|At the precasting factory, special forms were built for each type of dome piece. These included: hexagons, pentagons, and two sizes of quarter cylinders. Here we see the form for a hexagon.|
|Reinforcing bar was placed in the form. Expanded polystyrene block outs were inserted at places where openings were needed in the particular piece being formed.|
|Special block outs were used to make the “butterfly” ties that were used to “stitch” the pieces together with steel.|
|Where window or door frames were needed, they were cast into the dome piece.|
The piece was then cast with steel fiber reinforced cement, which makes the toughest concrete in the world.
|Screeding out the seven sack concrete mix, filled with millions of two inch steel fibers was very hard work.|