The American Ingenuity Dome Kits
are DIY Prefab Dome Homes for Owner Builders or for a Contractor
The prefab dome kit can be a Do It Yourself Project with the owner builder utilizing family and friends or hiring his own workers for kit assembly. Or the home owner can hire a builder who hires the independent Kit Assembly Specialist who travels world-wide to supervise your kit assembly and the application of the first layer of fiber concrete into the panel seams and onto the entryways and dormers. Then either your workers or your builder’s workers complete the second layer of concrete in the seams & on the entryways and dormers. For interior finishing complete yourself or hire local subcontractors to complete the plumbing, electrical, framing, window/door installation, wall board finishing, kitchen cabinetry, bathroom fixtures, etc. To view pictures of prefab concrete panel assembly, click on Dome Kit Assembly.
American Ingenuity’s (Ai’s)dome kit is affordable, strong and can be assembled by Do It Yourself individuals because the kit is engineered as a system of pre-finished prefabricated component panels. Each panel is cut at a computer-generated angle so that it fits flush with the adjacent panel. The edges are precisely beveled at the seams where steel and concrete will unite to complete the structure. All panel materials are noncombustible and contain no food source for mold growth.
Building an Ai dome from prefab concrete panels makes home construction easier than stick built construction and results in the dome exterior having a 225 mph wind and F4 tornado guarantee. The process of stacking the panels, overlapping/locking the steel mesh of adjacent panels and filling the seams with special fiber concrete, produces the structural components of the home, the finished concrete surface, installs the insulation and all the dome shell 1/2″ drywall.
This advanced building system makes it easier for an owner builder to construct an American Ingenuity dome than a conventional house or a wooden dome. No exterior walls, no roof trusses, no sheathing, tar paper, or shingles, no soffit, exterior trim, insulation or siding to install and no interior shell drywall to install. During the dome kit assembly, owner builders or builders can email pictures of the kit assembly. At no cost to you, Ai will review the pictures and give feedback about rebar and cable installation, etc. Due to large size of panels in 45′ and 48′ domes, considering hiring the consultant to assist in your assembly.
The building plans contain blueprints for the installation of the foundation and installation and location for each panel. Within the plans is a nomenclature blueprint that shows lettering and numbering for each panel. An example of a nomenclature blueprint is above.
An Expanded Assembly Manual is now available with each dome kit order that explains step by step the panel assembly. (Once a deposit with signed order is received, the manual can be shipped). In the blueprints and Manual is the recipe for the concrete. Ai wants the concrete mixed on site to have the same properties as the concrete that is applied at our factory; as a result the same two liquid admixtures and fibers are shipped with each kit. In the manual is a list of tools and materials to have on site. To view a list, click on Materials and scroll down the page to view the list.
American Ingenuity’s prefabricated component panel consists of:
1. 7″ thick, rigid, nontoxic E.P.S. Insulation (not Styrofoam): The E.P.S. Ai utilizes is a closed cell with a 1 lb. per cubic foot density. Seven inches of sturdy, rigid R-28 expanded polystyrene foam insulation forms the core of each component panel and is:
- Chemically/thermally stable
- Resistant to mildew and mold
- Provides no nutritive value to animals/plants/microorganisms
- Non-irritating to the skin
- The insulation will not rot, shrink, absorb moisture, compact, or deteriorate due to age or the weather.
- No CFC, no HBCD (hexabromocyclododecane), no TCPP (1-chloro-2-propyl) phosphate, no Chlorofluorocarbon (CFC) and no Formaldehyde
2. Concrete: the concrete in your dome out performs other exteriors due to our specially developed formula. Because of this exceptional composition, it actually gains strength over the years. The special concrete formulation of fibers and admixtures improve concrete characteristics.
3. Galvanized Steel: Galvanized steel wire mesh is encased in the concrete of each panel. As your dome is assembled the mesh of each panel overlaps and is locked to the mesh of adjacent panels with C rings commonly called hog rings – resulting in your home being completely wrapped by steel mesh.
4. Half inch (½” ) Georgia Pacific DensArmor Drywall: The DensArmor is not conventional sheet rock. Conventional sheet rock consists of conventional gypsum and paper backing. The paper backing can be a food source for mold growth. Sheet rock when it gets wet crumbles and molds. The DensArmor gypsum when it gets wet does not crumble due to fiberglass reinforced core. It has fiberglass backing on both sides. After the DensArmor dries out it goes back to its original firmness and consistency per the manufacturer.
Dome Exterior Has No Wood To Burn or To Rot or For Termites To Eat
No Shingles or Roof to blow off in high winds
To support the panels during dome kit assembly, a temporary wooden rib system is installed. Once all the seams are concreted and the entryways and dormers are concreted, the dome is self supporting and the wooden rib system is removed. Most of the wood can be recycled as interior framing.
In this view of dome kit being assembled a side view of a component panel can be seen. The panel exterior is 3/4″ concrete reinforced with galvanized steel mesh. After the mesh is overlapped and locked between panels, special fiber concrete mixed on site is hand troweled in the seam areas in two applications — bonding agent is applied between the two layers. The seam areas are about 3″ deep by 5″ wide with average of 2″ thick concrete. In this picture you see the first scratch coat applied to the exterior of the entryway panels and first layer of concrete in some of the seams between the panels.
Steps for American Ingenuity Concrete Building Kit Assembly:
- Foundation installed. Standard foundation is monolithic slab; however Ai can design basement plans, pilings or columns, stem wall, etc.
- Depending on size dome two to five workers are needed. Some with concrete experience.
- Installing the first row of panels which are the 4’ vertical riser panels, base panels of the entryways and any first floor door dormer base panels
- Erecting a temporary wooden rib system to support the triangle and riser panels during assembly using your locally cut, drilled and painted 2×4’s bolted to steel hubs borrowed from Ai.
- Placing the panel’s one row at time using a hoisting mechanism (man lift) on to the rib system.
- overlapping steel mesh from adjacent panels, locking mesh with C rings and pliers and depressing the steel mesh in the seam
- mixing concrete with mortar mixer following concrete recipe in the manual (Portland Cement Type III, masonry or stucco sand, fibers, liquid admixtures)
- installing cables per blueprints
- installing rebar around back of entryway panels, back of first floor door dormer panels, top of entryway panels & around first floor window dormer panels per building plans
- form up and install beams or troughs around lip edge of entryway panels, first & second floor door dormer panels, channels in top of the entryways
- Concreting the seams between the panels (5″ wide and 3″ deep) with two separate layers of concrete using a bonding agent between the layers; and watering down all cured concrete before applying bonding agent or new concrete. Seam areas average 2” thick concrete.
- Concreting the entryways, window dormers, door dormers, cupola and link with two layers of concrete. Sponge float finish the final layer of concrete to blend seam concrete to the panel concrete.
- Framing in the entryways and dormers and installing your locally purchased exterior doors and windows.
- Removing the temporary wooden rib system. Return the steel hubs to receive a full deposit refund if returned during five month rental period and if all hubs are intact.
- Wash efflorescence off concrete, prime, paint the exterior concrete per waterproofing instructions in Assembly Manual.
Onsite concrete is only applied in the seam areas between the panels and on the entryways, dormers (or possible link or cupola). Concrete is not applied over the pre-concreted component panels. The interior shell drywall can be finished similar to conventional sheet rock with adhesive fiberlass and joint compound. To blend the seams joint compound can be skip troweled over the drywall before priming and painting.
If I am not ready to assemble my dome immediately, can the kit be stored outside? Yes, however if you expect to have your kit outside for more than two to three months, request that the E.P.S. edges be painted. On site if you need longer than 2-3 months prior to assembly, then on site the EPS edges can be painted again. (some boxed items & wooden 2×4 ribs if ordered should be stored inside.) The dome kit should not sit outside in the winter as freezing can harm the drywall. Please call us for details at 321-639-8777 - Monday - Friday 9-5 eastern time.
American Ingenuity - 8777 Holiday Springs Rd. - Rockledge, Florida 32955 email: [email protected]