Thin-shell Concrete Quasi-spherical Buildings for Durable, Low-cost, Low-impact Shelter, Volume Production
We used a novel, proprietary forming and construction process by which to achieve this strength with envelope thickness of 1-2 cm, non-ferrous primary reinforcements to create a resilient composite envelope, very low material-to-enclosed-volume ratio, and rapid construction cycle time of about one per 4 days, on an easily-transportable, reusable forms set. The construction concept is intended to greatly reduce the amount and cost of material, tooling, tools, and expert labor required to quickly build, on-site, several or many structures of size and shape determined by the male forms set. We thus achieve low embodied energy, durability, low cost, and the ability to Earth-shelter the structure from climate, weather, flood, and tsunami extremes, and from small arms fire and shrapnel in war zones.
We intended this method for use in remote communities, in Alaska and anywhere, to avoid the high costs of transportation and mobilization. The thin-shell concrete structure may be insulated to any desired rating with closed-cell UR foam spray on the interior, with a protective overcoat. Bagged pre-mix of portland or other cementitious materials, additives, and distributed small-scale reinforcements must be imported, combined with local aggregates and water.
Forms sets for a range of structure sizes and shapes may be designed in CAD, with the FRP (glass-only, or enhanced systems) forms sets manufactured on tooling economically built from CAD. Scale-up from our proof-of-concept prototype, primarily tooling design, build, and manufacture of a few forms sets, will cost about $ 500-700,000. See: https://alaskaappliedsciences.com/wp-content/uploads/FOA-2459-3-E-4261-5Apr21.pdf