Articles & News
Articles & News
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Forty years into the dome-building process, Dome Technology continues to innovate as it builds each custom dome, and with more […]
Forty years into the dome-building process, Dome Technology continues to innovate as it builds each custom dome, and with more than 600 domes in the portfolio, it’s easy to see why.
“We built the first wood-pellet dome and have since built all of the wood-pellet domes around the world,” said Dome Technology CEO Bradley Bateman. “As a pioneer in the dome-construction process, we innovate and provide optimal systems for our customers, proving to be the trusted experts for bulk storage.”
The model of choice for wood pellets is the DomeSilo™, a robust structure that rivals silos in cost efficiency and dominates in storage capacity. Although each project is unique, a few benefits are constant with every DomeSilo:
Small footprint, affordable foundation
Prime portside property comes with a big price tag, and companies get less land for the money than they likely will elsewhere. A DomeSilo makes the most of available property, providing more storage than silos or flat storage with the same size footprint.
Because of its geometry, this kind of dome allows companies to store more product. The double curvature of a dome lends itself to the ability to build up, rather than out, and the curve provides strength at all points of the structure, even at the apex. The entire interior of a dome, then, can be used to store product.
Establishing the right foundation will always be of utmost concern on a port with its low-strength soils. The Dome Technology team specializes in exploring innovative alternatives to expensive deep foundations; some common options include the following:
- Where the top six to eight feet of ground is less-than-desirable material, it can be replaced with controlled structural fill. This model allows for some settlement, but the amount will be within tolerable parameters for a dome.
- When the top 15 to 50 feet of soil doesn’t provide the needed bearing strength, stone columns are a workable option. Crews use an auger to remove soil in about a 30-inch (76-cm) diameter hole down to a suitable, soil-bearing layer. Rock is placed in the hole and compacted, increasing the strength of the soil. With soft or clay-concentrated soils, a casing must be used to prevent it from collapsing on itself.
- The dome ring foundation or ring beam is a shallow foundation system that can be used at sites with acceptable soil conditions. This is an especially viable option at sites with consolidated soils from supporting heavy storage facilities in the past.
For areas where deeper foundations are required, other systems are available.
Various foundation systems can work for a dome and its smaller footprint, and a front-end engineering design study will determine which is best and provide budgetary numbers so companies can compare costs with other storage types. That being said, a dome might not require a deep foundation at all. Steel-reinforced concrete on its own tolerates some degree of settlement and movement compared to a large flat storage.
Customization
As a pioneer in dome construction, Dome Technology’s company culture is steeped in innovation. Here are a couple recent additions to the list of custom features offered to customers:
Round explosion panels
Until now, square and rectangular explosion venting has been the norm in storing products prone to deflagration, but Dome Technology’s team has pioneered a round hybrid model that has been installed on domes since 2016.
“No matter what system, you’re creating a weak spot with panels, whether it’s a pre-manufactured rectangular panel or a metal cladding piece. This is a round panel, which in a dome is nice because you don’t get sharp corners for stress concentrators,” said engineer for Dome Technology Adam Aagard.
The proprietary explosion vents are comprised of a circular geodesic steel lattice covered with the same PVC fabric used in the dome construction process. The panel is anchored to the dome with explosion-venting relief screws that remain secure during the design dead, live and wind loads. But in the event of a deflagration event, the screws release the panel and allow for the release of the excessive internal pressure. The system is watertight and meets the required operational design loads.
When an explosion occurs, the fabric accepts the load and transfers it uniformly around the ring’s circumference. “Because it’s circular we can predict the load going to each of the fasteners really well,” said Jason South, Dome Technology Vice President of Engineering, Research and Development. “If it were rectangular, the pressure going to each fastener could be different,” and more difficult to estimate.
In addition, the shape of the structure channels energy through the openings, reducing the chance of the dome shell being compromised should an explosion occur. The truss-free structure removes dust build-up concerns, and the double curvature has proven in real-world examples that a dome is structurally stable under extreme fire and heat conditions.
The filling tube
Wood-pellet companies working with Dome Technology have the option of installing a filling tube as an innovative way to load pellets with reduced dust and better product protection.
The filling tube is based on a concept common in coal and ore storage. A belt conveyor moves product into the top of the dome, where pellets enter the filling tube. Openings are incrementally located along the tube’s shaft, and product rolls through the openings and into the pile, resulting in smoother, more even pile creation. Dome Technology sales manager Lane Roberts said he is fielding more calls than ever about installing filling tubes.
According to engineer for Dome Technology Doug Weber, the difference in the pile is obvious; pellets loaded with a filling tube look cleaner and are stacked more uniformly. This mode of filling also reduces the likelihood and/or severity of deflagration. This is possible since the airborne dust concentration is reduced. Most dust is confined within the tube; as a result, the filling tube acts as a crucial part of a dome’s deflagration-mitigation plan.
“To have an explosion due to dust particles, you have to have a certain concentration in the air, and we can drive this concentration below that level,” Weber said. “This is really mitigating the risk of deflagration.”
The tube also protects product integrity, minimizing fines generated during the drawdown process by reducing the pressure head on the product flow line. Although there are no guarantees regarding the reduction of fines, “based on experience, it reduces the fines considerably,” Aagard said.
Four filling tubes have been installed in four different wood-pellet domes, two for Savannah Bulk Terminal in Georgia, USA, and two for QSL in Quebec, Canada. Customers with a filling tube report lower percentages of fines during ship loading than previously experienced.
According to Peeples Industries project manager Brad Orwig, the filling tubes in the Savannah domes have worked very well for the company since installation four years ago. “The pack factor has been reduced or completely eliminated. The stratified dust blanket has been reduced or eliminated, allowing a reduction of degradation during storage as well as improving the breathability of the pile,” he said, adding that on the discharge side, the shear within the pile is reduced.
An existing structure can be retrofitted to accommodate a filling tube, but Aagard said the less-expensive option is to have the foundation planned and constructed with the filling tube in mind.
In an era when innovation and customization aren’t extras, they’re expected, more bulk-storage customers seek a structure that will last, that fits within the budget, and that will maintain product integrity. Dome Technology delivers an innovative, one-stop-shop solution.
“We can handle everything, from the soil solution they’re going to need to designing not just the storage but the handling and the safety side,” Roberts said.
Editor’s note: The preceding is an excerpt from an article about Dome Technology domes published in World Biomass and distributed at the U.S. Industrial Pellet Association conference in fall of 2018.
By Rebecca Long Pyper for Dome Technology
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Dome Technology will soon break ground on a community safe shelter in Tuscaloosa, Alabama. Tuscaloosa County Park and Recreation Authority […]
Dome Technology will soon break ground on a community safe shelter in Tuscaloosa, Alabama.
Tuscaloosa County Park and Recreation Authority (PARA) contracted with Dome Technology to build the FEMA-designed dome, which will meet ICC 500 specifications.
When complete the structure will stand 128 feet in diameter and 43 feet high and feature one regulation basketball court with bleachers and restrooms. The new building will be located just north of the existing McDonald Hughes Community Center; a covered walkway will connect the two buildings.
The City of Tuscaloosa and Tuscaloosa County Commission provided funding for this storm shelter.
“The 2011 tornado that left a one-mile path of destruction through the center of our city and the loss of 52 lives in our community helped us realize the need and value of storm-shelter availability,” PARA public relations and marketing manager Becky Booker said. The storm shelter will be the largest in Tuscaloosa County.
Storm shelters like these are important community assets because they provide protection for those who can’t evacuate, said Dome Technology sales manager Daren Wheeler.
“It can become an evacuation center, a triage center—there’s just a lot of uses for this building. It’s just a win for the community. The best part of it is that these buildings can now compete with any structure out there cost-wise,” he said, noting that when it comes to FEMA criteria, dome safe shelters are usually the most affordable option.
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Dome Technology is under contract to build a dome for amusement park Funtown Splashtown USA in Saco, Maine. The reinforced-concrete dome […]
Dome Technology is under contract to build a dome for amusement park Funtown Splashtown USA in Saco, Maine.
The reinforced-concrete dome will be an upgrade to the Astrosphere, an existing fabric dome housing a Scrambler ride with a laser and light show.
To this point the Astrosphere has been inflated constantly by fan, and the airform is approaching its 15-year lifespan. Park owners have employed air domes for this ride since the mid-1970s, requiring that the airform and ride be taken down for the off season, then reassembled come spring. Ready for something permanent with little maintenance, company leadership contracted with Dome Technology to build the dome.
“Once a concrete dome is up, it’s up. I don’t have to worry about hurricanes and wind storms and losing power,” said Funtown Splashtown USA senior vice president Billy Cormier. “What I’m looking forward to is a building that’s going to be hard as a rock. It’s going to save me work, it’s going to be turnkey—in the spring I’ll turn on the light, do a little dusting, and we’ll be ready to go.”
Conditioning the Astrosphere has also been difficult historically, with weather dictating temperatures inside, including highs in the summer that exceed those outside—”not good for equipment and not good for workers,” Cormier said. The concrete shell will moderate temperatures and provide a backdrop for new laser shows and other special effects.
Dome Technology’s crew will mobilize in November, and construction time is set for four weeks. When complete, the dome will stand 75 feet in diameter and 30 feet tall with a utility garage and emergency exit.
Funtown Splashtown USA is Maine’s largest amusement and water park. The park has 50 rides, water slides and pools covering the 72-acre property with some of the biggest attractions in northern New England. For more information visit www.funtownsplashtownusa.com.
Photo gallery shows inside of the current Astrosphere. Image courtesy Funtown Splashtown USA.
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Construction is underway on a new gymnasium for Hansen School District 415 in Hansen, Idaho. Dome Technology was contracted to […]
Construction is underway on a new gymnasium for Hansen School District 415 in Hansen, Idaho.
Dome Technology was contracted to build the auxiliary gym, a $1 million structure located outside Twin Falls, Idaho, on the District 415 campus. The dome gym will feature a roof 120 feet in diameter built upon a 14-foot insulated-concrete-form stem wall. Total square footage is 11,310.
According to superintendent David Carson, the new gymnasium will make it easier for students and locals to schedule practice time and community events. “We were able to get a good facility at the price point we were looking at,” Carson said. “This will be used as a community center as well. Anytime you can have a second gym, it helps in a lot of ways.”
Construction began Sept. 4, and completion is set for early 2019. Features will include a regulation basketball court, an exercise room, a walking track, ADA-compliant bathrooms and locker rooms.
District officials expect lower utility costs with the dome versus traditional construction, Carson said. According to Dome Technology sales manager Daren Wheeler, the gym will not need to be conditioned because the dome’s concrete shell will absorb the energy during the day and discharge it back into the building during the night.
According to Dome Technology, the dome’s indefinite lifespan makes it a wise investment for the long term.
“It’s highly sustainable in that it’s never going to have to be replaced as far as the building envelope goes,” Wheeler said, adding that when complete, the gymnasium will significantly exceed current building codes for seismic and wind loading.
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The importance of strength: BSA Cementos selected a dome for its new clinker facility in Santiago, Chile. What makes Dome Technology’s […]
The importance of strength: BSA Cementos selected a dome for its new clinker facility in Santiago, Chile. What makes Dome Technology’s model seismic resistant and capable of storing more product in a smaller footprint
By Rebecca Long Pyper
When a company operates in a part of the world where Mother Nature can be unruly, the strength of the storage is just as important as storage capacity itself. If the structure can’t withstand nature’s worst, the product inside just isn’t secure.
Such was the concern BSA Cementos faced when planning for new clinker storage. The company needed to store an additional 50,000 metric tons, but with the next earthquake not being a matter of if, but when, company management sought storage that could withstand the seismic activity typical of the region.
In 2016, with support from Coppex Engineering & Technologies in securing the deal, Dome Technology was contracted to build a reinforced-concrete storage dome that holds up to 50,000 metric tons of clinker and stands 28.5 meters (93.5 ft) high and 57 meters (187 ft) in diameter.
The dome is located at a new site where BSA Cementos could increase its production by 950,000 tons per year during the first stage of operation, with as much as 1,900,000 tons a year being processed per year.
Seismic activity is common in Chile, which led the country to adopt some of the most rigorous building codes in construction. And if BSA was going to build a storage facility, earthquake resistance was extremely important, said Luis Riveros Grove, who oversaw quality control for the project. “Chile is a seismic country, so it is taken very seriously, both to protect the build but much more importantly the safety of the plant operators,” he said.
According to Dome Technology Vice President of Operations Dan South, BSA Cementos was initially considering conventional silos with steel roofs. After multiple meetings with Dome Technology, BSA Cementos opted for a hemispherical concrete dome instead. For BSA, the key dome advantages included quick construction, small construction crew, a low-maintenance storage facility and innovative practices.
The dome will allow BSA Cementos to store 50,000 metric tons of clinker in case of a shipping delay. The plant is expected to have a continuous supply of clinker from the port for their production, and the dome will serve as reserve storage so that if supply is interrupted from the port, they have plenty to continue operating.
Seismic resistance and dome strength
Domes are a choice option in areas prone to seismic activity because a seamless shell makes it possible for a dome to withstand differential movement at the base.
A dome is able to meet and in some cases exceed Chile’s building codes, thanks to geometry. According to engineer for Dome Technology Doug Weber, a dome has the ability to distribute a given load in two directions, resulting in twice the strength of a single curved wall like that in a traditional silo. A seamless shell, comprised of reinforced concrete combined with the double curvature, makes it possible for a dome to more economically withstand given seismic forces and differential movement at its base.
Also, monolithic construction means a dome is free of corners or concrete beams meeting up to form a joint, a construction interface that creates a weak point that doesn’t exist in monolithic construction. The absence of weak points in the shell allows the structure to convert loading to an axial force going across the surface of the dome, rather than channeling the stress to a weak spot.
For these reasons, domes are also frequently built as safe shelters based on their tolerance fornatural disaster. A dome can be engineered to withstand winds exceeding 250 mph (which includes EF5 tornadoes). Domes can be built to meet ICC-500 specifications.
A dome is made more robust based on construction materials. The exterior airform acts as an impermeable membrane that keeps moisture at bay. The steel-reinforced concrete shell provides insulation and climate control inside. Combined with steel reinforcement and nature’s perfectly strong shape, domes are well-suited for weathering any storm.
All these qualities allow the dome to tolerate frequent loading and unloading. A dome’s tolerance for cyclic loading and unloading is high because of its structural integrity, compared to steel silos built with fasteners or welded seams.
At sites where settlement is a concern, domes can be designed to tolerate some movement; however, there may be other solutions besides deep (and expensive) foundations. Dome Technology helps customers explore options that may reduce costs while delivering necessary support at the base.
Customized throughput
At the BSA Cementos site, a substantial headhouse placed at the dome’s apex houses large equipment, conveyors and dust-control systems, weight that can be supported since the dome was designed to handle this type of load, no matter what nature throws at it. The dome has plenty of strength to handle the loads and stress other structures can’t, even in a seismic event.
To drop costs and aid in economics, material handling was kept simple: A conveyor running through the apex fills the dome with product, and a front-end loader unloads the clinker through a main door. Relying on loaders used for other factory functions means less equipment downtime and should be sufficient since stock rotation inside the dome will be minimal.
Editor’s note: This is an excerpt from a feature published in the 2018 issue of BMHR, a supplement to World Cement.
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Frac sand flows well and isn’t finicky about conditions—with one exception: Frac sand and water don’t mix. Keep moisture at […]
Frac sand flows well and isn’t finicky about conditions—with one exception: Frac sand and water don’t mix. Keep moisture at bay, and it is easy to process and store. Choose a dome, and you’ll be able to store a lot of frac sand, even in the harshest conditions. Choose a Drive-Thru DomeSilo, and you’ll have product protection plus a durable way to load and ship on repeat for the long term.
Here are the advantages of using a dome for frac-sand storage and processing:
Robust enough for cyclical throughput
Companies storing frac sand process a lot of product in a little time. The sand’s weight and abrasion can do a number on steel structures, but a concrete dome can tolerate the demands. The Drive-Thru DomeSilo is built for cyclic throughput and will not deteriorate even if product is cycled constantly.
Waterproofing comes standard
Each dome is built without seams and with a waterproof membrane covering the entire surface. No precipitation can enter the structure, and the combination of a waterproof membrane, insulation, and reinforced concrete shell prevents extreme interior temperature fluctuation and resulting condensation.
Ample storage
A DomeSilo allows product to be stacked deeper on a smaller footprint, requiring less property and freeing up land for future expansion. The increased capacity is made possible by geometry: The double curvature of a dome lends itself to building up, rather than out, and the curve provides strength at all points of the structure, even at the apex. While some businesses require three to five buildings for flat storage, one dome will likely provide the same amount of frac-sand storage in one structure. And the truss-free interior means each dome can be filled to capacity without any ledges or surfaces for sand or dust to collect.
Storage as rugged as the terrain
Harsh conditions are no match for domes, which are often the model of choice for storm shelters thanks to their strength in natural disasters. Location is also a non-issue; for instance, the Climax Molybdenum dome in Leadville, Colorado, was built at an elevation of 11,000 feet.
Conveyance covered
For every project our engineers design the best method for input and output. With a Drive-Thru DomeSilo, storage and conveyance are delivered in a single robust package that’s easy to operate and customized with frac sand in mind.
“Good neighbor” features
A dome meets and in some cases exceeds regulations for covering ground pile. Dust is contained within the seamless dome, even at the filling point, and a dust-mitigation system inside makes dust collection simple.
For more than 40 years, Dome Technology has been building custom bulk-storage domes around the world. Our team of engineers is expert in providing a storage solution with your product in mind.
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Shaping up nicely: Two domes provide ample fertilizer storage, product separation for one company in the U.S. By Rebecca Long Pyper […]
Shaping up nicely: Two domes provide ample fertilizer storage, product separation for one company in the U.S.
By Rebecca Long Pyper for Dome Technology
For one major chemical company in the United States, crystal bridging was really becoming a problem.
The company was shipping low-density ammonium nitrate via train, but because they did not have adequate means for curing, the product clumped together via transit, making it difficult to remove upon arrival to the customer.
In an effort to solve that problem in a big way, Dome Technology was contracted to build one dome, and eventually a second one, that would provide ample storage and the ability to keep different types of ammonium nitrate separate.
Initially the plan was simple: To construct a single dome designed to hold low-density ammonium nitrate. Dome Technology built the dome, which stands 99 feet tall and 198 feet in diameter and has a maximum storage of 16,000 tons. The dome is fed at the apex, where product is stacked in a kidney-shaped pile. A chute rotates to lay the pile in a thin layer that allows for better cooling, thus avoiding a deep pile where the center would never adequately cool. Maximum convey rate to the dome is 450 tons per day, and the reclaim rate is 800 tons per day.
The dome is temperature and humidity controlled, and a smoke-detection system ties in with louvers so that should fire be present, a fan will kick on to blow out fumes that could explode. The pile depth is capped at 45 feet to prevent degradation.
The low-density product cures in 10 to 20 days, then is ready for shipping via truck or rail to be used in explosive applications. By allowing it to adequately cure, crystal bridging is far less likely, resulting in better flow and a better product for customers.
As construction for Dome 1 was underway, the customer decided a second dome would be a good idea, this one to store high-density ammonium nitrate, particularly to keep up with spring-season demand.
Product in the second dome can be stacked deeper and is center filled because it doesn’t have the curing issues that low-density ammonium nitrate does. The customer fills the second dome completely to fully utilize the storage volume, Aagard said.
Both domes feature a ring-beam foundation, standard in dome construction, and soil improvement was completed prior to construction to set the stage for solid foundations. For both domes, a front-end loader reclaims product, dumps it into a hopper, and the hopper feeds to conveyors. But having two separate domes with distinct reclaim systems ensures that product types are never mixed.
In 10 months both domes and their conveyor systems were complete, customized specifically to the customer’s requests and providing the protection both types of ammonium nitrate demand.
“As we have seen over the course of several years, Dome Technology can offer solutions for material storage and handling for a wide range of storage needs. I am happy that Dome Technology was able to offer and provide solutions for this facility in storing their product,” Dome Technology project manager Jason Craig said.
Fertilizer storage + domes
Ammonium nitrate in general shows two faces, one that helps things grow and one that can make things explode. Whether destined to become an ingredient in fertilizer or a component for explosives, ammonium nitrate’s hygroscopic nature requires a controlled, secure environment.
More companies are seeking the benefits of steel-reinforced concrete domes that exceed those found in flat storage or steel bins. Unique and proven construction methods and materials contribute to a dome’s strength and flexibility of use. Here are a few key benefits of a dome for fertilizer storage:
Space requirements and storage ability
Domes store a large volume in a smaller footprint, stacking product deeper and taking up less property at the site. While some customers require three to five warehouses to store product, one dome will likely accommodate the same amount of material. Dome engineers are experts on stored products and will help customers determine how much product can be safely stored within a structure.
Domes can also be engineered with innovative load-in systems that ensure pile depths are within the appropriate parameters for product integrity. This is especially important for more volatile forms of ammonium nitrate.
The double curvature of a dome lends itself to the ability to build up, rather than out, and that curve provides strength at all points of the structure. The entire interior of a dome, then, can be used to contain product, so a dome will hold store more than a silo of similar diameter and height. In essence, the more fertilizer storage the customer wants, the more competitively priced a dome will be.
The preceding is an excerpt from a feature published in the July/August issue of World Fertilizer. For the full text, click here. For information on additional benefits, like strength, foundation options, moisture protection, fire prevention, material-handling solutions, and cost savings, click here to download the full article.
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Better long-term protection was the recurring theme at the Menan Fire Station grand opening Aug. 23 in Menan, Idaho. “I […]
Better long-term protection was the recurring theme at the Menan Fire Station grand opening Aug. 23 in Menan, Idaho.
“I want to say how proud I am of this building. She’s an unconventional building, but she’s built for a hundred years. I’d like to see my grandkids see this building still standing,” said Menan mayor Tad Haight. “There’s room for training here, there’s room for rest, there’s room for expansion, and I think it’s an investment in the future.”
Central Fire District contracted with Idaho Falls-based Dome Technology to build the station, a 11,300-square-foot structure with a dome roof system 100 feet in diameter built upon a 17-foot CMU stem wall.
The station includes five bays for trucks and a mezzanine for future expansion. The building’s low-profile post-tension concrete dome shell yields energy efficiency and moderates interior temps. Domes are built truss free, providing ample open spaces inside for community events and flexibility as station needs change.
“(This station) means that we are able to grow the community; we are able to support the community. We’re able to provide better services to the residents of Jefferson County that live in Central Fire District, we can back up our other sister stations, and we can also provide for emergency housing here if we have a disaster here—that was one of the main reasons that we built this type of dome,” station captain Mitch Bingham said.
The station will also protect equipment during natural disasters. In traditional construction, roof systems can collapse during extreme weather or seismic events. If equipment is trapped under the roof, volunteers aren’t able to assist the community as needed. “In this particular instance, that’s not going to happen. The roof will not collapse in any kind of natural disaster,” said Dome Technology project manager Daren Wheeler.
Dome Technology constructs architectural buildings and storm shelters around the world and is certified with the National Storm Shelter Association. Each project is customized to a customer’s needs and specifications.
To learn more about this building, see our Menan Fire Station project summary.
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In its May 2018 issue, Dry Cargo Magazine highlighted two Dome Technology’s DomeSilos built to store wood pellets for QSL […]
In its May 2018 issue, Dry Cargo Magazine highlighted two Dome Technology’s DomeSilos built to store wood pellets for QSL in Quebec City, Quebec, Canada.
The article explores QSL’s considerations prior to selecting the dome model for bulk storage, then discusses dome benefits like dust reduction, fire safety, and product protection.
In the article, QSL director of engineering Eric Lapointe calls out a dome’s good looks, dust control, and the ability to store massive amounts of pellets as three key benefits for the short and long term.
For the full text, visit Dry Cargo Magazine and view the free online May issue. The article begins on page 37.
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According to Corpus Christi, Texas, news station KRISTV, the Tuloso-Midway High School football team moved practice inside the district’s dome […]
According to Corpus Christi, Texas, news station KRISTV, the Tuloso-Midway High School football team moved practice inside the district’s dome storm shelter/gymnasium to escape temps exceeding 100 degrees.
“This dome has been amazing; it has really helped us out. You know the heat index, as high as they are, we want to keep kids safe and want to keep kids hydrated. Having this facility enables us to come out and do stuff and not have to worry about heat. We talk about hydration all the time, and we go out some, but when it is hot like today, this has been a godsend for us,” said Tuloso-Midway Head Football Coach Wade Miller.
Dome Technology built the 20,000-square-foot storm shelter in 2017 for Tuloso-Midway Independent School District. The shelter was built in part with FEMA funding and was finished as a gymnasium. It is located in the district’s sports complex. For the full story, visit KRISTV.