WO2009015426A2

WO2009015426A2 - An improved system, method and apparatus for constructing compound curve sandwich shell structures

Info

Publication number: WO2009015426A2
Application number: PCT/AU2008/001095
Authority: WO
Inventors: Christopher Brown
Original assignee: Christopher Brown
Priority date: 2007-07-31
Filing date: 2008-07-30
Publication date: 2009-02-05
Also published as: WO2009015426A3

Abstract

The present invention relates to a system, method and apparatus for constructing dome- shaped buildings and in particular dome-shaped buildings using Sandwich Shell technology. The invention has been developed primarily for use as a system, method and apparatus for: (a) designing Compound Curve Sandwich Shell Structures (buildings) to have the requisite performance characteristics to withstand specified environmental conditions, including: (I) a computer-based modelling facility; and (ii) a 'proof of concept' facility to verify the structure modeled against verified, calibrated data from FEA analysis and/or thermal, light and other geographic data; and (iii) a plan generation facility; (b) constructing lightweight Compound Curve Sandwich Shell Structure (C2S3) buildings to have improved structural ratings and more efficient acoustic and thermal performance qualities under extreme operating conditions, including cyclonic wind loads, extreme temperatures and seismic loads; and (c) constructing C2S3 under specified conditions including extreme conditions; and (d) providing C2S3 in a prefabricated form for transportation and assembly on site. However, it will be appreciated that the invention Is not restricted to this particular field of use.

Description

TITLE

AN IMPROVED SYSTEM, METHOD AND APPATATUS FOR CONSTRUCTING COMPOUND CURVE SHELL STRUCTURES INTRODUCTION

The present invention relates to a system, method and apparatus for constructing dome- shaped buildings and in particular dome-shaped buildings using Sandwich Shell technology.

The Invention has been developed primarily for use as a system, method and apparatus for:

(a) designing Compound Curve Sandwich Shell Structures (buildings) to have the requisite performance characteristics to withstand specified environmental conditions, including:

(i) a computer-based modelling facility; and (ii) a "proof of concept" facility to verify the structure modeled against verified, calibrated data from FEA analysis and/or thermal, light and other geographic data; and (iii) a plan generation facility;

(b) constructing lightweight Compound Curve Sandwich Shell Structure (C2S3) buildings to have improved structural ratings and more efficient acoustic and thermal performance qualities under extreme operating conditions, including cyclonic wind loads, extreme temperatures and seismic loads; and

(c) constructing C2S3 under specified conditions including extreme conditions; and

(d) providing C2S3 in a prefabricated form for transportation and assembly on site. However, it will be appreciated that the invention is not restricted to this particular field of use.

COPYRIGHT NOTICE

This document is subject to copyright. The reproduction, communication and distribution of this document is not permitted without prior consent from the copyright owner, other than as permitted under section 226 of the Patents Act 1990 (Cth). PROBLEMS OF THE PRIOR ART

Dome-shaped buildings constructed using Sandwich Shell technology are known to have faster construction times, lower construction costs, and higher thermal efficiency and structural ratings compared with buildings constructed using known techniques. However, known systems for constructing dome-shaped buildings using shell technology suffer various disadvantages, some of which are outlined below.

A collective disadvantage of known systems is that the performance characteristics of compound curved structures have previously been largely unquantified and based on the investigation of C2S3s for aerospace applications. No known system relies on quantified performance characteristics to determine the appropriate specifications for construction - for example, the ideal thicknesses of the foam core or cement layers, the diameter of the dome structure, the actual geometric design and the size of openings needed to withstand a given wind loading or seismic loading or extreme temperatures.

Known methods for constructing dome-shaped buildings, such as those used by the companies Monolithic and India Dome, include the construction of a reinforced concrete shell using an inflated, preshaped fabric Former made of a thermoplastic polymer such as a polyvinyl chloride (PVC). These methods have the disadvantage of utilising steel-reinforced concrete, which adds weight to the structure and also increases the cost of construction, including the placement of horizontal and vertical steel reinforcing rebar. Steel reinforcement above the concrete foundation suffers the additional disadvantage of being prone to rust.

The known method used by the company Monolithic, referred to above, involves leaving the fabric Former on the concrete shell to serve as a waterproof roof membrane. This method has the disadvantages of:

(a) relying on the integrity of the fabric Former to keep water out; (b) requiring an exterior coating (e.g. chain-link reinforced concrete) to protect the fabric Former, which can increase costs and construction times, depending on the coating used; and (c) lacking a structural coating on the exterior surface of the Former to fireproof, strengthen and protect the Former.

One known method, such as that used by India Dome referred to above, involves applying one layer of steel-reinforced concrete on the outer surface of a fabric (balloon) Former, then removing the Former and applying another layer of concrete on the interior of the dome. This method has the disadvantages of: (a) lacking the Insulating layer of foam; and

(b) requiring a layer of concrete to be adhered to the exterior surface of the balloon

Former, which is exposed to the elements (e.g. direct sunlight, wind) during construction. In some circumstances, this can negatively affect the quality of the concrete curing, because atmospheric conditions can cause inconsistent or uneven curing, resulting in crazing and cracking of the concrete.

Another known method used by companies in USA and India Involves constructing sandwich panels using fibreglass. The sandwich panels are made from a polyurethane foam core with two layers of fibreglass bonded with traditional two-pack resin, as used in a similar fashion to boat-building and surfboard construction. Dome-shaped buildings made from fibreglass sandwich panels are lighter and smaller and have different structural characteristics than dome-shaped buildings constructed from Sandwich Shell Panels made from glass fibre reinforced cement (GRC). The finish is also very different, with the former domes having the appearance of fibreglass.

Known methods of building with lightweight (or thin shell) sandwich panels involve applying reinforcement (e.g. wire mesh, glass fibre reinforcement) to the inner and outer surfaces of a foam core of the sandwich panel such as described in AU Patent No 551323. ln this earlier system, the mesh is embedded into the foam around the base as part of the tie-down system. The mesh extends out of the foundation and extends up around 400mm. This is different from the reinforcement (e.g. GRC) that is applied to the inner and outer surfaces of the foam.

Despite the reinforcement of the actual panels, certain structural weaknesses exist in the construction, including: (a) the lightweight nature of the panels makes it difficult to secure elements of the building, including securing the dome structure to the slab foundation and securing the frames of openings to the panels. The connections between elements can be compromised under certain stresses — for example, known techniques secure the panel to the foundation using a mesh embedded into the foam core (which is a serni- structural material). The mesh has the potential to pull out of the foam or cause the foam to fracture; and

(b) the presence of additional reinforcement around windows, doors or other openings does not structurally connect into the opening frame, which could separate from the panel under stress.

Known methods for constructing dome-shaped buildings using shell technology require the construction of at least one layer of the shell to be completed from the outside of the dome, which can be a serious disadvantage when building on-site in disaster areas or in extreme weather conditions.

There are no known methods for prefabricating a full Monolithic Domeshell and transporting it for assembly on site. Known methods for prefabricating dome-shaped buildings such as described in US Patent No. 4965970 involve the use of prefabricated panels. However, the domes described in this patent do not involve a structural sandwich panel system and are not necessarily permanent structures. They will not necessarily meet building specifications without the addition of cement coatings. Further, there is no provision for tying the panels to the ground. Rather, the panels sit on a temporary PVC circular track which is screwed down onto its supporting platform. This is not an adequate system of holding the completed shell to the ground. This is because the lightweight shell may be blown off Its supporting track. US Patent No. 4965970 makes reference to using a concrete foundation for permanent situations, although it does not provide any obvious structural means of hold down. Further, the specification does not provide detail about how to lift, handle and assemble such panels, which are all difficult to perform.

The prefabricated panel described in US Patent No. 4965970, although describing a lightweight material, will be too heavy and or awkward for handling without machines.

Lifting and manoeuvring a prefabricated panel requires a system that both:

(a) supports the panel from stress loads encountered during handling; and

(b) has Identified balance points for lifting to hold the panel in the desired plane or attitude.

The present invention provides an improved means of connection without the need for casting inside and outside. Longitudinal stresses in the present invention are distributed more evenly with better corresponding structural performance. This is achieved by various means including a multiple bolting system that clamps or stitches together the pa nels. Such clamping systems are not used In the known systems.

The present invention enables prefabrication and onsite fabrication of a dome-shaped building using Sandwich Shell technology. The Domeshell according to invention is rated for cyclonic conditions, thermal qualities and for other characteristics encountered in extreme conditions using finite element analysis and other methodologies. This enables Domeshell construction for specified conditions and circumstances.

The structural disadvantages of US Patent No. 4965970 are circumvented due to improved reliance on the structural qualities of the Sandwich Panel in the compound curve (GRC/polyurethane sandwich in the preferred embodiment) and providing an improved system of permanent structural tie down. The invention also provides a mechanism for manoeuvring the prefabricated Domeshell, including a system for lifting and transportation of a fully prefabricated Monolithic Domeshell. OBJECT OF THE INVENTION

It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

According to one aspect of the present invention there is provided a system for constructing a compound curve sandwich shell structure (C2S3) including:

(a) a construction means for constructing a Sandwich Panel, wherein said construction means includes: i. a Former; Ii. Mesh, wherein said Mesh is made of any suitable self-supporting material, including wire or glass; iii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material, including glass or glass fibre; and iv. Foam, wherein said construction means involves constructing all layers of said

Sandwich Panel from Inside said Former; and

(b) a securing means for securing said Sandwich Panel to a foundation , wherein said securing means Includes: i. a number of continuous links for assisting to secure said'CΣSS building to said foundation, wherein said continuous links are:

A. spaced at intervals around the perimeter of said foundation;

B. embedded in said foundation at one end;

C. embedded in said Sandwich Panel of said C2S3 at an opposing end, such that each said continuous link straddles the join between said foundation and said Sandwich Panel; ii. a first rod, wherein said first rod is threaded through said ends of said continuous links embedded in said foundation; iii. a second rod, wherein said second rod is threaded through said opposing ends of said continuous links embedded in said Sandwich

Panel; Iv. Mesh, wherein said Mesh:

A. at least partially covers an interior surface of said Sandwich Panel;

B. at least partially covers an outer surface of said Sandwich Panel; and C. is folded under said rod embedded in said Sandwich Panel such that said Mesh forms a continuous belt under said second rod and secures it into said Reinforced Cement at the point of contact with said foundation.

According to another aspect of the present invention there is provided a system for constructing a portable C2S3 including:

(a) a construction means for constructing a Sandwich Panel, including: i. a Former; ii. Mesh, wherein said Mesh is made of any suitable self-supporting material, including wire or glass; iii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material including glass or glass fibre; and iv. Foam, wherein said portable C2S3 is constructed off-site for subsequent transport and assembly; and (b) a lifting frame for lifting said C2S3;

(c) a transport frame for transporting said C2S3; and

(a) a hold-down meansfor securing said portable C2S3 to a foundation .

According to a further aspect of the invention there is provided a computer-based system for modelling a C2S3 including a calculating means for calculating optimal specifications required to meet specific requirements in given environmental conditions, wherein said specifications include:

(a) geometry of said C2S3, including diameter;

(b) thickness of one or more of the following: i. an internal coating of Reinforced Cement of a Sandwich Panel; ii. an external coating of Reinforced Cement of said Sandwich Panel; (c) thickness of a Foam core of said Sandwich Panel;

(d) size of one or more openings, wherein said opening(s) include(s) a door, a window, a skylight, a louver, such that information derived from calibrated models of performance characteristics, as obtained from finite element analyses and like analyses of C2S3 under identified stresses, are used by said calculating means for calculating said optimal specifications.

According to yet another aspect of the invention, there is provided a system for constructing a compound curve sandwich shell structure (C2S3) including:

(a) means for calculating a specified thickness of one or more of the following: i. a first internal coating of Reinforced Cement; ii. a layer of Foam; iii. a final coating of Reinforced Cement, required to withstand specified environmental conditions;

(b) means for attaching a Former to a Platform; (c) Mesh, for laying on interior surface of said Former;

{d) means for applying said first internal coating and said final coating of Reinforced Cement within said Former such that said Mesh is encased in both said coatings of Reinforced Cement;

(e) Foam; and (f) means for applying Foam to first coating of Reinforced Cement within said

Former such that said Foam forms the core of a Sandwich Panel, such that all three layers of said Sandwich Panel are constructed from within said Former.

According to still a further aspect of the invention, there is provided a system for designing dome-shaped buildings to withstand specific conditions, including

(a) a data repository, wherein said data repository includes data in 3 centralised database or a distributed file system accessible over the internet, wherein said data includes: i. a building element, including: A. a Domeshell structure; B. an opening, including a window, a door, a skylight, a louver or the like; ii. a pictorial representation of each said building element, including a three dimensional representation of each said building element; iii. technical specifications for each said building element, including size and shape; iv. structural performance characteristics for each said building element; and (b) a search facility that enables said data repository to be searched by means including one or more of the following: i. type of said building element; ii. size of said building element; iii. shape of said building element; iv. a performance characteristic (e.g. by cyclone rating, earthquake rating).

According to another aspect of the invention, there is provided a method for constructing a compound curve sandwich shell structure (C2S3) including the steps of:

(a) constructing a Sandwich Panel using a Former, wherein said Sandwich Panel includes: i. Mesh, wherein said Mesh is made of any suitable self-supporting material, including wire or glass; ii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material, including glass or glass fibre; and iii. Foam, wherein all layers of said Sandwich Panel are constructed from inside said

Former; and

(b) securing said Sandwich Panel to a foundation using a securing means, wherein said securing means includes: i. a number of continuous links for assisting to secure said C2S3 building to said foundation, wherein said continuous links are:

A. spaced at intervals around the perimeter of said foundation; B. embedded in said foundation at one end;

C. embedded in said Sandwich Panel of said C2S3 at an opposing end, such that each said continuous link straddles the join between said foundation and said Sandwich Panel; ii. a first rod, wherein said first rod is threaded through said ends of said continuous links embedded in said foundation; iii. a second rod, wherein said second rod is threaded through said opposing ends of said continuous links embedded in said Sandwich Panel; iv. Mesh, wherein said Mesh:

A. at least partially covers an interior surface of said Sandwich Panel;

According to yet a further aspect of the invention, there is provided a method for constructing a portable C2S3 including the steps of:

(a) constructing a Sandwich Panel using a Former, wherein said Sandwich Panel includes: i. Mesh, wherein said Mesh is made of any suitable self-supporting material, including wire or glass; ii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material including glass or glass fibre; and iii. Foam, wherein said portable C2S3 is constructed off-site for subsequent assembly on-site; and

(b) using a lifting frame to lift said portable C2S3;

(c) using a transport frame to transport said portable C2S3; and

(d) securing said portable C253 to a foundation.

According to a further aspect yet of the invention, there is provided a method for modelling a C2S3 including the step of calculating optimal specifications required to meet specific requirements in given environmental conditions, wherein said specifications include: (a) geometry of said C2S3, including diameter;

(b) thickness of one or more of the following: i. an internal coating of Reinforced Cement of a Sandwich Panel; ii. an external coating of Reinforced Cement of said Sandwich Panel;

(c) thickness of a Foam core of said Sandwich Panel; (d) size of one or more openings, wherein said opening(s) include(s) a door, a window, a skylight, a louver, such that information derived from calibrated models of performance characteristics, as obtained from finite element analyses and like analyses of C2S3 under identified stresses, are used to calculate said optimal specifications.

According to still another aspect of the invention, there is provided a method for constructing a compound curve sandwich shell structure (C2S3) including the steps of: (a) calculating a specified thickness of one or more of the following: i. an internal coating of Reinforced Cement; ii. a layer of Foam; iii. a final coating of Reinforced Cement, required to withstand specified environmental conditions;

(b) attaching a Former to a Platform;

(c) laying Mesh on the interior surface of said Former; {d) applying said internal coating and said final coating of Reinforced Cement within said Former such that said Mesh is encased in both said coatings of Reinforced Cement;

(e) applying Foam to interior coating of Reinforced Cement within said Former such that said Foam forms the core of a Sandwich Panel, such that all three layers of said Sandwich Panel are constructed from within said Former.

According to a further aspect of the invention, there is provided a method for designing dome-shaped buildings to withstand specific conditions, including the steps of:

(a) accessing a data repository, wherein said data repository includes data in a centralised database or a distributed file system accessible over the internet, wherein said data includes: i. a building element, including:

A. a Domeshell structure;

B. an opening, including a window, a door, a skylight, a louver or the like; ii. a pictorial representation of each said building element, including a three dimensional representation of each said building element; iii. technical specifications for each said building element, including size and shape; iv. structural performance characteristics for each said building element; and

(b) using a search facility to search said data repository by means including one or more of the following: i. type of said building element; ϋ. size of said building element; iii. shape of said building element; iv. a performance characteristic (e.g. by cyclone rating, earthquake rating).

According to still a further aspect of the invention, there is provided a connection means for connecting Domeshells, including: (a) one or more ferrules wherein said ferrules:

(i) are positioned along the intersection of a first and a second Domεshell; and (ii) have an exposed end on the outer surface of said first Domeshell; (b) one or more securing means, including a ring nut having a cross hole, wherein said securing means is secured to said exposed end of said ferrule; (c) a bar for threading through said securing means on the surface of said first

Domeshell.

According to yet another aspect of the Invention, there is provided a connection means for connecting building elements to a Sandwich Panel of a Domeshell, including:

(a) a jamb for an opening, wherein said opening includes a window, a door, a skylight or the like;

(b) one or more ferrules, wherein said ferrules sit across a join between said Sandwich Panel and said jamb

(c) one or more securing means, including a ring nut having a cross hole, wherein said securing means is secured to said exposed end of said ferrule; Jd) a first reinforcing bar threaded through said ferrules;

(e) a second reinforcing bar threaded through said securing means within said jamb; and

(f) Reinforced Cement at said join, wherein said Reinforced Cement encases said ferrule and said reinforcing rod threaded through said ferrule.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: FIGURE 1 is a schematic diagram illustrating the inputs for modelling of requirements to specific Sandwich Shell structure construction specifications to provide for required elements (doors, windows, skylights, air flow, etc) and withstand given extremes of environmental conditions (wind, heat, movement, etc) according to the invention;

Figure 2 illustrates a system of protection of Mesh (for example, glass mesh) during construction according to a preferred embodiment;

FIGURE 3 is a cross section of a slab to wall connection in a preferred embodiment;

FIGURE 4 shows a saddle connection according to a preferred embodiment, used here to connect two adjacent Domeshells shown in profile;

Figure 5 is a cross section of the saddle connection detail shown in Figure 4, in close-up. This connection means is used in a preferred embodiment to connect structural elements such as two adjacent Domeshells;

Figure 6 shows a side view of an alternative arrangement for connecting structural elements, such as two adjacent Domeshells. This connection means can also be used to connect modular components and opening configurations, or for custom designs;

Figure 7 is a plan view of the adjacent Domeshells 130 in Figure 6;

Figure 8 is a side view of the connection system shown in Figures 6 and 7, in close-up at the point 131 circled in Figure 7, which is at the level of the rebated upper edge of the openings;

FIGURE 9 illustrates the connection detail in a preferred embodiment between a

Domeshell and a rebated door jamb casting; Figure 10 shows the alternative arrangement for connecting structural elements in Figure 6 being used to connect a window or door hood assembly and a Domeshell Sandwich Panel;

Figure 11 is a close-up of the hood connection detail shown in Figure 10, in plan view;

FIGURE 12 illustrates a ring beam set up for the construction of a portable prefabricated Monolithic Domeshell according to a preferred embodiment;

Figure 13 is a cross section of the ring beam Formwork shown in Figure 12;

FIGURE 14 illustrates a lifting and transport system for a fully prefabricated Monolithic Domeshell according to a preferred embodiment. Shown is a horizontal section of a prefabricated Monolithic Dome, including a door and a window opening. The Domeshell has been fitted with an internal lifting frame, secured to the base beam at equidistant points;

Figure 15 is a cross section of a prefabricated Monolithic Domeshell placed onto a prepared concrete foundation, showing in close-up view an internal lifting point illustrated in Figure 14. A corresponding external lifting point can also be seen;

Figure 16 is a plan view of the ring beam assembly shown In Figures 12 and 13. A lifting ring plate and lifting ring can be seen secured to the external vertical plate;

Figure 17 illustrates the entire prefabricated Monolithic Domeshell shown in

Figures 14 to 16 being lifted and placed on a transport platform on the tray of a truck. The external and internal lifting frames can be seen. Chains secure the Domeshell to the frames. The internal chains connect at a central point inside the Domeshell. A single chain is connected from the central point up through the skylight hole to a crane hook;

Figure 18 illustrates a system for prefabrication of Sandwich Panels in orange-peel segments that can be transported for assembly on site in accordance with one arrangement. Prefabricated panels are constructed using a rigid Former in the shape of an orange peel segment which, when connected together, will form a complete Domeshell;

Figure 19 is a side view of a transport frame used to transport prefabricated orange-peel segment panels in a preferred embodiment. The orange-peel segment panels, lifted by a lifting frame, are stacked one on top of the other on the transport frame. Shown is the final position of a panel segment at the top of a stack of panels sitting on the transport frame. High density foam rubber cushions are used to separate the panels. When fully loaded, the transport frame can be placed on the deck of a truck for transport to site;

Figure 20 is a plan view of the transport frame shown in Figure 19;

Figure 21 illustrates the connection system for bolting together prefabricated orange-peel segments according to a preferred embodiment. The panels are connected by a stainless steel bolting system through a rebated solid edge made from Reinforced Cement {here, GRC), similar to the system illustrated in Figures 6 and 10.

DETAILED DESCRIPTION

A preferred embodiment of the present invention will now be described by reference to the drawings. The following detailed description In conjunction with the figures provides the skilled addressee with an understanding of the invention. It will be appreciated, however, that the invention is not limited to the applications described below.

Definitions of terminology used

The terms defined in Table 1 above are denoted with the use of capitalisation throughout the document. If a term is not capitalised then its plain meaning is to be construed, unless otherwise specified.

The elements of the invention are now described under the following headings:

^' System and method for designing Compound Curve Sandwich Shell structures for given environmental conditions

The present invention provides a system, method and apparatus for tailoring the construction of C2S3 buildings to meet specific requirements in given environmental conditions. Specified requirements include functional purpose built usage requirements (e.g. a surgery) for use in specified conditions (e.g. cyclonic winds, extreme temperatures, unstable land, etcetera)

Figure 1 illustrates schematically the data inputs required For designing and constructing a C2S3 building according to the invention. The client's design criteria (such as desired size, shape and openings) and intended use of the proposed building are referenced by computer against calibrated models of performance characteristics to determine appropriate parameters for construction.

The performance of a building constructed within the defined parameters can then be modelled by computer under various critical loadings and environmental conditions (e.g. gravitational loads, wind loads, uplift loads) using verified finite element analysis (FEA) models.

FEA modelling of the defined parameters enables the optimal building specifications to be determined in order for the proposed building to meet applicable building standards under identified stresses (e.g. cyclones, earthquakes, extreme temperatures). Examples of the variables that may be modelled include: (a) geometry (diameter) of the structure; (b) thickness (internal and external) of the Reinforced Cement layers of the Sandwich

Panel;

(c) thickness of the Foam core of the Sandwich Panel (Foam is used for its thermal qualities along with lightweight self supporting characteristics); and/or

(d) opening slze(s).

The present invention provides a computerised system for referencing proposed building parameters against verified, calibrated structural performance of fibre-reinforced composite material used as a structural support means that has a prescribed strength under specific conditions, and a method of manufacturing such support means. Computer enabled modelling of parameters to optimise building specifications prior to construction are optimised using materials of known qualities under specified conditions. This system also provides the FEA analysis modelling outputs to determine the building specification to enable the structure to withstand specific conditions. These advantages are not provided by known systems for constructing dome shaped buildings using Sandwich Shell technology.

According to a preferred embodiment, there Is provided a system for applying the results of FEA analysis and testing to model dome-shaped buildings and determine structural elements required for a dome-shaped building to withstand specific conditions. The system includes: [a) a data repository (such as a centralised database or distributed file system accessible over the internet) that contains the details, specifications, structural performance characteristics and a pictorial representation (including a three dimensional representation) of each element of a range of modular components such as a Domeshell, and window, door and skylight elements; (b) a search facility that enables the data repository to be searched by

(i) type of modular component such as door openings; (ii) available sizes of modular components; and/or

(iii) performance characteristics (e.g. by cyclone rating, earthquake rating) (c) a computer-based modelling facility whereby a modular component of specified type, size, performance characteristics can be:

(i) selected as an object (including having a three dimensional representation); (ii) pictorialhy placed on a building plan or drawing by dragging and dropping the relevant object on the computer screen (or other form of monitor that permits visualisation of the object); (iii) re-configured or arranged as necessary as additional objects are placed on the building plan or drawing (d) a "proof of concept" facility to confirm and test the structural performance of the overall structure modelled. This includes comparing the proposed Domeshell parameters against: (i) verified, calibrated data obtained from FEA analysis of structural performance; and/or (ϋ) thermal, light and other geographic data such as longitudinal and latitudinal co-ordinates of the proposed construction site, and solar passage at the relevant location;

(e) a plan generation facility whereby plans and other detailed drawings of the finalised, tested Domeshell model can be generated, in print and/or electronic output. This method of stipulating functional requirements to meet both with Domeshell specifications and Domeshell construction under specified conditions is enabled by having an improved system of Domeshell fabrication.

An improved system of fabrication

The present invention provides an improved system, method and apparatus for constructing Domeshells. Known methods for constructing dome-shaped buildings using Sandwich Panels are described in the section "Problems with the Prior Art".

fi) Application of three layers of a Sandwich Panel from inside the Former

According to a preferred embodiment, there is provided means for applying all three layers of the Sandwich Panel from inside the controlled environment of the Former. This has particular advantages when applying thin coatings, because thin coatings are particularly susceptible to the atmospheric conditions, which in turn, impact on the thin coating structural qualities. No known methods for constructing reinforced dome-shaped buildings involve construction of all three layers of the Sandwich Shell Panel from inside an inflated air Former or a rigid Former. The present invention overcomes the disadvantage of known methods, in which at least one coating is applied externally and is thus exposed to the elements, which can severely reduce the quality of curing.

The preferred embodiment utilises a rigid Former or, as with known methods of constructing dome-shaped buildings, a pre-shaped PVC fabric Former (also referred to as a balloon Former or air Former) stretched around the Platform such as a perimeter slab, floor Platform or base-beam Formwork (in the case of a prefabricated complete shell). The formwσrk, including the base beam assemblies, is enabled be arranged in any suitable configuration Including formworks that are:

1. inclined to compensate for non-horizontal terrains, or

2. radiate from a central location to provide for a more spherical dome shaped structure.

In the in situ arrangement of the preferred embodiment, the air Former is secured to a concrete foundation or floor Platform. In the fully prefabricated arrangement, an air Former is secured to the ring beam assembly. In both arrangements the method of securing the air Former in place is the same and will therefore be discussed only in reference to the prefabricated arrangement.

The air Former is stretched around a perimeter base-beam Formwork (or platform in the case of the in situ arrangement). This base-beam Formwork is reversibly secured Indirectly or directly onto the concrete foundation or floor Platform. A strip of material that is soft and easy to bend, such as aluminium, plastic or wood, is fixed over the beading at the base of the balloon Former into the vertical section of the base-beam Formwork (or platform) to hold it in place.

In the preferred embodiment, an aluminium strip clamped over the bottom cord of the balloon Former is riveted through the vertical base-beam Formwork plate. Rope stitched into the perimeter base of the balloon provides a system to hold down the balloon during inflation. The aluminium strip fixed in this way to a perimeter element acts as a hold down for the inflated air Former during inflation. A floor plate is pinned to the slab, holding the outer vertical section of the base-beam Formwork in place. A hanging flap around the position of a door opening will be connected to an air lock system to seal the pressure inside the air Former and for accessing the inside of the air Former. After the air lock is connected, the air Former is inflated. The air Former is left for a period of time to allow the air Former to take up initial stretching prior to commencement of fabrication of trie Sandwich Panel.

Hoses for Reinforced Cement and Foam spray equipment are threaded through the Former via a controlled opening in the air lock system.

Prior to the application of the first layer of Reinforced Cement, Mesh is held in place at the:

1. base beam, under the base beam horizontal steel bar;

2. interior surface of the Former. Here the Mesh is held in place by either having: a. self supporting Mesh such as wire Mesh, or b. fixing the Mesh in place, for example with fibreglass Mesh. This fixing of the Mesh into place may involve a variety of means including holding the mesh in position; as discussed below, such that when the Mesh is will become self supporting;

3. areas of termination of any external hoods (usually located above openings for doors, window, etcetera);

4. termination of the shell at any other location (e.g. a skylight); or 5. any combination of l to 4 above.

The process of fixing the Mesh onto the interior surface of the Former, for example, includes the following; a) fill the Former at the base with Mesh starting at, for example, the base beam rebate; b) apply the GRC to the Mesh; c) move progressively upwards to apply the Mesh followed by the GRC, then once Ihe base has been filled in, move to the next step: d) spray a fine mist coat of render onto the interior surface of the Former such that the Mesh is embedded in the mist so that the mist enables the Mesh (particularly fibreglass Mesh) to become self supporting; then e) spray the GRC onto the seff supported Mesh. Noting that wire mesh is often self supporting and that fibreglass Mesh is often a stiff material, the techniques for enabling the Mesh to become further self supporting vary. For example, the above mist application can be an initial light spraying of GRC, followed by pushing the Mesh into this GRC, then apply a further GRC application such that the Mesh is embedded.

The first layer of Reinforced Cement is applied into the surface of the Mesh. That is, one side of the Mesh will be cast into the first layer of Reinforced Cement. The other side of the Mesh will be cast into the final Reinforced Cement layer after the installation of the Foarn.

It is critical that the flaps of Mesh, which are to be encased in the final layer of Reinforced Cement, are:

1. protected from over-spray of any of the materials (e.g. Foam); and

2. held in correct position to be folded up into the plane of the final coating of Reinforced Cement. Once the first internal coating of Reinforced Cement is applied, Foam is applied with a specified thickness over the first coating of Reinforced Cement. After application of the Foam, the protected flaps of Mesh are released from their temporary protection positions and turned up into place to be encased in the final layer of Reinforced Cement. This principal applies where Mesh is encased in one layer and requires to be also encased in the final layer after the application of the Foam.

The system for protecting the Mesh during construction in the preferred embodiment is illustrated in Figure 2. Shown are:

(a) a Sandwich Shell Panel 30 during construction, including Foam core 32; (b) an inflated air Former 34, fixed to the concrete slab or floor Platform 20 by an aluminium strip 36 clamped over beading 38 at the base of the air Former;

(c) Mesh, 60 in place on the outer surface of the Sandwich Shell Panel 30, for casting into the outer layer of Reinforced Cement 50;

(d) a layer of material such as plywood 42, cut to the correct radius and pinned to the slab or floor Platform 20 and protruding over the base beam rebate (not shown); (e) Mesh 60 to be cast into the inner layer of Reinforced Cement 50 (on the internal surface of the wall panel 30) is folded over the plywood 42 and covered with a suitable protective material 44 to protect the Mesh 60 from contamination during construction;

(f) when the Foam 32 is in place, this part of the Mesh 60 is released from its protective covering and folded back up and encased in the final layer of Reinforced Cement 50.

(U) Use of a fibreglass Former

In an alternative embodiment, there is provided a means to build a prefabricated C2S3, such as a Monolithic Domeshell, using a rigid fibreglass Former instead of a fabric Former. No previously known methods for constructing Domeshells from Sandwich Panels employ a rigid Former such as a fibreglass Former.

The fibreglass Former is a fibreglass mould cast from a completed Domeshell structure. The mould is broken down into panels, which are subsequently bolted together for use as a rigid, self supporting Former. The Sandwich Shell structure can then be constructed in much the same way as with an air Former as discussed previously. However, the fibreglass Former offers the advantages that:

(a) it is very rigid, thereby assisting to ensure a high quality of concrete due to the lack of movement of the Former during curing of the concrete; and (b) it eliminates the need for an air lock, thereby reducing the time for fabrication of the

C2S3.

After completion of the Domeshell structure, the fibreglass Former is removed and can be re-used. Fibreglass moulds are less fragile than fabric Formers, so are better suited to re-use and require less maintenance or care than fabric Formers.

A technique for using a rigid Former is also described in relation to the construction of prefabricated panels of a Domeshell in orange-peel segments. An improved system of hold-down

The invention provides an improved system of hold-down and of securing the structural elements of C2S3 buildings for in situ construction.

Known methods for building dome shaped buildings using shell technology use wire or other mesh to secure the shell (panels) to a foundation, such as a floor slab. One example is described in AU Patent Application No 2002300738, in which a mesh material is secured to a foundation at the desired location of a sandwich panel and then embedded within a structural {reinforced cement) coating applied to one or both faces of the sandwich panel. The mesh material is secured to the floor Platform by a means of a clamping beam (a steel U-channel). The mesh is placed underneath the clamping beam such that the mesh extends to at least one side of the beam. The clamping beam sits within a rectangular rebate that typically runs around the perimeter of the building and is approximately the width of the panel. The clamping beam is anchored to the slab by bolts passed through the beam at spaced intervals.

The preferred embodiment provides an improved system of hold-down, or at least an alternative, to known methods for in situ construction. Figure 3 is a cross section of a slab- to-wall connection 10 in a preferred embodiment. The reinforced concrete slab 20 is constructed to engineer's detail. As with known systems, a rectangular rebate runs around the perimeter of the building and the Sandwich Panel 30 sits within the rebate. However, the steel U-channel of known systems such as the one described above is no longer used. Instead the Sandwich Panel 30 is secured to the foundation by the following means: (a) a number of continuous links 40 are spaced at intervals around the perimeter; {b) one end of each continuous link 40 is embedded into the concrete foundation 20;

(c) the other end of each continuous link 40 is embedded in the Reinforced Cement layer 50 that encases the Sandwich Panel 30;

(d) in this way, each continuous link 40 straddles the join between the concrete foundation 20 and the Sandwich Panel wall 30, in a direction substantially parallel with the wall 30; (e) each continuous link 40 has two steel reinforcing rods 70 threaded through it, at substantially opposing ends of the continuous link 40 - that Is, one rod 70 through the end of the continuous link 40 that will be embedded in the foundation and one rod 70 through the end that will be encased in the "thickening" 50 of Reinforced Cement, such as glass fibre reinforced cement (GRC), at the base of the Sandwich Panel 30;

(f) Mesh 60 is folded under the steel rod 70 at the base of the Sandwich Panel 30;

(g) the continuous link 40 passes through this Mesh 60;

(h) one end of the Mesh extends up the outer surface of the wall 30 (that is, the surface of the wall 30 at the periphery of the building) and is encased into the outer layer of Reinforced Cement;

(i) the other end of the Mesh extends up the interior surface of the wall 30 and is cast

Into the inside layer of Reinforced Cement;

(j) the Mesh 60 thereby forms a continuous belt under the steel rod 70 and bonds it into the rest of the Reinforced Cement that forms a relatively small beam at the point of contact with the slab or thickening (that thickening which encases the steel rod 70 and that is sitting in the rebate).

The preferred embodiment provides an improved method of hold-down from known methods for in situ construction because: (a) it dispenses with the need for a steel U-channel, which is fiddly and difficult to roll form to sit neatly in the rectangular rebate at the periphery of building foundation; and

(b) it minimises (or virtually eliminates) the use of steel above the slab level, saving materials, time and labour.

An improved system of connecting structural elements

The invention provides an improved means of connecting:

(a) adjacent Domeshells; and (b) structural elements to a Domeshell (such as door, window or skylight frames). Known methods suffer the disadvantages discussed in the section "Problems with the prior art", including:

(a) difficulty in securing elements such as door and window frames to the lightweight material that makes up a Sandwich Panel; and (b) lacking a structural connection between these elements and the Domeshell that can withstand environmental stresses.

(i) System for connecting adjacent Domeshells

Figure 4 is a saddle connection between two adjacent larger Domeshell structures 130 in profile according to a preferred embodiment. Figure 5 Is a cross section of the saddle connection detail, shown at the point 125 circled in Figure 4.

Referring to Figure 5, the Sandwich Panel 30 of a first Domeshell 130 (in this example, a larger Domeshell) Is secured to a second Domeshell 120 (in this example, a smaller Domeshell) using one or more threaded ferrules 140 positioned along the intersection of the larger Domeshell 130 with the smaller Dαmeshell 120. Each ferrule 140 is in a substantially perpendicular direction to the larger Domeshell 130 wall. Ferrule is used here to describe the metal ring, nut or cap put round the end of a bolt, threaded rod, etc., to hold the bolt/rod in place for strength and/or protection.

First, the larger Domeshells 130 are built and the Former is removed from each Domeshell. At that point, the ferrules 140 positioned along the intersection become exposed to the outer surface of the Domeshell. A ring nut 170 is screwed to the exposed end of each ferrule 140. Each ring nut 170 has a cross hole and a steel bar 160 is threaded through the cross holes on the outside surface of the larger Domeshell. Once the ring nuts on the outside of both larger Domeshells 130 have been threaded through with steel bar, the air Former for the intersecting Domeshell is fixed along the line where the ferrules and steel bar are sitting. Once this is complete, the air Former is then sealed to the slab and around its perimeter and inflated in the same way as air Formers for the larger Domeshells. This enables the Sandwich Panel of the intersecting Domeshell to be constructed inside this cavity, in the same manner as described above for in s/tυ construction of Sandwich Shells.

Structurally, there will be a rubber joint system between intersecting Domeshells - shown in Figure 5 at 150. This will enable movement, expansion and contraction without one Domeshell causing structural damage to itself or to the other Domeshell (or joining element) when movement occurs.

This saddle connection between adjacent Domeshell structures also has a foam coving 190 to form a gutter and a double elastomeric membrane for additional sealing and waterproofing qualities.

Figures 6 to 8 show an alternative arrangement for connecting structural elements, such as two adjacent Domeshells. This connection means can also be used to connect modular components and opening configurations, or for custom designs where a variety of Domeshells and/or elements are connected. Two adjacent Domeshells 130 are illustrated in Figures 6 to 8, each having a pre-formed opening 122 (e.g. a doorway) with matching or non matching opening size.

Figure 6 is a side view of the connection system 124 being used to connect two adjacent Domeshells 130.

Figure 7 is a plan view of the adjacent Domeshells 130 in Figure 6. Figure 8 is a side view of the two adjacent Domeshells 130 in Figures 6 and 7; the connection system is shown in close-up at the point 131 circled in Figure 7, which is at the level of the rebated upper edge of the openings.

At the terminating of the opening 122 is formed a rebated edge in solid Reinforced Cement, forming a seat 126; this is shown in Figures 6. The seat 126 has a continuous strip of compressible rubber 127 fixed to its surface (Figure 8). A pre-formed (upside-down) U- shaped panel 128 is placed to sit onto the seat 126 formed in the Domeshell openings (Figure 8). These elements are tied together by the use of continuous bolts 129 through the solid materiarat the point of connection. These bolts 129 clamp or tie the connection piece 128 to the corresponding separate Domεshells 130. The base of the connection element, shown in Figure 6 at 133, is bolted to the slab or platform at ferrules cast into the base thickening.

The connection means illustrated in Figures 6 to 8 is similar to the connection means used to connect adjacent prefabricated Sandwich Panels of a portable Domeshell made in orange-peel segments for transportation and assembly on site.

(H) Connecting other building elements to the Domeshell: openings A similar connection mechanism to the saddle connection means described above can also be used to anchor other building elements to the Domeshell structures including windows, skylights, louvers and/or jambs.

For example, Figure 9 illustrates the connection detail in a preferred embodiment between a Domeshell structure and a rebated door jamb casting 220. A ply or fiberglass Former is used to create jamb rebates for openings such as doors. Steel bars are connected to steel castings (ferrules) to provide extra reinforcement. Shown in Figure 9 is the Sandwich Panel 30 of a C2S3 secured to a rebated door jamb using one or more threaded ferrules 140. Each ferrule 140 has a steel ring nut 170 at one end (within the rebated door jamb casting 220) and a cross hole 170 at the other end (within the Sandwich Panel 30): The ferrules 140 sit across the Join between the Sandwich Panel 30 and the rebated door jamb casting 220. There is a Reinforced Cement thickening at the join, which encases the ferrule 140 and a reinforcing steel rod 160 threaded through the ferrule 140. A reinforcing rod 160 is also threaded through the steel ring nut 170 within the door jamb casting 220. The gap 230 in the Sandwich Panel shown in Figure 9 is as required for the opening plus door size. Shown also is a thickening of Reinforced Cement 240 at the termination (stop-end) of the hood opening. Encased in the thickening 240 is Mesh 250 extending each side of the end of the hood opening. The thickening at the end creates a beam around the opening edge. Figures 10 and 11 show the connection details between a window or door hood assembly and the Domeshell Sandwich Panel in an alternative arrangement. Figure 10 is a plan view of a window or door hood set out 430, showing:

(a) a Domeshell Sandwich Panel 30 with a rebated edge 460 made from solid Reinforced

Cement; (b) an opening 230 for a window or door - in this example, a sliding door;

(c) the sliding door 440; and

(d) a prefabricated Reinforced Cement external hood profile 450.

Figure 11 is a close-up of the hood connection detail shown in Figure 10, in plan view. The details are as described for connecting two adjacent Domeshells, in the section above. A compressible rubber seal 127 can be seen in Figure 11, between the Sandwich Panel's rebated edge 460 and the external hood profile 450. Self tapping masonry anchors 470 fix the external hood profile 450 to the edge of the Sandwich Panel 30. Shown also in this

Figure are the connection details for the face fixing sliding door system 480, which are bolted to the solid Reinforced Cement of the external hood profile 450.

System for prefabricating and transporting a portable Monolithic Domeshell for assembly on site

According to a preferred embodiment there Is provided a system for fully prefabricating and transporting for assembly on site a Domeshell, for example of a Monolithic form, made from lightweight Sandwich Panels with high structural ratings.

(I) Construction of a prefabricated Monolithic Domeshell Figures 12 and 13 illustrate a ring beam assembly 80 for the construction of a portable, prefabricated Monolithic Domeshell according to a preferred embodiment of the invention. Figure 12 is a perspective view of assembled Formwork 80 creating the casting for a ring beam of a C2S3. The assembled Formwork 80 is temporarily attached to a level working platform - for example, a concrete platform 20. A balloon Former is fixed to the outer vertical section of the ring beam assembly. The attachment of the balloon Former to the ring beam is the same as the method for attaching a balloon Former to a concrete slab when the Sandwich Shell Panels are constructed in situ.

Figure 13 is a cross section of the ring beam Formwork 80, illustrating:

(a) a completed Sandwich Panel 30 sitting in a channel 90 formed by the ring beam formwork 80;

(b) an internal vertical plate 86 and external vertical plate 88 lining the sides of the centre channel 90 and sitting adjacent to and parallel with the internal and external surfaces, respectively, of the Sandwich Panel 30;

(c) a steel bolt is fixed through the external vertical plate and into a threaded ferrule 100 holding the ferrule in position for placement of the Reinforced Concrete;

(d) the internal vertical plate 86 is supported by a brace 94.

The vertical plates 86, 88 have two functions:

(a) they hold the vertical sections of the ring beam Former 80 in place; and

(b) they provide a means for holding the cast in situ threaded ferrules 100 around the base beam; these ferrules 100 are used for lifting the entire prefabricated Monolithic

Domeshell when complete. The ferrules 100 are subsequently used for tie down when the prefabricated Monolithic Domeshell is placed into the rebate of a prepared concrete foundation. The connection to the concrete slab is through the ferrules 10O, which are bolted to the slab (as described in the tie down methodology previously).

An inner floor plate 82 and an outer floor plate 84 can also be seen in Figure 13. The floor plates 82, 84 are continuous around the ring beam Formwork 80 and horizontal with the floor. The floor plates are pinned to the slab, holding the vertical sections forming the ring beam in place. A steel bar 110 in the centre channel 90 of the ring beam is threaded through the ferrules 100, securing all ferrules 100 around the ring beam. Mesh 112 is folded under the bar 110 in the centre of the ring beam channel 90. The outside of the Mesh is encased into the outer layer of Reinforced Cement of the Sandwich Panel 30; the inside Mesh is cast into the insider layer of Reinforced Cement. (H) System of lifting and transporting a portable Monolithic Domeshell

Figures 14 to 17 illustrate a lifting and transport system for a fully prefabricated Monolithic Domeshell according to a preferred embodiment of the invention. Figure 14 is a horizontal section of a prefabricated Monolithic Domeshell, including a door opening 132 and a window opening 134. The prefabricated Domeshell 130 is not yet transported to its intended location, and so lacks a floor at this stage. Consequently, it is susceptible to damage from rotational and lateral stresses during movement. In order to protect the Domeshell and to hold it stable during lifting and transportation, an internal lifting frame 136 Is secured to the base beam on the ring beam Formwork 80 at equidistant points around the base beam. Shown in Figure 14 is a preferred embodiment in which the internal lifting frame 136 is bolted to ferrules 100 at four equally spaced points around the base beam of the ring beam Formwork 80.

A close up of the lifting points is provided in Figure 15, which shows a cross section of a prefabricated Domeshell 130 placed onto a prepared concrete foundation 20. The Sandwich Panel 30 of the Domeshell 130 is positioned in a rectangular rebate that runs around the perimeter of the foundation 20. Two threaded ferrules 100 can be seen. One protrudes from the external surface of the Domeshell wall 30; the other protrudes from the interior surface of the Domeshell wall 30.

The ferrules 100 are also seen in place in Figure 16, which is a plan view of ring beam Formwork 80 in close up. The ferrules 100 are threaded by a steel bar 110 In the centre channel 90 of the ring beam. The ferrules 100 on the external vertical ring beam surface (two are shown in this Figure) are used as external lifting points and for tie-down onto the slab, as described above. A lifting ring plate 92 and attached lifting ring 96 can be seen secured to the embedded ferrules at the external vertical surface of the ring beam.

The ferrules 100 on the internal vertical surface of the ring beam (only one can be seen in this Figure) are used as internal points to hold the Domeshell stable during transportation.

Returning to Figure 15, a heavy steel -braced frame 136 is bolted to the ferrules 100 on the internal vertical plate of the base beam to hold the Domeshell structure together (since it lacks a floor at this point) and to keep the structure stable during transport. For every external lifting ring 96, there is a corresponding internal tie (lifting ring) 138 inside the Domeshell.

Figure 17 is a cross section of a fully prefabricated Monolithic Domeshell suspended off the ground in a preferred embodiment. An internal lifting frame 136 secures the base of the Domeshell 130. Also shown is an external lifting frame 148 above the Domeshell 130.

After the internal lifting frame 136 is bolted into position at the base of the ring beam of the Domeshell 130, chains 142 of equal length are attached to the internal lifting rings 138. In the preferred embodiment, there are four internal lifting rings 138 and therefore four chains 142 of equal length. The chains 142 also connect at a central point 144 inside the Domeshell. A single chain 145 is connected from the central point 144 up through the skylight hole 146 to the crane hook (not shown).

In the preferred embodiment, the Domeshell 130 is also secured to an externa! lifting frame 148 by means of four chains of equal length 143. Four external lifting ring plates 92 are bolted to the base beam at equal intervals around the base beam. Figure 17 shows the corresponding positions of an external lifting ring 96 on the base beam and an internal lifting ring 138 on the internal lifting frame 136. A chain 143 passes through an external lifting ring 96 on the external lifting ring plate 92 to attach the Domeshell 130 to a lifting lug 147 on the external lifting frame 148.

The external lifting frame 148 is positioned to clear the top of the Domeshell 130 when the load is taken up. The entire Domeshell 130 is lifted and placed on a transport platform on the tray of a truck. In the preferred embodiment, the transport platform is made from sufficient standard uniform hardwood pallets tied together to exceed the diameter of the base beam. The Domeshell 130 is tied down to the truck, for example using webbed straps. System of prefabricating and transporting Sandwich Panels in orange-peel segments The present invention further provides a means for fabrication of panels in orange-peel segments that can be transported for assembly on site. Panels can be prefabricated using the same system and methods described above.

Figure 18 illustrates a perspective view of construction of a prefabricated dome-shaped building 260 in orange-peel segments. Prefabricated Sandwich Panels 270 are constructed using a rigid Form in the shape of an orange peel segment which, when connected together, will form a complete Domeshell. The rigid Form is secured to a mobile steel frame. The side edges of the segment Form will have a rebated solid edge to provide a thickening seat for the panels to connect by stainless steel bolting system (the connection system 360 is shown in Figure 21) through the edge. The edge thickening at the sides and at the base beam will have stainless steel ferrules cast Into the thickening at appropriate spacings for fixing to a lifting frame 280 for handling and assembly of the segments onto the slab on site.

Cast ferrules in the base section of each panel 270 are used for tie down fixing the panels to the slab. Openings for windows and doors have a cast rebate section for fitting and fixing of separately cast hood systems, which are installed after the assembly of the shells (as in Figures 10 and 11).

Once each panel 270 is complete and satisfactorily cured it is bolted to a steel lifting frame 280 which is in the shape of the panel. The lifting frame 280 is used to lift the panel 270 off the rigid mould segment and place it on a rigid steel transport frame. The lifting frame 280 can then be disconnected from the panel 270 and fixed onto a further panel 280 for lifting. Multiple panels 270 can be stacked on a transport frame, as discussed below.

Figures 19 and 20 are side and plan views, respectively, of a transport frame 300. The preferred embodiment of the transport frame 300 includes:

(a) a support rail 310 that supports a first panel (not shown) placed onto the transport frame 300;

(b) two removable posts 320 (see Figure 20) that sit on either side of the orange peel segment panel 270, towards the apex of the segment assembly;

(c) a removable post 330 that sits at the base of the orange peel segment panel 270; (d) a lock or rig pin 340 (see Figure 19) towards the base of each removable post 320,

330, which enables the height of the post to be adjusted; (e) a base frame 350.

In the preferred embodiment, up to eight orange peel segment panels 270 may be stacked one on top of the other on the transport frame 300. Figure 19 shows the final position of a prefabricated orange peel segment panel 270 at the top of a stack of panels 270 sitting on the transport frame 300. High density foam rubber cushions are placed between each panel. When fully loaded, the transport frame 300 can be placed on the deck of a truck for transport to site.

Assembly of the Domeshell using the prefabricated Sandwich Panels takes place by lifting and placing each orange peel segment panel 270 in position on the rebated section of the Floor Platform (refer Figure 18). When each orange peel segment panel 270 is in the correct position and before the release of the lifting frame 280, the orange peel segment panel 270 is temporarily propped with adjustable rated steel props. When the final orange peel segment panel 270 is in place, the panels 270 are bolted together.

Figure 21 illustrates the panel segment connection system 360. Shown are two adjacent prefabricated Sandwich Panels 270, each with: (a) a lightweight concrete or Foam core 380;

(b) Reinforced Cement 420 cast on the internal and external surfaces of the concrete or Foam core 380, as well as a "thickening" of Reinforced Cement 420 at the end of the core 380;

(c) a rebated edge 370 forming a "seat".

The rebated edge panel sections 370 are seated in place with a compressible rubber strip 430 in between the two panel seats and a polγurethane waterproof seal 400 along the remainder of the adjoining panel edges. The panels are bolted together by means of close- spaced stainless steel countersunk head nuts and bolts 390 through the Reinforced Cement 420 at the point of connection. The connection system for adjacent prefabricated orange- peel panel segments is similar to the connection system for connecting structural elements such as two adjacent Domeshells, or door/window hood connections to the dome Sandwich Shell Panel.

Once all the prefabricated panels are fixed together in this way the temporary props can be released. The external joint between the panels 270 is then sealed with a high grade waterproofing material 410.

Although this invention has been described with reference to specific examples, it will be appreciated by those skilled within the art that the invention may be embodied in many other forms.

Claims

The claims defining the invention are as follows:

1. A system for constructing a compound curve sandwich shell structure (C2S3) including:

(a) a construction means for constructing a Sandwich Panel, wherein said -construction means includes: i. a Former; il. Mesh, wherein said Mesh is made of any suitable self- supporting material, including wire or glass; ill. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material, including glass or glass fibre; and iv. Foam, wherein said construction means involves constructing all layers of said Sandwich Panel from inside said Former; and £b) a securing means for securing said Sandwich Panel to a foundation , wherein said securing means includes: i. a number of continuous links for assisting to secure said C2S3 building to said foundation, wherein said continuous links are: A. spaced at intervals around the perimeter of said foundation; B. embedded in said foundation at one end; C. embedded in said Sandwich Panel of said C2S3 at an opposing end, such that each said continuous link straddles the join between said foundation and said Sandwich Panel; ii. a first rod, wherein said first rod is threaded through said ends of said continuous links embedded in said foundation; iii. a second rod, wherein said second rod is threaded through said opposing ends of said continuous links embedded in said Sandwich Panel; iv. Mesh, wherein said Mesh: A. at least partially covers an interior surface of said

Sandwich Panel;

B. at least partially covers an outer surface of said Sandwich Panel; and

C. is folded under said rod embedded in said Sandwich Panel such that said Mesh forms a continuous belt under said second rod and secures it into said Reinforced Cement at the point of contact with said foundation.

A system for constructing a C2S3 according to claim 1, wherein said Former includes a Former made from a rigid material including fibreglass.

3. A system for constructing a C2S3 according to claim 2, wherein said Former is a fibreglass mould.

4. A system for constructing a C2S3 according to claim 3, wherein said fibreglass mould is constructed of panels fixedly engaged together for use by means including belts.

5. A system for constructing a portable C2S3 including:

(a) a construction means for constructing a Sandwich Panel, including: i. a Former; ii- Mesh, wherein said Mesh is made of any suitable self- supporting material, including wire or glass; iii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material including glass or glass fibre; and iv. Foam, wherein said portable C2S3 is constructed off-site for subsequent transport and assembly; and

(b) a lifting frame for lifting said C2S3;

(c) a transport frame for transporting said C2S3; and (d) a hold-down means for securing said portable C2S3 to a foundation.

6. A system for constructing a portable C2S3 according to claim 5, wherein said portable C2S3 is a monolithic Domeshell.

7. A system for constructing a portable C2S3 according to claim 6, wherein said said lifting frame includes:

(a) an internal lifting frame, to secure the base of said Domeshell; and

(b) an external lifting frame.

8. A system for constructing a portable C2S3 according to claim 5, wherein said portable C2S3 is a Domeshell fabricated in segments, wherein said segments are connected together to form a complete Domeshell.

9. A system for constructing a portable C2S3 according to claim 8, wherein said transport frame is enabled to carry one or more said segments arranged in a stack for transport.

10. A computer-based system for modelling a C2S3 including a calculating means for calculating optimal specifications required to meet specific requirements in given environmental conditions, wherein said specifications include:

(a) geometry of said C2S3, including diameter;

(c) thickness of a Foam core of said Sandwich Panel; (d) size of one or more openings, wherein said opening(s) include(s) a door, a window, a skylight, a louver, such that information derived from calibrated models of performance characteristics, as obtained from finite element analyses and like analyses of C2S3 under identified stresses, are used by said calculating means for calculating said optimal specifications.

11. A system for constructing a compound curve sandwich shell structure (C2S3) including:

(a) means for calculating a specified thickness of one or more of the following: i. a first internal coating of Reinforced Cement; ii. a layer of Foam; iii. a final coating of Reinforced Cement, required to withstand specified environmental conditions; {b) means for attaching a Former to a Platform;

(c) Mesh, for laying on interior surface of said Former;

(d) means for applying said first internal coating and said final coating of Reinforced Cement within said Former such that said Mesh is encased in both said coatings of Reinforced Cement; (e) Foam; and

(f) means for applying Foam ,to first coating of Reinforced Cement within said Former such that said Foam forms the core σf a Sandwich Panel, such that all three layers of said Sandwich Panel are constructed from within said Former.

12. A system for designing dome-shaped buildings to withstand specific conditions, including: ^• (a) a data repository, wherein said data repository includes data in a centralised database or a distributed file system accessible over the internet, wherein said data Includes: i. a building element including: A. a Domeshell structure; B. - an opening, including a window, a door, a skylight, a louver or the like; ii. a pictorial representation of each said building element, including a three dimensional representation of each said building element; iii. technical specifications for each said building element, including size and shape; iv. structural performance characteristics for each said building element; and

(b) a search facility that enables said data repository to be searched by means including one or more of the following: i. type of said building element; ii. size of said building element; ili. shape of said building element; iv. a performance characteristic (e.g. by cyclone rating, earthquake rating).

13. A system for designing dome-shaped buildings according to claim 12, wherein said system includes a computer-based modelling facility whereby each said building element can be:

(a) selected as an object (including having a three dimensional representation);

(b) pictorially placed on a building plan or drawing by dragging and dropping the relevant object on a computer screen (or other form of monitor that permits visualisation of said object); and

(c) re-configured or arranged as necessary as one or more subsequent objects is placed on said building plan or drawing, such that said modelling facility is enabled to model a structure using said building elements.

14. A system for designing dome-shaped buildings according to claim 12 or claim 13, wherein said system Includes a "proof of concept" facility for confirming and testing the structural performance of a proposed structure, wherein said proof of concept facility includes a means to compare compare the parameters of said proposed structure against one or more of the following:

(a) verified, calibrated data obtained from FEA analysis of structural performance; (b) thermal, light and other geographic data such as longitudinal and latitudinal co-ordinates of the proposed construction site, and solar passage at the relevant location.

15. A system for designing dome-shaped buildings according to any one of claims 12 to 14, wherein said system includes a plan generation facility, wherein said plan generation facility includes means to generate one or more of the following:

(a) a plan;

(b) other detailed drawings of said proposed structure such that said plan or said drawings can be generated in one or more of the following formats: i. print format; ii. electronic format.

16. A method for constructing a compound curve sandwich shell structure (C2S3) Including the steps of:

(a) constructing a Sandwich Panel using a Former, wherein said Sandwich Panel includes: i. Mesh, wherein said Mesh is made of any suitable self- supporting material, including wire or glass; ii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material, including glass or glass fibre; and iii. Foam, wherein all layers of said Sandwich Panel are constructed from inside said Former; and (b) securing said Sandwich Panel to a foundation using a securing means, wherein said securing means includes: i. a number of continuous links for assisting to secure said

C2S3 building to said foundation, wherein said continuous links are:

C. embedded in said Sandwich Panel of said C2S3 at an opposing end, such that each said continuous link straddles the join between said foundation and said Sandwich Panel; ϋ- a first rod, wherein said first rod is threaded through said ends of said continuous links embedded in said foundation; iii. a second rod, wherein said second rod is threaded through said opposing ends of said continuous links embedded in said Sandwich Panel; iv. Mesh, wherein said Mesh:

A. at least partially covers an interior surface of said Sandwich Panel; B. at least partially covers an outer surface of said

Sandwich Panel; and C. is folded under said rod embedded in said Sandwich

Panel such that said Mesh forms a continuous belt under said second rod and secures it into said Reinforced Cement at the point of contact with said foundation.

17. A method for constructing a C2S3 according to claim 13, wherein said Former includes a Former made from a rigid material including fibreglass.

18. A method for constructing a C2S3 according to claim 14, wherein said Former is a fibreglass mould.

19. A method for constructing a C2S3 according to claim 15, wherein said fibreglass mould Is constructed of panels fixedly engaged together for use by means including bolts.

20. A method for constructing a portable C253 including the steps of:

(a) constructing a Sandwich Panel using a Former, wherein said Sandwich Panel includes: i. Mesh, wherein said Mesh is made of any suitable self- supporting material, including wire or glass; ii. Reinforced Cement, wherein said Reinforced Cement is reinforced with any suitable material including glass or glass fibre; and iii. Foam, wherein said portable C2S3 is constructed off-site for subsequent assembly on-site; and

(b) using a lifting frame to lift said portable C2S3;

(c) using a transport frame to transport said portable C2S3; and

(d) securing said portable C2S3 to a foundation.

21. A method for constructing a portable C2S3 according to claim 17, wherein said portable C2S3 is a monolithic Domeshell.

22. A method for constructing a portable C2S3 according to claim 18, wherein said said lifting frame includes: (a) an internal lifting frame, to secure the base of said Domeshell; and

(b) an external lifting frame.

23. A method for constructing a portable C2S3 according to claim 17, wherein said portable C2S3 is a Domeshell fabricated in segments, and wherein said method includes the step of connecting together said segments to form a complete

Domeshell.

24. A method for constructing a portable C2S3 according to claim 20, wherein said transport frame is enabled to carry one or more said segments arranged in a stack for transport.

25. A method for modelling a C2S3 including the step of calculating optimal specifications required to meet specific requirements in given environmental conditions, wherein said specifications include:

(a) geometry of said C2S3, including diameter;

(c) thickness of a Foam core of said Sandwich Panel;

(d) size of one or more openings, wherein said opening(s) indude(s) a door, a window, a skylight, a louver, such that information derived from calibrated models of performance characteristics, as obtained from finite element analyses and like analyses of C2S3 under identified stresses, are used to calculate said optimal specifications.

26. A method for constructing a compound curve sandwich shell structure (C2S3) including the steps of:

(a) calculating a specified thickness of one or more of the following: i. an internal coating of Reinforced Cement; ii. a layer of Foam; iii. a final coating of Reinforced Cement, required to withstand specified environmental conditions; (b) attaching a Former to a Platform; (c) laying Mesh on the interior surface αf said Former;

(d) applying said internal coating and said final coating of Reinforced

Cement within said Former such that said Mesh is encased in both said coatings of Reinforced Cement;

(ej applying Foam to interior coating of Reinforced Cement within said Former such that said Foam forms the core of a Sandwich Panel, such that all three layers of said Sandwich Panel are constructed from within said Former.

27. A method for designing dome-shaped buildings to withstand specific conditions, including the steps of:

(a) accessing a data repository, wherein said data repository includes data in a centralised database or a distributed file system accessible over the internet, wherein said data includes: i. a building element, including: A. a Domeshell structure;

B. an opening, including a window, a door, a skylight, a louver or the like; ii. a pictorial representation of each said building element, including a three dimensional representation of e3ch said building element; iii. technical specifications for each said building element, including size and shape; iv. structural performance characteristics for each said building element; and

(b) using a search facility to search said data repository by means including one or more of the following: i. type of said building element; ii. size of said building element; iϋ. shape of said building element; iv. a performance characteristic (e.g. by cyclone rating, earthquake rating).

28. A method for designing dome-shaped buildings according to claim 27, including the steps of:

(a) selecting one or more building elements as an object (wherein said object includes a three dimensional representation of said building element); (b) pictorially placing said object on a building plan or drawing by dragging and dropping said object on a computer screen (or other form of monitor that permits visualisation of said object); and (c) re-configuring or arranging said objects as necessary as one or more subsequent said objects is placed on said building plan or drawing, such that said method enables a proposed structure to be modeled using said building elements.

29. A method for designing dome-shaped buildings according to claim 27 or claim 28, including the steps of confirming and testing the structural performance of a proposed structure using a proof of concept facility, wherein said proof of concept facility includes a means to compare the parameters of said proposed structure against one or more of the following: (a) verified, calibrated data obtained from FEA analysis of structural performance;

(b) thermal, light and other geographic data such as longitudinal and latitudinal co-ordinates of a proposed construction site, and solar passage at a relevant location.

30. A method for designing dome-shaped buildings according to any one of claims 27 to 29, including the step of using a plan generation facility, wherein said plan generation facility includes means to generate one or more of the following: (a) a plan;

31. A method for a constructing compound curve sandwich shell structure according to any of claims 16 to 24 wherein said Mesh is held in place at areas αf termination of said C2S3, including at:

(a) where said C2S3 meets said foundation;

(b) an external hood located above an opening; (c) around a skylight; and

(d) any other areas of termination.

32. A connection means forconnecting Domeshells, including:

(a) one or more ferrules wherein said ferrules: (i) are positioned along the intersection of a first and a second

Domeshell; and (ii) have an exposed end on the outer surface of said first Domeshell;

(b) one or more securing means, including a ring nut having a cross hole, wherein said securing means is secured to said exposed end of said ferrule; (c) a bar for threading through said securing means on the surface of said first

Domeshell.

33. A connection means for connecting building elements to a Sandwich Panel of a Domeshell, including:

(c) one or more securing means, including a ring nut having a cross hole, wherein said securing means is secured to said exposed end of said ferrule;

(d) a first reinforcing bar threaded through said ferrules;

34. A system for constructing a compound curve sandwich shell structure (C253) substantially as herein described with reference to the accompanying drawings.

35. A system for constructing a portable C2S3 substantially as herein described with reference to the accompanying drawings.

36. A computer-based system for modelling a C2S3 substantially as herein described with reference to the accompanying drawings.

37. A system for designing dome-shaped buildings to withstand specific conditions substantially as herein described with reference to the accompanying drawings.

38. A method for constructing a compound curve sandwich shell structure {C2S3) substantially as herein described with reference to the accompanying drawings.

39. A method for constructing a portable C2S3 substantially as herein described with reference to the accompanying drawings.

40. A method for modelling a C2S3 substantially as herein described with reference to the accompanying drawings.

41. A method for designing dome-shaped buildings to withstand specific conditions substantially as herein described with reference to the accompanying drawings.

42. A connection means for connecting Domeshells substantially as herein described with reference to the accompanying drawings.

43. A connection means for connecting building elements to a Sandwich Panel of a Domeshell substantially as herein described with reference to the accompanying drawings.