The Monolithic EcoShell Dome
The name “Monolithic” means “one piece” and refers to the Monolithic Dome Institute which developed the EcoShells. The name “Ecoshell” means “Economical, Eco-Friendly and Thin-Shell”. At DFTW we normally refer to these Domes as simply, EcoShells.
EcoShells are constructed with 2 or 3 inches of concrete and a modest amount of rebar.
EcoShells use less than 50% of concrete and rebar when compared to a conventional, rectangular building of the same square footage.
The compound curve of the dome makes it stronger than virtually any other structure. They also takes less money and time to construct. '
EcoShells are constructed of readily available and environment-friendly materials. Trees and other local natural resources are conserved. Construction can be done by hiring local labor with very little special skills and/or equipment.
These Domes are as disaster proof as a building can get. They will withstand tornadoes, earthquakes, hurricanes, and fire. They cannot be burned, eaten by bugs or destroyed by mold. They will last for centuries. And because of the concrete’s thermal mass, interior temperatures remain stable
EcoShell Construction
The EcoShell starts as a combination ring-beam footing and concrete slab floor reinforced with steel rebar. Vertical steel bars embedded in the outer ring later attach to the steel reinforcing of the dome itself.
An Airform -- fabricated to the proper shape and size -- is placed on the ring base. Using blower fans, it is inflated and creates the shape of the structure to be completed. The fans run throughout construction of the dome.
A grid of vertical and horizontal rebar placed over the exterior of the Airform. The verticals go against the Airform and the horizontals on the outside.
Next, enough concrete is applied to the exterior of the Airform to embed the rebar and can be trowelled smooth.
After the concrete has set, the Airform is removed from the inside and re-used.
The rebar still showing on the inside is brushed with a wire brush to remove any loose material. Then a finish coat of concrete is applied to the inside surface.