Robotic Shotcrete Dome Construction with Wood Framing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for safe, attractive, cost-effective dome homes that can be built quickly and provide protection from natural disasters, as traditional wood-structured homes often fail to withstand tornadoes, hurricanes, and wildfires, and current dome designs are not aesthetically appealing.
Innovation Solution
A robotics dome construction system that uses a membrane material to define the dome shape, applies shotcrete with a robotic sprayer, and embeds traditional wood-framed roofs to create a structurally stable and aesthetically pleasing structure, combining the benefits of dome construction with traditional building materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wood-structured homes are built, then construction follows conventional aesthetics and materials, but structural stability during natural disasters (tornadoes, hurricanes, wildfires) is insufficient
Solution Approach 1:
The patent combines concrete shotcrete (providing disaster resistance) with traditional wood framing (providing conventional aesthetics and manufacturing familiarity) to create a composite structure that achieves both reliability and ease of manufacture. The concrete dome shell provides tornado and hurricane resistance while wood trusses maintain traditional home appearance.
Solution Approach 2:
The structure is divided into distinct functional segments: a concrete shotcrete dome shell for disaster protection, embedded wood trusses for structural framework, and traditional roofing materials for aesthetic completion. This segmentation allows each component to optimize its specific function while working together as an integrated system.
2Reliability
If dome construction is used for safety protection, then structural stability is improved, but aesthetic appeal is reduced
Solution Approach 1:
Traditional wood framing and roofing materials are nested within the concrete dome structure. The wood trusses are embedded in the concrete shell, and traditional roofing materials are placed on the dome apex, creating a nested configuration where conventional aesthetic elements are contained within the protective dome form.
Solution Approach 2:
The patent applies different materials and qualities to different parts of the structure: concrete shotcrete for the dome shell (providing protection), wood framing for structural support (providing traditional appearance), and traditional roofing materials for the apex (enhancing aesthetic appeal). Each local area uses materials optimized for its specific function and visual requirements.
3Productivity
If rapid construction of dome homes is implemented, then building time is reduced, but construction complexity increases
Solution Approach 1:
The patent replaces manual mechanical construction processes with automated robotic spray application for the concrete shotcrete. This robotic system applies concrete rapidly and consistently to the dome shell, significantly reducing construction time while the automation handles the complexity of the curved surface geometry.
Solution Approach 2:
The concrete dome shell is constructed first as a pre-formed protective enclosure, with wood framing and traditional roofing materials added subsequently. This preliminary action of creating the protective dome structure first enables rapid completion of the overall building process, as the most time-consuming concrete work is completed before interior finishing.
4Ease of manufacture
If cost-effective dome construction is pursued, then building costs are reduced, but material quality and durability may be compromised
Solution Approach 1:
The patent uses concrete shotcrete with optimized mix parameters (water-cement ratio, aggregate size, additives) to achieve both cost-effectiveness and high durability. The robotic application process ensures consistent parameter control across the entire dome shell, maintaining material quality while reducing overall construction costs through efficient concrete usage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for rapid, cost-effective construction of safe and attractive dome homes that can withstand natural disasters while maintaining a traditional appearance, offering enhanced structural stability and reduced labor costs through precise shotcrete application.
Implementation Method 1
A robotic sprayer applies shotcrete to inner walls of the dome, over the foam, wire, and rebar
Implementation Method 2
Foam may then be sprayed over an interior surface of the membrane
Data Source
AI summary
The system allows a user to construct a dome while masking the dome within a structure built with traditional wood building materials. The system may include a membrane material that defines the walls and roof of the dome. The system may also have brackets that are placed into the roof formed by the membrane material. After foam has been sprayed, a user may insert wires into the foam. The wires are positioned so as to receive rebar to add structural stability to the dome. A robotic sprayer applies shotcrete to inner walls of the dome, over the foam, wire, and rebar. A traditional roof may be coupled to the completed concrete dome using the brackets that have been embedded throughout the initial construction of the dome.