Shotcrete and urethane

layered inside inflated form

Stratiform dome builders work out of the weather
BY

M. K HURD

Wide ranging applications

Two intersecting hemispherical air forms were used to

create an energy-saving residence in the Rocky Mountains
of Colorado. Architect Jon Zimmermans design statement
was influenced by his understanding of the stratiform
construction process.
pray a shell structure onto the inside of an inflated balloonfirst some layers of urethane
foam, then some layers of shotcre t e. So m e
call it stratiform, a generic term that refers to
its being built up in seve ral laye r s. Domes spanning
up to 230 feet have been built in this way, and enthusiastic proponents of the method believe stru c t u re s
f rom 500 to 1,000 feet in diameter are feasible. Although spherical and ellipsoid domes are the most
widely used, the method works with irregular or freeform shells whose shapes can be matched by a skilled
a i r- f o rm maker (see article on page 403).
The basic stratiform concept was developed by California architect Lloyd Turner and patented by him in
1966. Se ve ral users of the Turner method added their
own variations or innovations to Tu rn e rs theme, extending its range of practicability to eve r- l a rger shells.
The Turner patent is now in the public domain, and
anyone who develops the necessary skills is free to build
a urethane and concrete stratiform dome. Se ve ral companies do, howe ve r, license or franchise builders to use
their special proprietary systems of stratiform building.

Structures built with these layers of urethane and concrete can be efficiently heated or cooled because of the
layer of insulation that is seamless and free of cracks and
air leaks, and because of thermal lag afforded by the inner concrete layer. The urethane foam insulation can
have an R value of 7 or more per inch of thickness, depending upon the density selected. Having this insulation on the outside also protects the concrete shell itself
from temperature extremes and permits escape of any
noxious gases temporarily trapped in the urethane.
Stratiform domes are used today for storage of grain
and other commodities; for private residences; for institutional buildings such as schools, churches, and animal
shelters; and for water tanks and cold storage units.
Homeowners report heating and cooling costs that are
50% or less than for conventional homes of the same
size. The owner of one 4,400-square-foot cold storage
dome reported his utility bill to keep the freezer at 0 F
was only a fourth of the cost of operating a conventional
f re ezer. State highway departments that use the stratiform domes for salt storage say they have eliminated interior condensation problems.

The construction sequence

Construction of a stratiform shell involves several basic steps, with some differences in reinforcement and
maintenance of air pressure that vary with the size and
end use of the dome.
1. Generally a foundation perimeter tension ring must be
built first. Reinforcement dowels set in this base provide
a structural connection between the dome and its foundation. The base slab for the entire structure also may be
done at this stage.
2. The air bag form, typically hemispherical, is spread
out and attached at its perimeter to the foundation. One
variation of the process uses a steel ring to anchor the
balloon, then creates a steel-fiber-reinforced shotcrete
foundation continuous with the dome. After the form is
inflated, all work moves out of the weather to the inside
of the balloon. An air lock must be provided to enter the
balloon. Air pressure at this stage varies from 1 to 3 inch-

es of water column, equal to about 0.04 to 0.10 psi.

Forming and placing a perimeter tension ring is the usual

beginning of a stratiform operation. Vertical dowel bars will
be embedded in the foundation to overlap reinforcement for
the shell structure.

3. The balloon becomes the form for polyurethane foam

insulation which is sprayed on the inside, building up in
s e ve ral layers to the desired thickness. Four inches of
urethane is typical for a residence; larger storage domes
may have 2 to 5 inches, depending on the dome size and
end use. The urethane foam hardens to become the
form for shotcrete and a supporting medium for reinforcing steel. For some structures the blower can be
turned off at this point; the urethane and successive
shotcrete layers are stiff enough to be self-supporting.
For spans longer than 80 feet, the urethane thickness
needed to support itself and the first shotcrete layer becomes impractical. For these larger spans, the air pressure is maintained or adjusted to keep the desired structural shape until the shotcrete has fully hardened. One
system, promising for 400-foot or larger domes, is based
on carefully staged pressure increases corresponding to
load increases as the shell thickness grows.
4. The next step calls for reinforcement to be placed, usually attached to the foam layer. Sometimes the steel is a
self-supporting cage set on the dome floor. In either case
the steel must be close to the foam layer. Some residential domes have steel-fiber-reinforced shotcrete and little conventional rebar except at the connection to the
foundation. Larger span domes require a grid of reinforcing bars over the entire dome surface, overlapping
the bars projecting from the foundation. Some structures have both steel fibers and rebar. Depth indicators
can be anchored in or on the foam at this time to serve as
gauges for the shotcrete placement. Added re i n f o rc ement is placed around planned openings in the shell. An
engineering design determines the amount and location
of steel for each dome structure.

Spreading the air form and anchoring it to the foundation

ring come next. An air lock for worker entry is needed,
since all work is done from inside after the balloon is
inflated.

5. After the reinforcement is satisfactorily positioned, several thin layers of shotcrete are applied, building up the
necessary thickness, typically 2 to 4 inches. Larger
domes may be much thicker at the base.
6. After the shotcrete has gained sufficient strength, any
blowers that were required throughout the construction
process can be turned off. The air form may be peeled off
at this time, although some builders consider it cheaper
to leave it in place as a part of the exterior weatherproofing of the shell. A protective coating is required on the
outside since the urethane is both flammable and sensitive to ultraviolet light.

Preparing to spray the desired thickness of urethane foam

insulation onto the inside of the balloon. It is usually built up
in several layers. Light filters through the air form
membrane.

The owners advantage is the

builders opportunity
This is an economical method for
building insulated, energy-efficient
s t ru c t u res which can be readily
adapted to earth sheltering if desired. There is total flexibility of interior plan, since no load-bearing partitions are needed. Co n c re t e
functions secondarily as a fireproofing material because it is placed between the exterior layer of foam and
all interior spaces.
Energy efficiency, strength, and

design flexibility are strong pluses

for this new technology. It presents
both the opportunity and the need
for collaboration between designer
and builder throughout the process.
Yet because of its very newness in
most areas, builders must be prepared to develop effective marketing programs if they expect to profit
from it. They also must recognize
that sophisticated design procedures, executed by well-trained engineers, are required if the air-supported forming concept is to be

applied to large span structures.

Licenses are available from originators of some established systems.
Also consider the possibility of joint
venture with an already established
dome builder, or consult a designer
knowledgable in the specialized
techniques.

PUBLICATION#C880391
Copyright 1988, The Aberdeen Group
All rights reserved