Built in Place Domes
Because thin shelled concrete domes are incredibly strong, they require no interior load bearing walls to support the shell. They are extremely versatile and can be engineered to be built underground or above ground as tornado shelters. This versatility is best experience when we build in place because we are not limited by size and weight restrictions that face us building transportables. This proces begins with a base from which to attach the fabric form. When attached to the base which in this case is plywood, it can be sealed and inflated. The urethane foam is sprayed on the interior until we reach the full thickness. We generally use 3 inches of foam and place the rebar hangars into the face of the full thickness of foam.
We spray the first layer of concrete to hold in the rebar hangars and to place the rebar into the concrete, not against the foam.The rebar is then tied into the structures begining with the horizontals, then the verticals. Utilizing low slump shotcrete allows the rebar to be embedded generally in one pass of shotcrete.
We get uniformity, preparing for the finishcoat by cross raking the concrete after embedding the rebar.
Our finish coat is trowelled while it is very fresh and sponge floated to a nice textured finish
The exterior is finished after the interior shell is completed. Depending on how the overhangs are designed, they may be attached during the shell process and structurally tied into the concrete or attached only to the foam exterior. Coating is added over the fabric form with either textured urethane rubber or synthetic stucco being the finished exterior. We create the overhangs by making molds and forming high density urethane foam.
As we approach the finished product, our structures become attactive durable and highly functional