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Interior Shell Finishing
Once the Ai dome building kit is assembled, the 1/2" Georgia Pacific DensArmor gypsum wall board on the interior of the dome shell is ready to be finished. There will be a 1/2" gap between some of the panels that allows you to insert some of the electrical wiring without cutting the interior board. In other areas to install electrical wiring, cut a groove through the wallboard and the EPS, insert the wiring, use expanding foam to fill the groove and then apply a mixture of cement and perlite over the area.
The 1/2" gap is filled with a nonshrinking joint compound like "Gold Bond Pro Form". Then those seams and the other interior shell seams are finished with typical joint compound and fiberglass joint tape. Applying a textured paint using 50/50 mixture of paint and joint compound will likely hide the board seams. Or you can apply joint compound to the DensArmor in what is sometimes called a skip trowel finish, apply primer and then paint. Or to cover any wall board imperfections and blend the wall board to the sanded joint compounded seams, mix a 50/50 batch of paint and dry powder joint compound. Apply the mixture with a paint roller.
On the left hand side of our Home Page is a menu item titled FAQS. To view files that cover areas like Electrical/Plumbing, Framing, Fireplaces, AC Heating, Kitchens, Interior Finishing, Window & Door Sizes, Update Windows and Sound Reduction, lay your cursor on FAQS, then lay your cursor on Interior Finishing and then click on the file you want to read.
9" Thick Expanded Bead Polystyrene
The standard insulation in Ai's dome building kits consists of seven inch thick expanded bead polystyrene E.P.S. or R-28 which is comparable to eleven inches of fiberglass batting. You can purchase thicker 9" E.P.S. To learn more about E.P.S. as a vapor barrier click on Vapor Barrier.
Ai domes with 7" E.P.S. will easily outperform conventional housing with 11" thick fiberglass insulation. Instead of purchasing thicker EPS, purchase double or triple paned windows and insulated doors. Windows and doors are where your cooled or heated air will escape.
The cost of the 9" E.P.S. is the cost to upgrade the 7" E.P.S. to 9" E.P.S. for the entire component panel kit. Dormer and Entryway panels are 3 1/2" EPS.
American Ingenuity includes a four foot tall riser panel 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 and greater headroom on the second floor. The first floor ceiling height in the 22', 27', 30', and 34' domes is 7 1/2 feet. The first floor ceiling height in the 36' and larger domes is 8'.
Domes are connected together with a Link which consists of E.P.S. insulation with steel mesh attached on site (mesh can be purchased from ai) and concrete applied on site. The Link panels consist of precut 3 1/2" or 7" thick E.P.S. The Link EPS panels can be purchased with wallboard adhered. On site you assemble the Link E.P.S. panels, cover them with steel mesh and coat them with the fiber concrete.
The Link connects to the adjacent domes in the same locations as an entryway or a door dormer. The thickness of the E.P.S. in a Link is usually 7" when it takes the place of an Entryway and 3 1/2" when it connects at a door dormer. The width of the links depends on the size of the domes and whether the domes are connected at an entryway or door dormer. The length of the Link is usually 5 ft. Because the riser wall is a standard 4’ high, all domes will match each other despite a difference in diameters.
The width of the link that connects to the 22' dome is about 5'5" to 6' wide. The width of a link that connects to a 27' dome is about 6.75' wide. If the link connects onto domes 30' or larger the width of the length where it connects to the larger dome varies depending upon whether the link connects to the larger dome at a door dormer or a standard entryway. For example, if the link is connected to a 45' dome at an entryway (taking up two risers) the width of the link where it connects to the 45' dome might be 13'. These are approximations, the Plan's Supervisor will give you a more accurate number, once he sees your plans sketches.
Ai does not recommend extensions to entryways for the following reasons. Extensions add exposed surface area faster than they add floor space therefore reducing the energy efficiency. Extensions add to the cost of construction faster than they add floor space therefore increasing the cost per square foot. The long flat roof of the link or extension connects to the curved dome...the link/extension and the dome expand and contract at different rates...a crack will occur where they meet. Ai recommends applying elastomeric patching compound & elastomeric paint where the link panels abutt the dome panels.
American Ingenuity's Assembly Manual does not include extensions although they are assembled much like entryways or links. In general, domes have inherent advantages because of their shape and deviations away form the dome shape lessons the advantages.
The E.P.S. link panels range in price depending on the length of the link and the size domes the link connects to. Once your plans are finished Ai will know the length and width of your link and can calculate the link's EPS panel's pricing, steel mesh pricing and and wallboard pricing.
Can I use Links to connect domes into a circle with a court yard in the middle? Yes. The idea of domes in a circle with a center court yard will work. Ai would recommend that the 360 circle be filled with five domes. Although if you don't want the circle completely enclosed you would not have to build all five. Ai is just suggesting that the geometry be designed around a five dome placement. The domes would then be connected by links replacing either entryway or door dormer panels in each dome.
The cost to design such a job and supply full plans would be around $1,650.00 plus the cost of an engineering seal if required (mandatory in Florida).
Garage Dome Kits
Do you have separate garage dome kits available? Yes. Ai has developed two garage dome sizes, 22' and 27'. These garage domes are two frequency icosahedron geometry. This geometry differs from Ai's other domes in that it utilizes fewer but larger panels. By having larger panels Ai can create a wider opening that is needed for a garage door. You can install a 9' wide garage door in the 22'. The 22' dome can have a second floor of 148 sq.ft. The 27' garage dome can have a 16' garage door and the 27' dome can have a second floor of 225 sq.ft.
Previously a 34' dome was needed to pull two cars in side by side. Now you can have a two car garage in a 27' dome which is more cost effective. The 22' dome provides an economical one car garage. Either of these garage domes can be connected to another dome or built independently from the house.
The 34' garage dome is utilized when you want more first floor perimeter room around the vehicles or when you want a second floor above the garage for an apartment or study, etc. The second floor of the 34' dome can have 614 sq.ft.
You can find the pricing for the garage kits on the bottom of the Stock Floor Plan Price List that is in the Stock Floor Plan Booklet. Or click on Stock Plans & Stock Kit Prices and scroll to the bottom of the chart.