The concept of mass producing aircrete domes through the use of forms and mass pours is often considered. The complexities involved with such forms have prevented most attempts, but I know it can be done.
When making concrete we are able to make use of slowly turning drums because the shifting weight of the rocks and sand actually do most of the work of mixing for us, like lead balls in a can of spray paint. In contrast, aircrete has no such heavy bits. Slow churning has no effect. The closest we can come to that type of production is with a continuous aircrete generator, which is mostly just a concept at this point. I have seen such devices on the commercial market selling for a couple hundred grand. A few mad scientists have been actively developing a consumer model for years, and continue.
Assuming you find a way to make dome forms, the best currently known way to make aircrete using commonly available equipment is in a 55 gallon drum with a foam generator and a mud-mixer. A 45-gallon batch takes about 10 minutes with some practice. Questions begin to arise about how to get the aircrete into the dome forms.
@Ignacio-DHOME Good idea. You have to contend with the particals thou. perhaps wetting it and then shopvac. I'm just thinking it might be better to hepa vacume it up as dust. Wetting it might make it harder. would have someone stand next to me and vacume as i saw. I don't know but it's a discussion no one seems to be having. I know it's not the fun part, but still important. I saw a photo of someone who knelt on his wet slab (trying to screek it) and didn't wash it off and ended up in the hospital for weeks with burns down to the bone. So it's not like it's nothing. I always were a mask but after its cut it falls to the ground where it can easily be kicked back up. I mean the particals don't disappear after i'm finished cutting. I have designated a "toxic" area on my property where we don't plant and animals aren't allowed so I have a place to clean tools and buckets etc, the making and cutting is done is habitable areas.
@ormom8 Yes! Aircrete presents us with new paradigms of creativity. You could just tack your wiring up to the inside of the walls and finish with the earthen or "other" finish. Then if you need to change it just scratch them out. They would only be an inch or so deep. and re-plaster. The conduit would provide some protection from something banging into the walls and shorting out a wire. I encourage everyone to NOT create new "Aircrete rules boxes". Live creatively and outside the "boxes"
@naeveh1 I don't see why not. Being that it's lightweight it could work great. Make sure to use the poly fiber on the inside of the pour to hold it all together monolythically. Also, will give you an insulative ceiling...FYI: You may not be able to walk on it though. Also, how do you expect to mix and pour this? Look in to a plaster mixer if necessary....this may be a good alternative to hand mixing. Too bad you did'nt use this for your walls. You would have insulative walls by now and a finished surface to paint.
@Zander earth choice dishwashing liquid is great. The earth choice laundry detergent however is a disaster. Failcrete all round.
Another good one available in Longreach is
“Trucking Blue. Not only makes fine aircrete but the car sparkles. Might be harder to get out your way. Transporting cattle and mining gear on the highways, unsealed roads and dust paddocks of Outback Oz the only sign of life the a million insects dead on the windscreen, you need a heavy duty cleaner to spruce up.
@PeterG Thanks for that information and suggestions. My water to cement ratio was exactly the same, and the cement was brand new straight off the delivery truck from the manufacturer. Interesting that your block moulds were giving off that much heat. .... Mine never got hot.
I may try your ratio of foaming agent to water and adjust the pressure to create the right weight to volume ratio. I am going to try making them in a heated space with warm water as the temp up here in May was 5C - 14C.
Really appreciate your comments.
@Altitude-High Oh! sorry. Well, I am not an engineer so if you want an empirical answer, I am not the one to give it. My only thought on this topic is that an egg shaped dome will be much more resistant to load and will shed the snow more easily. I also believe that the compressive strength because of the vertical lift of the shape, has greater strength. An egg shape is incredibly strong. The dome is as well, but not as much. The Florence domes were based on the quinto acuto because of its vertical lift to counter act gravities forces downward that causes "lateral stress".
@spectrumjim Hello I am attempting to get a building permit is Victoria and CRD have given me a form called "Alternative Solutions" and I have emailed Hajjar as he is an architect and the Chief building inspector has indicated they will issue a building permit if Hajjar signs the form. Good luck in Nelson.
I'm a Aircrete Harry fan! Between him and Haijar, my imagination has been awoken! The possibilities are endless. I will be designing my aircrete injector this summer! I will be making some aircrete mushrooms for yard decorations this summer!! Big ones!! HahAHA LOL
@susan no not yet I study all stuff at domegaia and volunteering to help build a dome in Sedona Arizona I will be building my dome I’m in the process self education talking to community as domegaia and build myself . There’s many on site here that gave built domes offering services I can’t wait to build dome I’m mire studying as much as I can from domegaia volunteers helping others build domes