one car garage.
A 40′ dome before painting.
Apply concrete primer and two coats of paint. Ai dome owners prefer Ames Research Laboratories primer & paint.
The above dome is a 34′ in diameter built on a full basement. Behind the deck railing is a standard entryway that was framed in on site to accept a door and window. This dome was painted a blue grey; however, you can paint your dome any color tan or moss green, etc.
Another finished American Ingenuity dome. The dome on the left has a standard entryway framed in to accept six small windows. The wall under the second floor dormer contains two small windows. And the cupola on top was framed in to accept five opening windows.
Dome with two standard entryways on basement
45′ dome on full basement
27′ dome garage linked to 40′ dome home.
40′ dome home linked to 34 garage dome.
45′ dome living room
Painting the American Ingenuity Dome:
The component panels do not come with any paint on them. Ai. does not add any color to the concrete. On site you concrete the seams so if we painted the panels or added color to the concrete it would not match your painted seam concrete. The concrete shell is painted with two coats of good quality exterior concrete paint after the entire kit is assembled.
- 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.
Around 1948 Latex paints became the first water-based alternative to oil-based paints. Many improvements have been made but perhaps the most significant is the introduction of Acrylic Resins. Paint of 100% Acrylic is more resistant to ultraviolet rays, retains its color longer, is less prone to chalking, retains its elasticity, is more alkaline resistant and can be cleaned up with water.
It is not difficult to paint the dome….there are no soffits or gutters to have to deal with. You know when to repaint the dome when you rub your hand on the paint and it chalks. Best to roll the paint on to get a good mill thickness.
Typically the American Ingenuity dome is repainted every 4-5 -6 years, it depends on your personal preference.
- Clean the dome prior to painting killing algae with bleach/water mixture or oxygen bleach and water and then pressure washing.
- The sides of the dome can be painted using an extension ladder and paint roller on a pole.
- Yes you can walk on any of the domes. If you do not have a cupola, install an eye bolt in the top of the dome to tie a rope through to attach to harness.
- To paint the top of the dome stand on the dome with the rope tied to your harness.
- To access the top of the dome either climb out a cupola window or put an extension ladder to the top of a second floor dormer and then walk onto the top of the dome.
Ai dome owners recommend the following primer and paints: (In the Dome Kit Assembly Manual is a section on waterproofing the dome.)
- Ames 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….NOT TT3)
- Sherwin Williams: Loxon XP Paint, Loxon Primer and Conditioner
- Richards Paint: Rich Flex 245; use Rich Flex Alkali Resistant 100% Acrylic Masonry Primer
- Behr’s Premium Elastomeric Masonry, Stucco & Brick Paint –Home Depot
- Seal Krete Paint (pigmented) –Home Depot
Exhaust fans and energy recovery ventilator or heat recovery ventilator are installed in the dome to exhaust water vapor from showering, laundry, cooking, etc.
Specialty paints like epoxy are unable to stretch and the epoxy paint can “in some areas” crack and allow water to pass through. Also 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.