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Ultra Thin Shell Dome Construction Jay Emery Dingley Dell Enterprises Limited - UK Construction – Low Cost Housing Solution. January 5, 2011 . Dome Home – A Low Cost Housing Solution for Emerging Countries :-. Culturally preferred in many countries Low cost Quick and easy to build

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Ultra Thin Shell Dome ConstructionJay EmeryDingley Dell Enterprises Limited - UKConstruction – Low Cost Housing Solution

January 5, 2011

dome home a low cost housing solution for emerging countries
Dome Home – A Low Cost Housing Solution for Emerging Countries :-
  • Culturally preferred in many countries
  • Low cost
  • Quick and easy to build
  • Disaster resistant
  • Secure
  • Fire proof
  • Environmentally friendly
  • 20- 40mm thickness
  • Reduced quantity of raw material used
  • Ideal for emerging countries and disaster relief
primary market our market research
Primary Market: Our market research :-
  • RDP Housing South Africa
    • Reconstruction and Development Program is a South African Socio-economic framework
    • 2 million houses in 5 years
    • 400 000- 500 000 units per year
    • SA Gov: R16-billion( 1.6 billion Euro) RDP housing & sustainable human settlements for 2010/11
    • 2nd largest world housing construction program
    • It will cost South Africa R1,3-billion ( 143.5 million euro), or 10% of this year's budget, to rectify badly built (RDP) houses
  • Pilfering of site materials a major problem
    • Corrugated steel & wood are stolen from construction site – Alternative solution now sought after

Typical RDP House

construction process
Construction Process:-
  • Screw piles or Slab laid
  • Air form attached with stainless steel straps
  • Air form inflated
  • Unique window arch formers and blanking plates are attached
  • Glass fibre rebar is tied and anchored
  • 20mm-30mm thick Layer of concrete is either hand or spray applied
  • Concrete allowed to set 48hrs
construction process cont
Construction Process cont:-
  • Air Former is removed and re-inflated at next site
  • Approximately 100-150 Houses per kit
  • Window arches and blanking plates removed
  • Unique glass fibre reinforced waterproof concrete top coat is applied
  • Cast window frames and door frames are installed and glazed
  • Internal stud walls and electrics fitted
technical information
Technical Information:-
  • Type of cement
  • Size of dome
  • RDP target pricing
  • Build time
  • Durability
  • Strength
  • Concrete mix 30mm
  • Glass fibre reinforced cap 10mm
  • Other
  • Portland type 1
  • 8M dia – 52M2
  • R56k-R70K
  • 3 days
  • 80-150 years expected
  • Exceeding 2kn Sqm at 2cm thick
  • Standard sieve analysis
  • Modified GRC
  • Electrics & plumbing in floor and internal stud walls
finite element analysis and structural calculations
Finite element analysis and structural calculations

20mm GRC structure without glass fibre rebar

  • Result Summary
  • Name Minimum Maximum
  • Volume 1695110000 mm^3
  • Mass 3390.23 kg
  • Von Mises Stress 0.00597724 MPa 6.67419 MPa
  • 1st Principal Stress -0.636598 MPa 7.68419 MPa
  • 3rd Principal Stress -2.69216 MPa 0.902609 MPa
  • Displacement 0 mm 1.51284 mm
  • Safety Factor 0.449493 ul 15 ul
  • Material(s)
  • Name GRC GRADE 10
  • General Mass Density 2 g/cm^3
  • Yield Strength 3 MPa
  • Ultimate Tensile Strength 4 MPa
  • Stress Young's Modulus 10 GPa
  • Poisson's Ratio 0.3 ul
  • Shear Modulus 0 GPa
  • Stress Thermal Expansion Coefficient 0 ul/c
  • Thermal Conductivity 0 W/( m K )
  • Specific Heat 0 J/( kg c )

Von Mises Stress Mpa

Safety factor ul

3rd principal stress Mpa

Displacement mm

test results 10mm thick grc sections
Test Results 10mm thick GRC sections

These tests were conducted by Graham Gilbert A founding member of the Pilkington glass fibre development team

Dingley Dell’s work on large domes in GRC is another major development. The combination of GRC with GRP rebars expands the use of GRC.

The complementary properties of these 2 materials combined together have been studied for several years but it is the application into large span domes that is unique. Add to this the use of AR meshes and the resultant structure should prove to be one the strongest, thinnest, most robust and durable cement based composite in the World whilst still being cost effective.

Congratulations and keep up the good work.

Graham T Gilbert, CChem., MRSC

GRC with glass rebar

Standard GRC

Modified GRC

multiple levels of innovation in
Multiple levels of innovation in:-
  • Air form design
  • Methods of anchoring domes
  • Window arch former & blanking plates
  • Proven glass fibre concrete mix design
  • Concrete window frame moulding techniques
  • Glass fibre rebar substitution (no corrosion)
  • Composite concrete construction
  • Reduced carbon footprint per unit

Other uses

  • Potable water storage
  • Bio digesters
  • Insulated panels

Intellectual PropertyPatent application made 2009Initial searches competed 2010

PCT applications made 2010

Dingley Dell Product display

Glee International Trade show

Proven track record of innovation since 1999

commercialisation
Commercialisation:-

Latest Dialogue

  • Supplier partnerships required for base materials in SA: [Portland Cement]
  • Demonstrator building in advanced technology park SA
  • Pilot project 20 domes
  • License to manufacture: Contractors
  • Supply of key components in kits

CharitableOrganisations

Project O Children of Aids Orphanage

Samaritans Purse

Article 25

Habitat

Domes for the World

Nail Mellon Township Trust

James Caan Foundation

British Embassy

Pretoria

Durban

Municipality

Theewaterskloof

Municipality

Kits comprise of:

Kit 1: Air form and moulds

Kit 2: Additive ingredients

Kit 3: Glass fibre rebar

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Conclusion:-

  • Your vote of support is all that stands between my vision the dreams and the reality!
  • A truly viable housing solution for all of humanity.
  • Using a simple process utilising local labour and materials

Dingley Dell Enterprises Limited

www.dingley-dell.com

Innovators for GRC and Glass Fibre Rebar Applications