The Process for Building Dome enclosures has been refined and streamlined over the years. There are two principle types of dome enclosures: Monolithic Domes, larger insulated homes and buildings, and EcoShells, smaller domes developed especially for disaster relief and redevelopment of substandard housing.
A form for a concrete footing is constructed.
This form is approximately 18 inches deep and wide, creating the footprint for the dome structure Three foot lengths of rebar are placed into the wet concrete every 10 inches, apart from where there are to be entrances.
The Concrete footing is poured and then the Airform is attached. The Airform is both the form for construction of the dome and the outer roof membrane of the shell when it is finished. The inflator fans run throughout the construction of the dome shell.
With the airlocks attached it is secured to the outside of the footing and then inflated. The internal pressure is kept regulated at approximately 2 inches of water pressure during the whole process.
A two-inch layer of insulating foam is sprayed on to the inside of the Airform
Concentric circles are drawn on to the dome 10 inches apart. Every two feet along the lines a "sticker" is stuck into the foam. Another layer of foam is sprayed onto the stickers to trap them in place.
Rebar is then added vertically every ten inches, tying in to the rebar in the footing. A 'birdcage' of rebar is created with no gap more than ten inches.
Shotcrete,' a specific mix of concrete, is sprayed onto the rebar, a half inch layer at a time.
With all the rebar covered and the concrete sprayed to a thickness of between 3-6 inches (in different parts of the dome), the fans are turned off.
The airform is then cut away to reveal windows and doors etc etc.