Ecoshell I Third Edition with Addendum - November 15, 2013 David B South Edited by Freda Parker, Melinda South Illustrated by Merrisa Ramirez

177 Dome Park Place Italy, TX 76651 www.monolithic.com [email protected] (972) 483-7423 - 2013 EcoShell I – Simple Low Cost Permanent Housing Introduction The EcoShell is a simple, low cost concrete dome. If 100 Domes are built from 1 kit the forming costs It is ideal for low cost housing around the world as drop to less than $50 per 20 foot diameter dome. a replacement for the junk that is presently in place. In addition to the kit you will need 1 roll of Basalt It can be built primarily by hand and requires mini- Rope for the EcoShell and enough rebar for the floor. mum costs and equipment. (The floor can be reinforced by steel rebar or basalt rebar - budget ). Consider rebar at 15 to 18 inches The EcoShells can be built of many sizes. Each on center both ways in the floor. It can be 10mm or size requires an Airform of that size. A small 10ft even 8 mm steel rebar (3/8 inch diameter) or 6 mm diameter by 8 feet high is ideal for a storage. But it basalt rebar. can be lived in as well. It is small at 78 square feet (7 plus square meters). In addition you will need the hand tools to mix the concrete, apply the concrete, the hooks to hold the Our favorite for low cost housing is 20 feet diam- rope to the floor and a few miscellaneous supplies. eter (6 m) with a height of 10.5 feet (3.2 m). It has You will also need about 100 stainless steel hooks a floor area of 314 SF (29 SM). The UN recom- for the reinforcing at about $65 per dome. mendation for a family of 8 is 28 SM. The floor will take about 4 cubic yards (3.5 CM) of They can also be built 30 ft (9.14 m) for 707 SF concrete plus some extra for the perimeter depend- (65 SM) for a larger home or a classroom or small ing on how deep it is wanted. In many places it is clinic. And we like the 40 ft (12 M) diameter for negligible. The shell will take 4 to 5 cubic yards (3.5 a medical clinic, school and more. Virtually any to 4.5 CM). The thickness is variable due to applica- modest size will work. tion and desires. (The calculations are for 2 plus inch thickness. Practice will make it possible to use 1.5 The following is an example to build an EcoShell inch thickness). The floor should be a 6 bag mix and 20 ft in diameter of 314 SF (29 SM) To build the the shell an 8 bag mix. EcoShell an Airform with tie downs is needed and an inflator fan. We call them a kit. In some places Obviously you will need the kit for many domes. a generator will also be needed to run the fan. At And you will need the supplies for each dome built. least 100 EcoShells can be built with the single kit The concrete can be applied by hand or it can be ap- if it is properly taken care of. Currently (November plied by equipment. The equipment can be a simple 2013), a 20 ft kit is worth about $4300 FOB. Italy as hand tools or a simple hand help spray gun or a Tx shotcrete pump. All of this equipment is shown on our website. Ecoshell 1 David B South Edited by Freda Parker, Melinda South David B. South is president of Monolithic, Inc. and chairman of the Domes For The World Foundation (DFTW).

Monolithic, Inc. is a family of companies with a mutual goal: to improve the lives of people worldwide through the introduction and construction of Monolithic Domes and Monolithic EcoShells, for personal and public use. DFTW is the newest member of that family.

Established in 2006, DFTW has been registered as a nonprofit 501(c)(3) with federal tax status.

Domes For The World Mission Statement: DFTW will initiate and coordinate efforts to alleviate housing shortages in struggling cultures and impoverished lands. We will seek grants and donations to fund important projects worldwide. We will train local crews in our construction methods and technology.

The UniShell is an EcoShell I with a diameter of 20 feet and a living area of 314 square feet, suitable for family habitation in developing nations. EcoshellDavid B South 1

Many countries beyond the United States The EcoShell’s construction method has (Cost does not include labor, windows, doors, can benefit from the construction and use of also been used to build bridges over small exterior coating, interior finishing.) EcoShells. rivers and streams. We here at Monolithic think that its applications are virtually In countries such as the Union of South Monolithic created this step-by-step manu- unlimited and that, in the future, more ideas Africa, India, Pakistan, Korea, Mexico, Ghana, al and illustrated it with cartoon-like drawings for this construction procedure will be gen- Philippines, Honduras and others, the need for so that all workers -- regardless of what their erated and implemented. low-cost housing is staggering. Housing short- native language may be -- can learn and use ages range from 500,00 to 1,000,000 in each. these instructions to complete an EcoShell I. Monolithic EcoShells Solve World Hous- ing Problems So the need for structures is obvious, and An EcoShell’s construction process is a the solution is the UniShell. Unfortunately, modern adaptation of the building of the Pan- The United Nations has determined that there is a missing part to that equation: money. theon and thousands of other domes, erected an average family habitation in developing over the centuries. The ancients built them by areas needs to be about 28 square meters or For that reason, in 2006 we established piling mounds of earth or by creating large, 302 square feet. Domes For The World (DFTW), a nonprofit false works of timber in the shape of a dome. organization determined to promote practi- They then covered these forms with brick, One EcoShell design, the UniShell, fits cal, affordable and safe housing in developing stone or a monolithic layer of concrete. Once that bill perfectly. The UniShell has a diam- nations. To that end, DFTW actively seeks the covering settled or set, they removed the eter of 20 feet and a living area of approxi- grants, contributions and funding. forms. mately 314 square feet. Monolithic’s Promise Monolithic has substituted an inflatable Its construction, including the floor and Airform for the earth work or false work. To dome shell, requires less than eight yards of We want to support you in your construc- construct an EcoShell, concrete and rebar are reinforced concrete -- or 64 sacks of cement tion goals. Our website www.monolithic.com placed on the outside of the Airform. (This for a cost of about $320. The price of the is a carefully maintained source of informa- differs from the construction of a Monolithic aggregate will vary from place to place, tion, that can answer many questions about the Dome; it calls for rebar and concrete on the but assuming that it’s about $10 per yard, nature and construction of Monolithic Domes, inside of the Airform.) that adds another $80. The 1,250 pounds Monolithic Crenospheres and Monolithic of rebar will cost about $375. So the total EcoShells. EcoShells built for habitation in develop- cost of the materials for a UniShell home, ing areas with desert-like or tropical climates that will last for generations, is about $800 But you are also welcome to contact us with are not insulated; nor do they usually need to (2002 Prices) your questions and concerns. be. But they may need roof coatings. Never- theless, EcoShells make super-strong dwell- The Monolithic Dome Institute ings, impervious to fire, tornadoes, hurricanes, Phone: (972) 483-7423 earthquakes, and termites. They can be built Fax: (972) 483-6662 by native labor for a fraction of the cost of Email: [email protected] any comparable structure.

We estimated that a single Airform can be used to build more than a hundred buildings, thus making the cost of forming negligible. Because the EcoShell is a thin shell, its actual volume of concrete is very small -- far less than that used in conventional buildings (see table).

The EcoShell is perfect for any type of building that doesn’t require insulation. (Note: In climates requiring insulation, the uninsu- lated EcoShell can be insulated.

Conventional buildings require 200% to 300% more concrete, 300% to 400% more reinforcing bar and double the labor of comparably sized EcoShells. Ironically, EcoShells are far stronger and better able to withstand natural disasters. Clear all obstructions, debris and organic material, such as trees, bushes and grass, off the ground on which the EcoShell will be built.

Then level the ground.

Ecoshell I 3 3

The ground should have approximately the same firmness completely across it. This can be done using a hand tamp or The ground smhoeuclhda nhiacvael eaqpupirpomxeimnta.tely the same firmness completely across it. This can be done using a hand tamp or Tamp the ground with am handecha ntampical e orqu imechanicalpment. equipment until it has an even, all-over firmness.

Drive the center stake in the center of the structure, then the perimeter can be marked using the center stake. Drive the center stake in the center of the Setst rau stakecture ,into the nthe th centere perim ofet theer c sitean b thate ma therke dEcoShell using th ewill cen occupy.ter stak e. This center stake will act as a guide for marking the perimeter. 2 ECOSHELL Ecoshell I 4 2 ECOSHELL 5

Set a nail in the center of the center stake. Measure from the center point to the outside stakes with a measuring device such as a tape or pole. Set a nail in the center of the center stake. Measure from the center point to the outside stakes with a measuring device such as a tape or pole. Set a nail into the middle of the center stake. Using a tape or pole, measure the distance from the center stake to points on the perimeter where the forming stakes will be placed.

Drive the forming stake at the appropriate distance from the center. These stakes should be carefully measured to the correct distance from the center. Be sure to allow for the thickness of the forming material Drive the forming stake at the appropriate distance from the center. Drive the forming Tstakeshese s intotake sthe sh oground.uld be ca Allref uforminglly measu rstakesed to t shouldhe corr ebect atdis thetan csamee from distance from the center. Be sure to allow for the thickness of the forming material the center so that a circle is formed. Be sure to allow for the thickness of the forming stakes. ECOSHELL 3

Ecoshell I Ecoshell I 4 ECOSHELL 35 7

The perimeter (forming stakes) outline where the foundation/floor slab edge will be. They should be spaced about every 2 feet around the perimeter. The perimeter (forming stakes) outline where the foundation/floor slab edge will be. They should be spaced about every 2 feet around Space the forming stakes about 2 feet apartth earound perime theter .perimeter. That perimeter, created by the forming stakes, outlines the site for the foundation/floor slab edge of the EcoShell.

2ft or 60cm

The perimeter stakes should be driven deep enough to hold the concrete pressure even after the footing trench is dug around the perimeter. The perimeter stakes should be driven deep enough to hold the Drive the formingconc rstakesete pr deepessur enoughe even a softe thatr th ethey foo willting tholdrenc underh is du theg a rconcrete’sound the pressure perimeter. even after the footing trench is dug around the perimeter. 4 ECOSHELL Ecoshell I 6 4 ECOSHELL 9 9

Remember the forming stakes (perimeter stakes) must be the distance Refmreommb tehre t cheen ftoerrm pilnugs stthaek tehsi c(pkenreismse otfe rt hseta fkoersm) imngu sbto bared tsh. e I dti shtealnpcse if from the center plus the thicktnhesys a orfe tlehvee fl.orming boards. It helps if they are level. Remember that the forming stakes must all be at the same distance from the center stake plus the thickness of the forming boards. Center stake and forming stakes should all be at the same level.

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Check level and distance each time. Level can be marked on the Check sletavekle sa nrda tdhisetra tnhcaen e darcihv itnigm teh. e Lme vteol tchaen sbpee cmifairekde dle ovenl .the stakes rather than driving them to the specified level. Check level and distance for each stake. Instead of trying to drive the forming stakes all to the same depth, mark the set stakes and cut them at the level you need. ECOSHELL 5 ECOEcoshellSHELL 5 I 7 11

Consider using screws to attach the form boards. Nailing to the stakes will sometimes knock the stakes out of alignment. The forms are to contain the floor/footing. They do not have to be perfect. The forming stakes will contain the floor/footing. While they do not have to be perfect, it helps to have them all as level as possible.

Consider using screws to attach the form boards. Nailing to the stakes will sometimes knock the stakes out of alignment. The forms are to contain the floor/footing. They do not have to be perfect.

The floor is necessary for the EcoShell to hold the Airform down as it is being inflated. A 20 (6m) diameter EcoShell inflated may have an uplift of 15,000 lb.. (7,000 kgs).

The floor will hold the Airform down as it is inflated. When inflated, the Airform for an EcoShell with a 20-foot (6m) diameter may have an uplift of 15,000 pounds (7,000 kgs). 6 ECOSHELL The floor is necessary for the EcoShell to hold the Airform down as it is being inflated. A 20 (6m) diameter EcoShell inflated may have an uplift of 15,000 lb.. (7,000 kgs). Ecoshell I 8

6 ECOSHELL 13

These instructions are for a small to moderate size EcoShell. Larger EcoShells may require deeper and wider footings. After the stakes are driven they should have a final diameter check. These instructions are for a small to moderate size EcoShell. Larger TheseEcoS instructionshells may re arequir fore d eae smallper an tod wmoderateider foot sizeings. EcoShell. After th eLarger stakes EcoShells are driven they should have a final diameter check. may require deeper and wider footings. After the forming stakes are driven in and leveled, they should get a final diameter check.

20 cm

Next a footing trench approximately 8x 8 (20 cm x 20 cm) on the inside of the perimeter stakes. Next a footing trench approximately 8x 8 (20 cm x 20 cm) on the inside of the perimeter stakes.

ECOSHELL 7 Dig a footing trench approximately 8” x 8” (20 cm x 20 cm) on the inside of the forming stakes. ECOSHELL 7 Ecoshell I 9 12in or 30cm

12in or 30cm

15 Forming material is needed. Usually this is plywood cut into 12 (30 cm) widths. Many other products will work such as heavy sheet metal, plastic panels, siding, etc. Forming material is needed. Usually this is plywood cut into 12 (30 cm) widths. ManyForming other pro materialducts wil l isw oneeded.rk such aUsuallys heavy sthishee tis m plywoodetal, plast icutc into 12” (30 cm) widths. But many other products,panels, suchsiding as, e theavyc. sheet metal, plastic panels, siding, etc., will also work.

Plywood is the generally used material. Wetting the plywood will allow the wood to form to desired shape. Also multiple layers of more pliable material may be used. Plywood is the generally used material. Wetting the plywood will allow the wood to form to desired shape. Also multiple layers of more pliable material may be used. 8 ECOSHWetELL the plywood. Wetting allows you to bend the plywood into the shape you need. If plywood is not available, multiple layers of a pliable material may be used.

8 ECOSHELL Ecoshell I 10 17

The plywood used for forming may need to be manually bent. This may require the plywood be soaked for a day or two. Usually 1/2 (10 to 12 mm) plywood works best. ManuallyThe p lbendywoo dthe us eplywood.d for for mBeforeing ma ybending, need to thebe mplywoodanually b mayent. needThis to be soakedma yfor re qau dayire torhe two. plyw oUsually,od be so 1/2”aked (10for toa d12ay mm)or tw plywoodo. Usuall yworks 1/2 best. (10 to 12 mm) plywood works best.

The formed boards should be placed on the inside of the stakes and fastened, preferably with screws, but nails or staples con be used in place of screws. The formedN bOoTaEr:d sE aschho uelndd boef tphlaec pelydw oono dt hise f iansstiednee do ft otgheet hsetra ksoe sit a dnodesnt move fastened, preferably with screwwhse,n b cuotn cnraeiltse oisr psltaacpelde sin sciodne be used in Place the formed boards inside thepl aformingce of sc stakesrews. and fasten them to the stakes, preferably with screws,NOT Ebut: E nailsach en ord o staplesf the pl ycanwoo dalso is f abest eused.ned t oFastengether stogethero it does nthet m endsove of the forming when concrete is placed inside boards so that they will not move when concrete is poured inside. ECOSHELL 9

Ecoshell I 11 ECOSHELL 9 19

This is what it looks like with the plywood all the way around.

This is what it looks like with the plywood all the way around. With plywood all the way around, the footing perimeter looks like this.

Check for proper trench diameter and be sure the floor is level. After the reinforcing is placed it is very difficult to make changes.

Check for proper trench diameter and be sure the floor is level. After the reinforcing is placed it is very difficult to make changes. Check for proper trench diameter and be sure the floor is level. Keep in mind that 10 ECOSHELL changes/corrections are hard to make once reinforcing rebar is placed.

Ecoshell I 10 ECOSHELL 12 2 121

ToT ion sintsatlla plll upmlubmibngin, gs,e sweewre, ro,r o erl ecletcrticraicl,a al, tar ternecnhc hsh sohuoldu ldb eb de udgug uFornudne dplumbing,renrenaetaht hth teh sewerpel ypwlyowo orodo dpelectricale preimriimteitre trinstallations,o t toh teh sep sopto wt h wdigehree r ate htrench teh uet uilti tiunderlyit wy iwll ilthel plywood perimeter to thebebe spotinstalled. installed. where the utility will be placed.

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ThTeh ep ipeipe is isl isdli din itnh teh ter ternecnhc han adn dpl apclaecde din itnh teh per porpoepre pro psoitsiiotnio.n.

Slide pipe into the trench and up to its proper position.

E CEEcoshellOCSOHSEHLELL 1L1 1I1 13 23 23

Two continuous reinforcement bars 1/2 (12 mm) in diameter should Two contibneu opulas creedin ifno trhce mtreenntc bha. r sT h1/e2y m (1a2y bmem s)p liinc eddia wmietthe ar 1s2ho uolvderlap (30 be placed Placein tchme two) t. r Fe oncontinuouscr ha. l aTrhgeeyr mE rebarsacyo Sbhee s ll3/8”p sliecee d(10mm)s pweictihf iac 1ein2n gdiameter ionveeerrlainpg ( d3intoe0ta ithels. trench. cm). For a largRebarser EcoS mayhell sbeee splicedspecific with engi nae 12”erin (30g de cm)tails .overlap.

24 24

See fig. 38 See fig. 38

The perimeter rebar (ring beam tendons) should be held up off the The perimdetiretr brye b3ar a (nrdin bge b 2ea min tfernodmo nfso)r msheodu eldd gbe he mldi nuipm oufmfs t. h Neext the dirt by 3 and be 2 in from flooromre rde beadrg ec an bmein pimlaucmeds. Next the floor rebar can be placed. Use bricks to hold perimeter rebar (ring beam tendons) 3” off the dirt and at least 2” in from the formed edge. Then place the floor rebar.

12 ECOSHELL 12 ECOSHELL Ecoshell I 14 See fig. 38

See fig. 38

25 The floor rebar should be in the middle of the slab. A cross pattern of #3 [3/8(10cm)] rebar 15(35cm) on center is adequate for most 25 floors. Hold about 2 (5 cm) from edge. The floor rebar should be in the middle of the slab. A cross pattern Place flooro rebarf #3 [in3 /the8( 10middlecm)] r eofb ather 1 5slab.(35 cAm cross) on c epatternnter is ofad e#3q u(3/8”ate f oorr m10o stmm or 6mm Basalt) rebar 15” (35 cm) fonloo centerrs. Ho isld adequateabout 2 (for5 c mmost) fr ofloors.m edge .Stop rebar about 2” (5cm) from edge.

Mix: 1 bag cement 6 buckets of rock 4 buckets of sand Mix : 1 b a2g buckets cement of water 6 b u------ckets of rock 4 b u1c batchkets o off s acementnd 2 buckets of water ------1 batch of cement

26 This is what is needed for the footing mix. Cement type I or II, 5 gallon buckets (21 liters), and a screen with 25mm holes for sifting.

This is what is needed for the footing mix. Cement type I or II, 5 gallon buckets (21 liters), and a screen with 25mm holes for sifting. Materials for the footing mix: Cement Type I or II, several 5 gallon (21 liters) buckets, a sifting screen with 25 mm holes ECOSHELL 13

Ecoshell I 15 ECOSHELL 13 3ft 3ft

6ft 6ft

27 27

To use the screen for sifting, the unsifted dirt should be thrown at tThoe utsoep tohfe t shcer escerne feonr asnidft ainsg i,t t rhoel lus ntsoi fttheed bdoirtt osmh otuhled pbreo tphero mwinx at Siftth ethe to pgravel of th eby sc throwingreensiz aned will athes i t fallunsifted ro lthrough.ls to tdirthe bato tthetom top th eof p rtheop escreen.r mix As size will fall through. the gravel falls to the bottom, the proper mix size will fall through.

28 28

You can either mix the concrete in a wheelbarrow or a mixing box. You can either mix the concrete in a wheelbarrow or a mixing box.

Mix the concrete in a wheelbarrow or a mixing box.

14 ECOSHELL 14 ECOSHELL Ecoshell I 16 29

29 The mixing box is made with a sheet metal floor. The sheet metal can be anything, however, 22 guage galvanized is recommended. The box is made larger for two people. Exact dimensions are not important. The mixing box is made with a sheet metal floor. The sheet metal can be anything, however, 22 guage galvanized is recommended. The box Mixing boxesis ma arede lmadearger fwithor t wsheeto peo metalple. E xfloorsact di menclosedensions a inre nwoodot im pframes.ortantThe. sheet metal can be anything, but 22-gauge galvanized steel is recommended.

A piece of sheet metal measuring 36 by 72 ( 1m by 2m) is adequate for two people. Often it can have a factory bend made where it is purchased. If not it can be field bent. A piece of sheet metal measuring 36 by 72 ( 1m by 2m) is adequate for two people. Often it can have a factory bend made where it is For 2 people, sheet metal measuringpurchas e36”d. Ixf 72” not (1mit ca xn b2m)e f ieisl dadequate. bent. Factory bends can often be made at time of purchase. If not, the sheet metal can be field bent. ECOSHELL 15

Ecoshell I 17 ECOSHELL 15 31 31

The Tshee sth meeett aml esthaolu sldh obueld f abset feansetde wneitdh w sictrhe swcsr.e wIts .c aInt bcea nn abiele nda iled espeecsiaplelyc iwaliltyh w riitnhg rsihnagn skh naanikls n. a Kiles.e pK teheep stchree swcsr ecwloss ec ltoosgee ttohgeert thoer to Fasten sheet metalmin itommi izwoodneim leizae kframes alegaek. a Lge witha. k Laeg aescrewsk wagilel swt ioorllp s ringwtoitph w shanktihteh ftih rnails.es tf ibrast tToc bha .minimizetch. leakage, place screws close together. First batch of concrete that’s mixed will stop leakage.

32 32

Any Ahoney whoilel wwoilrl kw foorrk mfoixri nmgi.x iTngh.e Tbheest b heosets h aorees laarreg ela arngde hanadve h tahve the doubdleo uhbollee sh.o lTesh.i s T chriesa ctreesa at esd oau bdleou bmleixi nmgi xaisn git a iss idtr iasg dgreadgged throtuhgrho tuhgeh mthixet murixet. ure.

Mix concrete using a hoe. Any hoe will work, but the best hoes for mixing concrete are large and have double holes that provide twice the mixing action. 16 E1C6O ESCHOESLLHELL Ecoshell I 18 33 33

Mix concrete for the floor, by hand if you like. Concrete should be placed fast enough to The floor can be hand mixed as well. It should be placed fast prevent coldeno joints.ughT thoe Keepp frleovoer n puttingcta nc obled hfreshjaonindt sm concrete.i x Kedee aps p wagainstuetltli. n gI tf rsolderehsohu lcd concreteo bnec rpeltaec ea dallg af iathensstt way around. enough to prevent hec oolldd ejori natlls t.h eK weeapy pauctrtoisnsg. fresh concrete against the older all the way across.

34 34

Use care in the placement to maintain the rebar in the middle of the Use care sinla bpouringU. s Ce hceacrke the tino tmconcretehaek epl ascuer emso eth nthatet tpol a rebarmcianign t ostaysafi nt hthe inec or thenecbra emiddlert ien dtohe s ofm ni odthetd kle nslab. ocfk t hChecke to slab. Check to matkhee sfuorrem tsh oeu ptl aocfi nagli gonfm tehnet .concrete does not knock make sure that the placing of thet hconcretee forms odoesut o fnot ali gknocknment the. forms out of alignment.

Ecoshell I 19

ECOSHELL 17 ECOSHELL 17 35 35

If the concrete is hand mixed and poured over a considerable amount Ifo ft hteim ceo naclwreatyes piso uhra nfdr ommix oende asnide p aocuroesds otvoe rt hae c ootnhseidre. r Dabo leno atm doou nats of times haolwwany asb poovuer ufnrloemss o anlel osfid teh ea cfrlososr tcoa nt hbee optlahceerd. Dquoi cnkolty .do as Place concrete. If placingshown of ab allov eof u ntheles sconcrete all of th cannote floor becan done be p linac e15d qminutes,uickly. start the concrete placing on one side and continue placing by moving across to opposite side.

36 36

As the concrete is being poured, it should be leveled with a scArese tdh eb ocaorndc raest seh iosw bne. i nEgx pcoeusrse cda,n i tb seh mouolvde db ea hleevaedle odr wrietmho aved. scrAese dth beo caorndc arse tseh ohwarnd. e Enxsc iets csa cna bne b ter omwoevleledd a thoe aad f oinre rre fminoivsehd. . Level the concreteAs th ewith con car escreedte har dboardens it as ca it’sn b ebeing trow epoured.lled to aExcess finer f caninis hbe. moved ahead or removed. As concrete hardens, it can be troweled to a finer finish. 18 ECOSHELL 18 ECOSHELL Ecoshell I 20 37 37

Important:Importa nBeforet: Befor ethe th econcrete concrete f floor/footingloor/footing sets usetsp, t heup, up rtheigh tsuprights must be plamustced. be placed. Uprights are #3 rebar (3/8” These are #3 rebar I(3m/p8or otarn 1t0: mBemf)o. r Teh teh es hcoorntc lreegt eg ofeloso irn/ tfhoeo tfilnogo rs eatbso upt, 1 th fer oumprights must be placed. or 10 mm).th ePlace edge. Ithet sh Tshortohuleds eb e aleg rteu r# nintoe3d r aesb theamru (c 3hfloor/ 8as poro s1sabout0ib mlem t)o. w T1”ahr defrom ss hthoert cthe leengt geedgeore. s in tandhe f lturnoor a bit,ou tas 1 frmuchom as possible, toward the center. the edge. It should be turned as much as possible towards the center. If basalt rope is used, place stainless steel hooks in place of bent rebar. Hooks are to be stainless steel, 1/4” shaft, 3/4” hook and 3” long.

38 38

The placement shown is for a 10 to 20-foot diameter EcoShell. Larger structures mTayh eh apvlaec deimffeenrte snhto ewnng iinse feorri nag .1 0 A tlwo a2y0s- cfohoetc kd ifaomreter EcoShell. LPlacementarger stru cshowntaccuracy.ures misa yfor ha anve EcoShelldifferent withengin ae e10’rin gto. 20’Alw adiameter.ys check Largerfor structures may require differentaccuracy. engineering. Always check for accuracy.

ECOSHELL 19 Ecoshell I 21 ECOSHELL 19 3 939

Place two uprights or hooks on each side of a doorway, but do not place any uprightsDoD noo tn op tlwithina pclea cuep ruipg rhtheitgsh tin sdoorway. dino odrowoarywsa.y sP.l a DigPclea ctew aotw esmallox terxat ruap rutrenchipgrhitg hotn oe naapproximately ceha cshid sei doef odfo odrowoarywsa .1”y sA. sA(25m samll amm)ll wide and 3/4”tretnrcehn tocahp pa1”rpopxr iodeepmxaimtealtye into1ly( 215(2 mthe5m m) m wfresh)i dwei daen d aconcrete n¾d t¾o t1o( 215(2 m 5betweenm m) md)e edpe esph o suthehlodu bld euprights, bdeu gd uing tinh et hf eexceptr efsrhesh for door- concrete between the uprights. This trench will be 2 wide and 1 deep on larger buildings. conways.crete b eFortwee nlarger the up rstructures,ights. This tre nthisch w itrenchll be 2 w ishouldde and 1 dbeee p2” on lwidearger b anduildin g1”s. deep.

4 040

AfAtfetre trh teh ceo cnocnrcerteet ies isse ste t us uusaullayl ltyh teh nee nxetx dta dya, yt,h teh feo fromr mb obaoradrsds cacna bne b ree rmeomvoevde. d T. oT por porvoidveid ae saa sfaef aen adn cdl ecalena jno jbo sbi tseit, ec,l ecalena ann adnd stsatcakc tkh teh feo fromr mb obaoradrsd fso fro fru ftutruer ues ues.e. Remove the form boards once the concrete sets -- usually the next day. Provide a safe and clean job site by cleaning and stacking the form boards for future use.

202 0 E CEOCSOHSEHLELLL Ecoshell I 22 4 411

AA g guuididee l ilninee 1 1 ( 2(255 m mmm) )f frroomm t thhee u upprrigighhttss i sis m maarrkkeedd. . T Thhisis i sis w whheerree Mark a guidelinetthhee e e d1”dgge e(25 o off t mm)thhee A A ifromrirffoorrm mthe i sis tuprights. too b bee f foorr tGuideline thhee E EccooSShh eindicateselll.l. where the edge of the EcoShell’s Airform will be.

4 422

PPlalaccee t thhee A Airirffoorrmm a ass s shhoowwnn. . U Ussee 1 1, ,2 2 o orr 3 3 c coonnccrreettee a anncchhoorrss a ass needed. The anchors can be a screws (Tapcons), or a wedge foot Place Airformneed easd. shown. The an cUsehor s1, c a2n or b e3 a concrete screws ( Tanchorsapcons )as, o rneeded. a wedg eAnchors foot aanncchhoorr. . I Itt m muusstt b bee r reemmoovvaabblele. . can be screws (Tapcons) or a wedge foot anchor. It must be removable.

Ecoshell I E ECCOOSSHHEELLLL 2 22311 43

43 43

Continue to place clamp angles along the guide line. Care must be taken to stretch the fabric along the line to keep it even. If not there will not be enough to go all the way around. Continue placing clamp angles along the guideline. Carefully stretch the Continue to place clamp angles along the guide line. Care must be takCfabriceon ttion ualongset rteot pc thelha cte hguideline, ec lfaambpr iacn ag lldistributingoensg a tlohneg l itnhee tthegou ki dfabriceee pli nite .eevenly vCeanr.e Im fallu ns otaround.t be If nottak stretcheden tthoe srter ew evenly,tilcl hn otth eb thereef aebnroi ucmayg ahlo t nonotg gto hbe ea l l ienoughnthee t ow akye to eapr go oitu nealldv.e then. I wayf no taround. there will not be enough to go all the way around.

44 After the clamp angles are all in place the joint must be sealed. This can be done with caulking (must be cleaned up); or by using plastic wrap and sand. Both will work.

44 After the clamp angles are all in place the joint must be sealed. 44 TAfterhAisf tcea allrn tb hclampee d colname anglespw iatnhg clea sareu lakr iineng a place,l(lm inu sptl abthecee c tjointslheea njeod imustn utp m);u obesrt bsealed.ye usseianlge Cleand. 22 ECOSHELL This can bep ldaosnteic w witrha pc aunldk isnagn d(m. uBsott bhe w cilel awnoerdk .up); or by using the joints and sealplas tthemic wr awithp an dcaulking sand. B oorth with will wplasticork. wrap and sand. See last page for drawing of Clamp Angle.

22 ECOSHELL Ecoshell I 24 22 ECOSHELL 45 45

As theA psl atcheem pelanct ecmonetnitn uceosn,t itnhuee sm, atnh eo rm maen no rp lmaceing p tlahcein cgl atmhpe acnlagmleps awniglll ewsi nwdi lul pwind up As placementinside. i n sTcontinues,ihdey. w Tilhl enye ewd iworkersl lt noe cerda wtol oc uplacingrta wthl roouutg t hhthe rthoue g clampshle tehvee sp leanglesroevied epdro. v willIidte ids .o wind fItte ins ho upeftlpef ninsideu hl elpfu lof to have a saw horse or other bracing device to hold the fabric off the installers. the Airform.to hav Workerse a saw hor scane or crawlother b outracin throughg device t theo ho lprovidedd the fabric sleeve. off the iAns tsawaller shorse. or other bracing device used to hold the fabric off the workers is helpful.

46 46

After Athfete wro trhkem weno rhkamven e hxaitveed e txhitreodug thh rtohueg shle tehvee silte ceavne bite c raonl lbede ruopl laendd u tpi eadnd tied After all workersoff. M ohaveafkfe. aMs aexited,akire taisg hatir rolla tsi gpho tsup saisb andlpeo. s sNi botieltee. : off N aost ttheeh: e a pssleeve,l atcheem pelanct making eomf e cnlta mofp theacnlagml eAirformps angles as air tight as possible. p Asrog rplacementepsrso, gitr eis so,f ite iofns ho feclamptlpefnu hl teol p anglessftual rtto tsht eaprogresses, rbtl otwhe rbsl otwo evre sventilaten tiola vteen utnildate underer uthndee Ar ithertfhoer AAirformmi.rform. by starting the inflators.This is eTThisshpeisc ias l liseys up seespeciallyecfiaulll yi fu sae lfaurlg eif fa a nlusefula risg eu sfeadn oiifsn luy s feao drlarge otnhlyis fpohr a fansthe.i s T pishaes Eeused.c o TShe l lE bconlyoloSwheerl l mforbuloswt ebthisre m uusse td phase.bteo used t o The EcoShell Inflator must be usedprope rtolyp irnofproperlyplaetrely tihnefl aEtceo Stinflatehhee llE cAoirSfhoer lml the Afiorrf o cromEcoShell’sn sftorru cctoionns.tructio nAirform. for construction.

ECOSHELL 23 EEcoshellCOSHELL 2I3 25 47

47 Start the rebar hanging with a few rebar tightly bent around a center ring (1.5 to 2 ft in diameter (45 to 60 cm). Place the ring in the middle top of the Airform and hang the rebar to the perimeter.

Start the rebar hanging withSt ar fewt th erebar reba tightlyr hangi nbentg wi taroundh a few a r centerebar t iringghtl y1.5’ ben tot a 2’ro u(45nd toa 60 cm) in diameter. center ring (1.5 to 2 ft in diameter (45 to 60 cm). Place the ring in Place the ring in the centerthe of m itheddl eAirform’s top of th tope A iand,rfor mon a nthed h outsideang the ofre bthear Airform,to the pe rhangimet ether. starter rebar from the center ring to the perimeter. It is far better to use basalt rope or basalt rebar than steel reinforcing.

Tie the starter rebar as shown to the uprights. Do an even layout. The layout will vary depending on the size of the dome. Maintain a maximum spacing of 10 (25 cm) each way. Vertical rebar should lay against the Airform.

24 ECOSHELL

Tie the starter rebar as shown to the uprights. Do an even layout. The layout Tie the starter rebar tow ithell va uprightsry depend iasng shown,on the s icreatingze of the andom evene. M alayout.intain a mDependingaximum spac oning theof size of the dome, the layout will vary. Maintain10 a (maximum25 cm) each spacingway. Ver tofic a10”l reb (25ar s hcm)ould eachlay ag away.inst t hVerticale Airfor mrebar. should lay against the Airform. Please use basalt rope or basalt rebar rather than steel.

24 ECOSHELL Ecoshell I 26 49

Cut out the pieces that make up the augmentations from plywood or boards. Scribe them to fit the Airform. They can be leaned against the Airform and fastened to the rebar. Cut out the pieces that make up the augmentations from plywood or From plywoodboa rords boards,. Scrib ecut th epiecesm to f thatit th wille Ai rmakeform. up T htheey caugmentations.an be leaned ag aScribeinst them to fit the Airform. Then tleanhe A themirfor magainst and fa theste neAirformd to th eand re bfastenar. them to the rebar.

When the vertical rebar is more than 10 (25 cm) start another vertical. These should be attached to the horizontals. Always place the horizontal bars on the outside. When the vertical rebar is more than 10 (25 cm) start another Position vertical rebars 10”vert (25ical . cm) The apart.se sho Placeuld be horizontal attached trebarso the h overorizo thenta loutsides. Alwa ofys theplac verticale rebars. Attach horizontals to verticals. Pleaseth usee ho basaltrizont areinforcing.l bars on th e It o uwilltsid note. be destroyed by rusting. ECOSHELL 25

Ecoshell I 27 ECOSHELL 25 51

51 51

Rebar should be placed around the augmentations. It should tie back to the shell rebar. Leave the existing shell rebar in place. It can be cut out later. Rebar shouldPlace be p lrebaraced aaroundround t thehe aaugmentationsugmentations. andIt s htieou itld toti ethe ba cshellk to rebar.the sh ell rebar. Leave the existing shell rebar in place. It can be cut out later. Leave existing shell rebar in place; it can be cut out later. Use basalt rope or basalt rebar.

52 52

Place two or more pieces of extra rebar on top and the sides of Place two or more pieceso poefn einxgt rina trheeb asrh eolnl. top and the sides of opening in the shell. Place two or more extra rebars on top of and on the sides of the opening in the shell.

26 ECOSHELL Ecoshell I 28 26 ECOSHELL 53 53

The shotcrete mix is stronger than the floor mix. It is designed as 4000 psi (280 kg/ cm!) concrete. If the sand has coarse material in The shotcreit ea dmdix a niso tshtreorn pgaeirl otfh aitn, tahned fleloaovre mouixt. t Ihte irso dceks. igned as Shotcrete4000 psi mix(280 is k gstronger/ cm!) c othanncre thete. floorIf the smix.and It’s ha s designedcoarse m aast e4000rial i npsi (280 kg/ cm3) iconcrete.t add ano tIfh esandr pa icontainsl of it, an coarsed leave material,out the r oaddck. another pail of sand and omit the rock. Add nylon fibers and Kel-Crete to the mix.

54 54

Make final inspection. Rebar should be close to the Airform with Make finalth einspection. horizontal bRebarars t oshould the ou laytsid eon. theThe mAirformaximu m withspa chorizontaling of the bars on the Moutside.ake fin aMaximuml inspercetbioa nspacingr. isR e1b0a ir nbetween cshheosu l(d2 5b e rebarc mcl)o se eisa ct h10”o wtha e(25y .Ai rcm)for meach wit hway. the horizontal bars to the outside. The maximum spacing of the rebar is 10 inches (25 cm) each way. Use basalt rope at 12 inches maximum spacing (30cm). ECOSHELL 27 ECOSHELL 27 Ecoshell I 29 55 55

First layer can be hand applied. It can be trowelled or flipped on by using a small mason trowel. It also can be applied by use of a shotcrete pump. Place only what will stick.

Apply first layer of concrete.First la yeConcreter can be canhan dbe a phandplied .applied It can bybe troweling trowelled oorr flippingflipped iton on, using a small mason trowel. It also bcany u sbein gapplied a small withmaso an Shotcretetrowel. It pump. also c aBen b suree app tolie placed by u onlyse of whata will stick. We now recommend application ofsh o1/2”tcre ttoe 3/4”pump of. P concretelace only beforewhat w ilayerll st iofck reinforcing.. Then place the basalt rope after the first layer of concrete has had time to set (24 hours).

Since a second and third coat will be needed, wait until the concrete is hard to the touch before applying the next coat. Try to keep the concrete moist between coats.

28 ECOSHELL 56

Note:Sin Ace layer a sec ofon dconcrete and thir dshould coat w beill bharde ne etod ethed, wtouchait un beforetil the capplyingoncrete isa new layerh ofar dconcrete to the t overouch bit.e fBeor esure app lfirstying tlayerhe ne xist chardoat . beforeTry to applyingkeep the second concrete moist between coats. and second is hard before applying third. Keep concrete moist between coats.

28 ECOSHELL Ecoshell I 30 57 57

After the exterior concrete is cured enough to stand remove the AftAeir ftohrem e. x Utesruiaolrly c tohnec rceotnec rise tceu rweidll ebneo sutgrho ntog setnaonudg hr einm 2ov4e h tohuers Airfaofrtme.r Uthseu allalsyt t choea cto. n Icnr ectoeld w wilel abteh setrr iotn mg aeyn otuagkhe ian f2e4w hdoauyrss. Removeafter the the Airform last coa tafter. In thecold exterior weathe rconcrete it may t ahaske acured few d--a yusuallys. about 24 hours after the final concrete coat has been applied. But in cold weather, curing may take a few days.

58 58

Clean the exposed rebar inside of the dome and place a 1/2” layer of concrete over it. Concrete can be troweled or sprayed onto the dome’s interior. After the Airform is removed clean the exposed rebar and coat the Afintseird eth oef Athiref odromm eis. rAe m½o ivnecdh claleyaenr tshheo uelxdp boese tdr orwebelaler da nodr csoparat ytehde on inside of the dome. A ½ inch latheyer interior. should be trowelled or sprayed on We are no longer building this way. It is betterthe to applyinterior. a 1/2 inch to 3/4 inch layer of concrete to the Airform first, then put the basalt rope or basalt rebar, followed by the last layer of concrete. It still works to build this way the way illustrated above, but the other is better ECOSHELL 29 ECOSHELL 29 Ecoshell I 31 5 9 59

Interior plaster may requireT htwoTeh ien tcoats.inetreiorri oIfrp ltheapslat esinteriortre rm amya rwillye rqeu qinotrueir t ebew tow subjectedcoo caotsa.t s T. h T etoh i enwater, ninenre cro limecaotsa tcs acan cnan be added to those hahvaev leim liem ien cinlucdluedde fdo fro era esaes oef o tfr otrwoewlleinllgin igf itfh teh ien tientreiorrio wri lwl inllo nto bte be inner coats to smakeusbujbecj theetectd e trowelingtdo t woa wteatre. reasier..

Plaster is not necessary if you put 1st layer of concrete over Airform befor placing basalt reincforcement.

6 0 60

ThTeh Eec EocSohSehlle ilsl inso nwo swt rsutrcutucrtualrlayl lcyo cmopmleptlet. e I. t I sth sohuoldu lbde b ceo caoteatded witwhitahna enl aeslatostmoemreicr icco caotiantgin tgo t oh e hlpe lwpi twhit sho slaorl arre rfelefcletacntacnec aen adn tdo to EcoShell is pnowrportoe structurallytcet catg aginasint spt o complete.psosisbslieb llee alek Itsask fs rexterior ofrmo mha hira shouldilrin lein cer ac becrak cscoatedk. s. with an elastomeric coating to help with solar reflectance and to protect against possible leaks from hairline cracks. 303 0E C EOCSOHSEHLELLL Ecoshell I 32 Fabric Mixer

The Monolithic Fabric Mixer is simplicity itself -- fast and easy to use.

Here’s how it’s used: A cubic foot or less of concrete ingredients are put into the center of this fabric. The fabric is then agitated from side to side by two people. The completed concrete can then be trans- ported to its point of use.

Here’s the mix design we suggest for use with the Monolithic Fabric Mixer when building a concrete EcoShell: one container of cement, four containers of sand and water as needed. Start with one liter of cement, four liters of sand and one liter of water. Adjust the water to the conditions. Adjust the sand, if needed, by adding some 3/8 minus pea rock.

Ecoshell I 33 Basalt Addendum

Over the years we have become aware of another reinforcing made of basalt. Basalt is another name for volca- nic. It is a fiber pulled from the basalt basically as fiberglass fiber is pulled from a mixture of rock. The basalt fibers are then put into a rebar like pattern by using an epoxy to form the rebar. Basalt has some really good features. First and foremost it doesn’t rust. Because it doesn’t rust, it doesn’t need nearly as much concrete covering it up to protect it from rusting.

The basalt rebar is a little more than twice as strong as steel rebar and weighs about one fifth as much.Again, this has some huge ramifications in building EcoShell I buildings. If the rebar is basalt we don’t have to worry about leakage of rain water getting into the reinforcing, rusting it and exploding the concrete.

We have been buying basalt in coils woven as a rope. In the EcoShells we are now using a six millimeter basalt rope. My preference is the rope as it coils tighter and ships easier. My recommendation is to put the 6 mm rope about 12 inches on center in both directions.

If you use the basalt rebar and if you have quality control on building the structures you can use a total thickness of one and a half to two inches.

It is always smart to coat the outside of the EcoShell buildings. The best coating we have found to date is sili- cone but other water proof coatings can be used. The huge advantage by using basalt rebar, is if over time the coating should start to leak water into the rebar, the building will just be bothered by unsightly spots where the leak occurs. But it will not have any structural problems.

It is fascinating and fun to contemplate the millions of houses we can build using the combination of concrete and basalt.

6/15/11 1/8th inch thick angle iron is used to hold the Airform to the concrete slab..