ROOF PANELS

My latest idea is pre-fabricated, arched triangle, roof panels. 12 -18 ft wide--On the ground you build arched triangles in a dish shape. Finish the inside of the dish , flip the dish over, set with a crane and this becomes the ceiling of the dwelling.--No overhead plastering. A row of tiles inside, finishes interior ceiling.

The panels can either be set in a circular pattern to form a "dome" or  alternating in a line to roof a rectangular shaped room. Building triangular dishes-- start with insulation then structural layer and then polish the inside of the dish. THE HARD PART--Turn the dish over and stack it in vertical pile until the crane comes to set 8 dishes. Crane --reality check-- for these dishes on the first floor I'd say 4 hrs at $150/ hr is $600-- or $75 X 8 panels. Set the dishes and stick them together in the valleys-- form work very simple using plaster lath-- mix this pour on site, (pour out of a 5 gal bucket) and vibrate from above.1/2 yd should go a long way

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This is the first roof panel we cast in Texas. More or less a sand cast in an old creek bed. This one was quick using semi-skilled folks . After curing a week this panel was drug out of the form with a backhoe.The owner plans on reinforcing/fixing the lower mold since we need 5 more roof panels from it and the idea seems to be working. More coming on flipping and setting the panels.

BO'S COMMENTS

I used "Smooth Geometry" modeling with Booleans to cut up sections. Then measured and labeled square footage for flipped parts. Maybe other cuts are needed. Cut 219 sf module in half, just a quick look here.  Catenary window and door cut outs wold be great too, just add wooden rough openings.

Ya, I bet ferrocement with light-weight aggregate would do it well. Leave reinforcement exposed at seams and at beams, for bonding, etc, etc... Add some wood cross supports, hooks at centroid and as axle holes both sides? Go for it. Actually low 100 sf panels can be handled by a few guys, since the bulk of roofing material goes on last, no? No crane needed, really. Hire the right guys. Alternatively reduce module complications by use of riser-walls which shorten the catenary legs.

Meant to say, these 3D surfaces can be unfolded inside CAD software. Then you will have precise patterns to rely on. The hard part however is deciding on one's preferred, personal design. My sister has been designing her dream house for decades and it keeps evolving. Once we commit to stone, it becomes very hard to change it. (Said from hard experience). see Bo's Page