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Bruco, The Texas Italian Caterpillar

Bruco is our manufacturing plant for assembling the Airforms used in all Monolithic Domes. Here is a small photo album of its construction.

Bruco started as a footing that traces the base of the structure. For most domes the footing would be a simple circle made of concrete and reinforced with steel rebar. The footing forms a tension base, or ring, for maintaining the integrity of the Monolithic Dome.

An Airform shaped as seven inter-connected domes is stretched and attached to the footing. Airforms are custom made to whatever shape is required.

 

Once inflated, fans maintain the shape and size of the Airform until construction is complete. Bruco's seven interconnected domes form a caterpillar that is 240' long and 60' wide.

Foam is applied directly to the interior surface of the Airform. Approximately 3" are sprayed with special rebar hangers embedded in the foam.

 

Stickers are attached to the foam and then an inch of foam is sprayed on them to lock them in place. After that, rebar is tied to the hangers and shotcrete is applied.

 

Shotcrete is a special spray mix of concrete. It is applied to the interior surface, embedding the rebar. Once it is set, the fans are shut off and Bruco is complete.

 

Of course, once Bruco is finished, you still need to paint on its boots.

 


177 Dome Park Place - Italy, TX 76651
Tel (972)483-7423 - Fax (972)483-6662
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