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Step One
The
Monolithic Dome starts as a concrete ring foundation,
reinforced with steel rebar. Vertical steel bars embedded in
the ring later attached to the steel reinforcing of the dome
itself. Small domes may use an integrated floor/ring
foundation. Otherwise, the floor is poured after completion
of the dome.
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Step Two
An Airform
-- fabricated to the proper shape and size -- is placed on
the ring base. Using blower fans, it is inflated and the
Airform creates the shape of the structure to be completed.
The fans run throughout construction of the dome.
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Step Three
Polyurethane foam is applied to the interior surface of the
Airform. Entrance into the air-structure is made through a
double door airlock which keeps the air-pressure inside at a
constant level. Approximately three inches of foam is
applied. The foam is also the base for attaching the steel
reinforcing rebar.
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Step Four
Steel
reinforcing rebar is attached to the foam using a specially
engineered layout of hoop (horizontal) and vertical steel
rebar. Small domes need small diameter bars with wide
spacing. Large domes require larger bars with closer
spacing.
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Step Five
Shotcrete
-- a special spray mix of concrete -- is applied to the
interior surface of the dome. The steel rebar is embedded in
the concrete and when about three inches of shotcrete is
applied, the Monolithic Dome is finished. The blower fans
are shut off after the concrete is set.
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