Design Desk Inc.
Self Building Dome
Please note Pykrete is similar to Pycrete ...I changed the spelling due to the composite epoxy coating then atop the deposition of ice mixed with powered corn husks / wood fiber recycled news papers...and or lawn clippings "ground yard grass".. :) c composite...
Hopper feeders feed the fiber mass wood dust/ lawn clippings to the mechanisms blower / vacuum system and electric pumps, pump the water and plastic materials to the systems application unit.
The reason for this advancement in house / building construction is as follows;
1. reduction in labor cost per square foot
2. superior strength in final product ..providing a safer structure in inclement weather conditions
3. Fire safety...Structures that do not burn down in wild fire or house fire conditions.
4. energy consumption ..as they , the domes, then become earth covered and will maintain about 58 degrees Fahrenheit
Awnings and door jams/ frames will then be made of a plastic composite form to then attach to the base coat plastic form atop the Pycrete and the be layered with metal reinforcement mesh to then accept sprayed concrete atop the plastic dome to the correct depth required for the earth loading atop the concrete. The sprayed concrete thickness will vary depending upon size of the dome depth of earthen cover. Atop the concrete will be then deposited a water barrier such as an acrylic polymer or other Ultra Violet light resistant water repellent coating. The polymer is then of course under the earthen cover. After the exterior sprayed concrete had cured the "Pycrete" will then be heated by fuel less forced hot air and then the melted material will or can then can be dried and reused.
For speed and correct concrete deposition an articulating mechanical robotic control arm will mount to the top of the dome (plastic covered Pycrete ) and also sense the concrete deposition referencing the metal reinforcement. The water top coat, earth moving requirement (to cover), awnings , floor brackets ...and "wire cage" (ree-bar structural reinforcement) may also be assembled upon the dome plastic form by robotic / mechanical methods. The different application "deposition work heads ", will be interchangeable upon one mounted articulating robotic arm also containing boom extenders.
In wild fire prone locations exterior shutters and door protectors will be require composed to the correct material to with stand the thermal conditions produced in forest fire situations.
*Note* due to the type and nature of this design a dug foundation is not required as the base of the dome becomes the foundation ( thicker sprayed concrete at the base). This reduces time labor and construction cost.
The interior decks for the flooring system will be attached to the dome with a bracket system that is partially embedded within the concrete and locked by the deposition of concrete. The "bracket" will penetrate the dome structure bolting atop a required amount of cured concrete atop a mounting plate that is also welded to the ree-bar metal reinforcement within the domes structure. The interior part of the bracket ( within the domes interior) will the be accepting of the decking allowing for a of floor plans as the system is also supported by the domes load bearing exterior concrete wall. Interior load bearing walls will require a poured footer that will also lock into the concrete "slab" (optional).
Since the floors are supported by the exoskeleton the interior 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 poly styrene 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. As an option a single cloth curtain then sprayed with a plasticizer with fire retardant in the plastic to also then be covered with stucco is also an alternative. The curtain would also snap into the floor and ceilings to be secured
The electrical systems for the house can allow for the fuel less harvest of humidity for the air allowing for greater safety obtaining the water required for the dwelling . The dehumidification can be powered by fuel less electricity. This will allow for a reduced operating cost for the structure and makes arid regions also more habitable ( land is also cheaper in inhospitable regions). Population density and clean water availability have been cumbersome issues...this may solve the issue due to the power density and constant operation of the fuel less power systems. These systems also will open up a return to localized agriculture for a healthier food choice providing water in remote locations with minimal cost.
To also aid in fire safety the ceiling will then be of plaster upon a thin metal backing plate with inverted " Y or T " shape locking supports allowing for the plaster to also then appear continuous.
May also be used for spheres of ice then coated with additional material for space station construction.....
The "boom" arm of the design can be extended to accommodate multiple diameter distances of the dome structures. From the very large (volcano capping not as a dwelling.. :) ) to the small storm shelters / houses to hotel size or factory size applications. * for "Super" volcano multiple buried / control vented, above large calderas is an option ....acts as shock absorbers.
LOW COST CONSTRUCTION METHOD !
2. PVC 2.5" pipe and unions (unions will be cut when removing the support frame of "sucker rods")
3. oil rig "sucker rods" / fiberglass poles
4. Pressure washer
6. electric water pump (feeds the pressure washer)
7. used wood fiber, lawn clippings ground paper etc...
8. metal mesh ( chain link fencing - intermittent- snips staggering then bent to lift fence off of the pycrete 1" to 1 1/2" / wood screws to affix the mesh ree-bar for hemisphere grid matrix ..tie intersection with wire ,weld wire to ree-bar grid.
9. electric drill required bits etc...
10. concrete and hand deposition tools...for the concrete
11. top coat water sealer.
12. required lumber for awnings door openings
13. fiber blower (optional) ..fiber by hand deposition...
Assemble the "tent" shape of a dome (sucker rods into the pvc inserted into the ground about a circle.pulled to dome form by rope anchored by center weight..)..cover with the parachute wet....let freeze with fiber then embedded within the ice repeat until thickness required for weight of load atop is reached (varies according to dome size) attach metal mesh ...apply concrete to required depth of earth loading atop the dome.... and top coat once the concrete has cured remove "tent" then heat or let the Pycrete melt affix windows doors....bury to insulate. Floor slab pour to level and seal the interior...don't forget the ree bar union locking pins ...attaches the dome base to the floor slab... :) Please reference information on using cold weather concrete and apply the requirements.
ALTERNATIVE LOW COST CONSTRUCTION METHOD.
1. obtain a pre-fab roofing truss...cut in half at the apex ( normal horizontal position ) to the the base and box the two halves so that they allow for a 2x2x12' long "boom arm" to hinge at the 90 degree right angle produced when the roof truss has been cut ...the end of the roof truss in it's normal position then becomes toward the center pivot pointed upward... of what will become an Ice Dome . The roof truss then acts as a boom arm guide to assist in the construction and thin ice layers that will be the base dome for the second layer of mixed bio-mass and ice deposition. The flooring is also produced in a similar way with a thin house wrap material then stretched across the interior of the dome taught and slowly layered and supported by temporary supports safely to then allow for concrete floor pour atop the ice ( cheaper than plywood structure ) with metal reinforcement in the concrete and floor to dome wall locking anchors.
2. assemble the boom arm to required dome diameter.
assemble the spray box deposition head with leading edge roller to assist in the spray box sliding across the dome deposition adjust clamped spray nozzle to slow drip.
3. use ree bar safety along the plywood boom arm and junction boxes ( attached by bolting and or clamping. )
4. obtain a construction generator ( http://designdeskinc.com/Drip_Irrigator.html ...for on site water harvesting to use for the first dome layer... / http://designdeskinc.com/Power_Stick.html ) and mount toward the circumference of the dome connected from base rail 2"x8"x12' elongated base board also the to cause a box that will also mount an electric bench grinder driving a drive wheel ( small tires safer a bicycle tire may have trouble but might work for small applications ). The bench grinder is then driven by chain and variable resistor / house hold dimmer switch that will reduce the current to the bench grinder that is then driving the wheel rotating the roof truss ice deposition assembly.
5. a water ring transference mechanism or slip ring will need to be fashioned to allow for the mechanism to rotate and be able to have the water then constantly flowing as the roof truss assembly is rotating about a center pivot . Center pivot a tow hitch ....atop a post placed and secured in the ground within the center of the dome connecting to the roof truss assembly.
6. A second construction generator will be required to power the water pump feeding the roof truss assemblies spray box.
7. A pressure washer is also required to spray the mix coat atop the ice dome (from the exterior) . The second top coat also then contains bio-mass such as wood fiber / mulch or yard grass /lawn clippings.
8. The awnings dome openings (doors / windows) are formed while the top coat containing the bio-mass is being deposited cloth frame atop 2"x2" frame or bent to form ree bar plus cloth base.... used card board may also work in place of cloth ...... to accept the bio-mass mix ice deposition.
9. The next step is the to wire mesh ( chain link fencing / ree bar grid hemisphere) cover the bio - mass "top coat of ice deposition .
10 Hand trowel concrete or use sprayed concrete to cause the required depth of deposition for structural stability for earth loading atop the dome post water seal...water seal .....(recycled water bottles melted...) stucco in visible areas . Insulate with earth cover. melt ice dome and bio- mix ice layer remove material stucco interior of the dome....could fresco :) so space no top really? smile I love you....... :)
Granted intellectual property license to http://homeboyindustries.org/ and http://www.habitat.org/
Another method of low cost construction of concrete dome is to use chain link fencing then curved upon a preformed mandrel ( ply wood ) to the curvature of the dome in with the chain link fencing then cut into strips say 3' wide to make them easy to handle...the vertices then wire tied and tac welded to cause the fencing to hold it's form.... then upon the inside of the curvature then affix ( sew ) a plastic and or house wrap ( to both sides of fencing ) to then cause a backing system to catch the ice that will form upon the top exterior surface by pressure washer deposition.. A tree works for "center pole" and or pulley system may assist in hoisting the fencing into place to then affix the fence curvatures into the dome form by top ring securing system......
The inner fencing then can be removed and placed upon the exterior of the ice dome with the house wrap removed...to then accept concrete with snipped and bent pieces of fencing random stagger to then support the fencing 3/4" to 1" above the ice dome and be supported correctly by the correct ice thickness of the dome. This will then allow the fencing to be embedded as concrete reinforcement to assist in the strength of the concrete The layering process is critical for final loading also factoring the weather sealing and the earthen cover upon the maximum top layer ....
Additional ree bar grid hemisphere welded together will also be required to lock the concrete deposition ...ree - bar grid hemisphere embedded within the deposition.
Openings for doors and windows where required then also formed for with additional fencing to thicken the "jams" ( doors and window orifices ).
Additional amenities as required.....
* Note - Also this system may be used to produce spheres.... with internal fuel less pumping... to then be sunken hollow spheres within coastal bays to then allow storm surges to then
fill the spheres then with the addition of fuel less pumping system within the spheres to then use fuel less pumping to control the incoming storm surge....