With so many natural disasters happening every year Design Desk Inc. has conceived of a special type of dome construction. The process involves using a plastic extruder to coil a dome. If recycled materials are used, ,fallen ground up tree leaves for fill, the plastic form would greatly reduce the cost of housing with an improved durability for resistance to natural disasters. The dome would be erected using less man hours reducing the cost of safe construction. The extruder is mounted at the end of a radial steel mounting arm with a center pivot system. The core mounting system is motorized by electric motor causing rotation of the radial arm and extruder head that also has motorized drive wheels.
The bio mass and plastic feed system is by vacuum from the center to the extruder head where the plastic is heated by electric resistance then mixed with the powder bio material (tree leaf) and deposited in a circular fashion atop a base ring that is circular to then cause a dome.
The top center of the dome will remain open and as an option for the thin shell concrete spray deposition a brace is placed at the top open orifice . The brace will have docking port for the automatic curved exterior concrete spray system. For the most part the intention is let the mechanism build the structure and the operator then can observe and operate the control system.
A separate curved spray head for the algae/hemp fiber top coat will be used after the exoskeleton and thin shell concrete deposition have cured. The curved thin shell concrete and top coat deposition spray system is also motorized and has a motorized wheeled carriage the goes round in circles on the ground. The material for deposition is pumped through the top of the dome's open orifice going through a flexible tube system containing a slip ring so that the spray system can rotate 360 degrees. Some manual deposition of concrete and plastic top coat will be required around the awnings and spaces the spray system misses.
The dome would then have a concrete coating with metal reinforcement , water sealant and then an algae hemp fiber plastic top coat then covered with 18" to 24" of earth atop. A stucco fire proof interior coating will also be required. In some environments a glass top coat may be used to reduce environmental material winders.
For large dome structures the addition of a concrete rib structure on the exterior of the dome may be required to support the multiple floors within the dome. The concrete ribs are aligned from to to bottom and vertical also containing steel rod / bar steel reinforcement. The pour forms for the ribs are left in place and are made of algae plastic with hemp fiber reinforcement and will have wire mesh to retain the concrete as it is poured into the form. This " support rib skeleton" will be under the algae / hemp plastic water proof top coating. The metal connectors embedded within the "ribs" will allow for the locking in of multiple types of floor construction material and will support the floor decks allowing for large open spaces within the structure.
Since the floors are supported by the exoskeleton the walls then are not required to be load bearing. This will allow for greater flexibility in the interior design. A balloon cloth wall system will be the choice. The plasticized cloth will also be designed so that it is inflatable and is able to accept stucco or masonry on the exterior surfaces. The base and top of the balloon are then secured by snaps and angle braces attaching the wall to the floor and the wall to the ceiling. Once the masonry or stucco is applied and cured the air pressure is released and the cavity is filled with rigid foam.The cloth wall system can also be designed to accommodate the electrical and plumbing requirements within a trough on the cloth balloon and will allow maintenance . The cloth wall system may be stabilized by injection of a rigid polystyrene or urethane foam with an ecologically safe fire retardant. . The trim and door jams will be installed after the hard stucco or masonry has cured locking into the then rigid surface.
Their will also be provided in this housing concept pre-formed door and window awnings that will secure to the Plastic form before the thin shell concrete is sprayed atop the metal reinforcement. Once the plastic has cured in place the orifices will be cut open to allow for window and door installation.
It may be possible to use an Algae plastic with hemp fiber reinforcement for the top layer making a barrier that is easily repaired. Additives can be added to the exposed areas to increase the resistance to UV light and cause greater weather resistance. The Hemp fiber /Hemp plastic /Algae plastic would be under the earth cover but exposed on window openings. In this design the glass used should be of laminated type rated to prevent projectile from other stick built housing types due to storm or tornado. The doors should also be rated for high velocity projectile.
*note* We have chosen to financially indenture ourselves using the internal combustion engine burning what could be a cost effective method of housing construction and produced structures that in some weather conditions are not adequate for human safety. So we have "burned " our houses then slave in debt for mortgage payments? Strange to me...then the Stick built designs become hazards in high velocity storm conditions and are destroyed. Design Desk Inc. seeks cost effective alternatives.that are also safe for fire conditions.
*note* It may also be , as a method to reduce cost of construction, a water/ ice system with wood fiber blown upon the wet ice while forming to form a composite dome by coiling deposition. This will greatly reduce the cost of manufacturing. This would be for the base shape form to then accept sprayed concrete with a steel rod / bar re-inforcement with plastic / glass coatings...then the ice would melt and the wood fiber saw dust would then be removed...when the ice has melted and the wood fiber then dried and ready for the next use.
Design Desk Inc.