Concrete in housing

Geodesic dome of polystyrene and concrete

Saves money, space, and energy
BY

M. K. HURD

ut 6-inch-thick triangles of extruded polystyrene foam, assemble a geodesic dome, and encase it with reinforced concrete. This method of homebuilding requires no heavy equipment, uses locally fabricated materials, and delivers a strong, ene rg y-efficient dwelling suitable for many climate zones. Shell costs are moderate for the space enclosed.

crete dome are arranged in hexagons and pentagons to approximate a spherical surface. Take a close look at a soccer ball and youll see the same pattern. Dome designs are available in 32and 40-foot base diameters. Each dome is about three-eighths of a complete sphere. The aerodynamic

shape helps it resist strong winds, and snow tends to form its own arch over the dome structure. The dome is designed for a safe snow load of 50 pounds per square foot and for a wind velocity of 120 mph. The shell of concrete and polystyrene has an R value of 27. This insulating capability can readily be in-

Geodesic domes: What and why?

A geodesic dome may be described as a part of a sphere constructed of multiple straight bars arranged to form triangles. The bars are called geodesics and the triangles are facets. Structurally, the geodesic dome is a space truss and is the strongest known straight-line form enclosing space. It is efficient as well as strong; there is no straight-line geometric form that requires less surface skin to enclose a given amount of space than a geodesic dome. In the concrete and polystyrene dome described here, folds in the concrete shell replace the straight bars. The folds, howe ve r, act just as the bars would to transmit loads to the foundation.

The concrete geodesic dome

The triangular facets of this con-

Five rectangular base panels are first erected on the slab foundation. Then preassembled pentagons are mounted on top of them and braced and shored to the slab.

sign. Dowels embedded in the edge beam project 1 foot into the dome shell to tie it to the foundation. The center of the slab must be clearly marked as a reference point for polystyrene panel erection. The dome designer recommends using a polyethylene film membrane under the slab as a vapor barrier.

Cutting and assembling the triangular panels

All the components for the concrete geodesic dome can be fabricated at the site. Two sizes of triangular panels and several rectangles must be square cut from 6-inchthick extruded polystyrene foam. Since it may be difficult to get the necessary accuracy with a hand saw, a power saw is suggested. Cut to whatever depth you can with your power saw and cut the rest by hand. You can even break the panel along the power saw cut, since only one edge, the inside one, needs to be completely accurate. The triangular panels are preassembled into pentagons and half hexagons before being erected in the dome. Metal clamp plates, two for each joint, hold the panels together at the outside surface. A bolt through the clamp plate and the polystyrene foam secures a 2x4 rib on the inner surface (see detail drawing). Joints between the polystyrene panels are filled with a twocomponent polyurethane which expands after it is poured into place. Five rectangular base panels are glued in place on the foundation to start the final dome assembly. Typically, door and window openings are formed between these panels.

Welded wire fabric in two layers is placed over the polystyrene panels to reinforce the geodesic dome. A hoop of reinforcing bars circles the dome (at level of workers foot) to reinforce a ring beam.

creased with selected interior finishing materials to R-35 or more.

Foundation requirements
A 32-foot-diameter dome weighs about 25 tons. That weight usually can be carried by an edge beam 12 inches wide and 110 feet in perimeter, resulting in soil pressure less than 500 pounds per square foot. Local soil conditions should always be investigated to be sure the soil is

stable, with adequate bearing capacity. Where the soil is subject to f re ezing, the footing must be placed below the frost line, with perimeter insulation to reduce heat loss through the foundation. The 4-inch slab on grade with its edge beam can be laid out as a 10sided polygon. The slab is thickened to 12 inches at the location of any load-bearing interior partitions called for by the architectural de-

Then the preassembled pentagons are set on top of the base panels and joined with clamping plates and interior wood ribs. Next the half hexagons are clamped into place, and assembly proceeds with more panels until the dome is complete. A continuing check measurement from panels to the center point of the base slab maintains the geometrical accuracy of the dome. Any joints not filled during the preassembly must be filled with urethane as the erection goes on. Internal struts and shores are added to support the dome and workers on it when they place reinforcing steel and concrete. Why are the polystyrene panels all square cut and erected this way even though they join at an angle? The polystyrene is not dimensionally stable enough to be glued accurately. It expands slightly as panels are cut from the manufactured billets. Also there are nine different angles, which would make panels difficult to shape. The polyurethane foam is like mortar between bricks; it allows for any imperfect cuts and surfaces. When the polystyrene is fully assembled and braced, it should be temporarily anchored with tie wires to prevent uplift by wind.

ESTIMATED MATERIALS FOR GEODESIC DOME BASE SLAB AND SHELL

DOME DIAMETER 32 feet 40 feet

SLAB ON GRADE WITH EDGE BEAM 3000-psi concrete, cubic yards Wire mesh, 6x6W10xW10, square feet Rebar for edge beam, pounds 6-mil vapor barrier, square feet DOME INCLUDING ARCHES (FIVE OPENINGS) Extruding polystyrene (density 1 pound per cubic foot), board feet Galvanized wire mesh, 6x610Wx10W, square feet Hoop rebar, #4, Grade 40, pounds 3000-psi concrete, cubic yards Lumber, 2x4 framing grade, board feet Urethane foam, two-component, gallons Latex rubber cement, gallons Galvanized 14-guage steel for clamp plates, square feet Galvanized 1/4 -inch threaded rod, feet 1/4 -inch galvanized nuts, each 1/4 -inch galvanized washers, each

16 1,150 750 920

23 1,700 900 1,400

9,025 3,500 250 11 425 16 1.5 30 158 420 210

14,200 5,500 430 16 550 20 2 30 158 420 210

The builder has a choice of three ways to apply the concrete: s Troweling by hand s Shotcreting, either wet- or drymix s Laminating with a plaster gun For the owner-builder who trowels the mix on by hand in small quantities, a stiff mix using one part cement, two parts sand, and three parts pea gravel (by volume) is suggested. You place the concrete in 8inch layers, working up from the base of the dome. By the time you have made a full circle around the dome the first layer has begun to set enough to support the next layer. As you go higher and the slope of the polystyrene is less steep, depth of the layers can be increased. Built with shotcrete, the dome requires a 3000-psi mix. Or, using a plaster gun, a stucco mix of sand and cement can be applied in several layers, each 38 to l2 inch thick. Whatever method of application is

chosen, 7-day moist curing of the concrete is recommended.

Interior and exterior finishes

Some hairline cracks in the dome can be expected because of settlement, creep, and shrinkage However, the designer considers the typical dome waterproof when simply painted on the outside, if the quality of the concrete and its application are satisfactory. If there are any reservations about waterproofness, the owner may select from a variety of waterproofing membrane materials. Another exterior finish treatment uses 2x2 cedar or redwood ribs to accent the ridges of the dome. Wood shakes can be applied over the concrete for a more traditional finish. Or textured stucco can be used. On the inside it is possible to plaster directly onto the polystyrene without use of lath or wire mesh. Perlite plaster about 58 inch thick provides a permanent finish that increases the basic shells R value of 27. The plaster can be applied between the 2x4 ribs that were needed

Setting steel and applying concrete

Principal reinforcement for the dome consists of two overlapping layers of galvanized welded wire fabric, 6x6W10xW10. Ungalvanized mesh may be used if a waterproof membrane is planned for the domes outer surface. The two layers are placed at approximately onethird and two-thirds depth, respectively, of the 134-inch concrete shell thickness. Wood spacer blocks are used as needed to maintain steel in the proper position. Wood blocks are also glued to the panels as gauges for the application of concrete to proper thickness. Added reinforcing steel is placed around openings in the dome, and a ring of five #3 bars encircles it at the level of the top of the door openings.

for erection of the dome, or the ribs can be removed to permit continuous application of plaster. Gypsum board can be installed over wood furring strips if preferred. Interior partitions are of conventional wood framing. Typically a loft or second floor is placed in the center of the dome where 8 to 10 feet of headroom is available.

Costs and material quantities

The designer has estimated materials costs at about $10,500 for a 32foot-diameter dome, and $16,000 for a 40-foot dome. This includes a slab on grade, the dome shell, doors and windows, plus rough interior framing of partitions and loft. You can use the quantities given in the table to estimate your own costs for the slab and dome shell. Main floor area of the 40-foot

dome is 1,300 square feet, with 500 square feet more on the upper floor. The 32-foot diameter dome has 850 square feet on the main level plus 300 square feet in the second floor loft. Both are designed with two bathrooms. Standard plans and step-by-step construction procedures are available from the designer for 32- and 40-foot domes. Larger diameter, high-profile geodesic domes up to 50 feet in diameter are available as custom designs.

Credit Architect: Peter M. Vanderklaauw, Miami

PUBLICATION #C881018
Copyright 1988, The Aberdeen Group All rights reserved