Patent Publication Number: US-8973336-B2

Title: Systems and methods for providing rounded vault forming structures

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 13/117,090, filed May 26, 2011, and entitled SYSTEMS AND METHODS FOR PROVIDING ROUNDED VAULT FORMING BUILDINGS. This application also claims the benefit of U.S. Provisional Patent Application No. 61/525,113, filed Aug. 18, 2011, and entitled SYSTEMS AND METHODS FOR PROVIDING ROUNDED VAULT FORMING STRUCTURES. Both of the applications are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to systems and methods for providing rounded vault forming structures. In particular, the present invention relates to systems and methods for providing a level foundation and building a monolithic building thereon, the monolithic building having one or more arches, one or more integrated hip structures, and a non-circular outer circumferential shaped base. 
     2. Background and Related Art 
     A monolithic dome is a dome-like structure which is cast in a one-piece form. As compared to a traditional home style, monolithic buildings are relatively straight-forward in their construction, exceptionally strong and comparatively inexpensive to construct. As such, monolithic dome homes are desirable in areas prone to natural disasters as well as financially poor areas of the world. 
     The process for providing a monolithic dome typically begins with the formation of a round foundation which approximates the general outer circumferential shape of the dome&#39;s base. A dome form, such as an air form (i.e.: an air bladder) is generally secured to the cured foundation and inflated to provide a three-dimensional form. A lattice of rebar is provided to the dome form and then covered with a cementitious material, such as cement, concrete, plaster, stucco, Air Krete® or fiber-reinforced cement. Once the cementitious material is cured, the form is deflated or otherwise removed from the structure thereby revealing the surface of the structure. The resultant dome structure provides a large interior dome-shaped living space that is generally energy efficient. 
     In some parts of the world, the exterior dome shape of the building is considered aesthetically undesirable, most especially when located in a neighborhood consisting of traditional rectangular-shaped homes. For this reason, most home builders will forgo the financial, natural disaster resistant properties, environmental and energy savings of building a monolithic dome home, in favor of a home build with a more traditional shape and structure. 
     Thus, while techniques currently exist for providing monolithic dome structures, challenges still exist. Accordingly, it would be an improvement in the art to augment or even replace current techniques with other techniques. 
     SUMMARY OF THE INVENTION 
     The present invention relates to systems and methods for providing rounded vault forming structures based on bi-secting arches. In particular, the present invention relates to systems and methods for providing a level foundation and building a monolithic building thereon, the monolithic building having one or more arches, one or more integrated hip structures, and a non-circular outer circumferential shaped base. 
     In some implementations of the present invention, a method for providing a monolithic building includes steps for coupling an air form to a surface of a foundation, providing a hip form to a surface of the air form such that the air form supports the hip form, and applying a building material to an outer surface of the air form and an outer surface of the hip form. The method further includes a step for providing a foundation on which the vaulted building is constructed. In some implementations, a laser mounting device is used to level and square the foundation forms. 
     In some implementations of the present invention, the hip forms comprise a plurality of modular sections that are interconnected to form a desired form shape. The hip forms include an inner surface, an outer surface, a base surface and an interface surface, wherein the base surface abuts the foundation, and the interface surface of the hip form abuts the outer surface of the air form to provide a monolithic building form. In some implementations, a modular form securing system is provided having a channel for receiving a portion of a base surface of an air form, the modular form securing system further having a fastener whereby to secure the modular form securing system to the foundation, wherein the base surface of the air form is secured to the foundation via the modular form securing system. 
     In some implementations of the present invention, a set of color coded construction plans and color coded measuring tape or other device is provided which uses colors, symbols, and codes to provide instructions for constructing the monolithic building of the present invention. 
     Further, in some implementations of the present invention, a monolithic vaulted structure device is provided which includes an arch structured shell having an inner surface, an outer surface and an interior volume, the device further having an integrated hip structure having an interior volume in fluid communication with the interior volume of the dome shell. In some implementations, the integrated hip structure is a structural feature of the device which is at least one of a dormer, a garage, a nook, an entryway, a room, or other structure having an appearance that is different from the arch structured shell, yet is itself constructed monolithically. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to set forth the manner in which the above recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
         FIG. 1  as shown in parts A-E provides perspective views of monolithic buildings having a plurality of integrated hip structures in accordance with representative embodiments of the present invention; 
         FIG. 2  as shown in parts A-C are perspective and plan views of a laser mounting device in accordance with a representative embodiment of the present invention; 
         FIG. 3  is a plan side view of a laser mounting device and foundation form in accordance with a representative embodiment of the present invention; 
         FIG. 4  as shown in parts A and B is a modular form securing system for securing an air form or other arch structured form to the foundation in accordance with a representative embodiment of the present invention; 
         FIG. 5  as shown in parts A and B is another modular form for securing an air form or other arch structured form to the foundation in accordance with a representative embodiment of the present invention; 
         FIG. 6  is a cross-sectional view of an air form or other arch structured form secured to the foundation via a modular form securing system in accordance with a representative embodiment of the present invention; 
         FIG. 7  is a perspective view of a fan manifold system in accordance with a representative embodiment of the present invention; 
         FIG. 8  is a plan view of an air form or other arch structured form and various hip forms supported by the air form or other arch structured form in accordance with a representative embodiment of the present invention; 
         FIG. 9  as shown in parts A-C is a perspective view of an assembled hip form in accordance with a representative embodiment of the present invention; 
         FIG. 10  is a perspective, exploded view of a disassembled hip form in accordance with a representative embodiment of the present invention; 
         FIG. 11  as shown in parts A and B is a cross-sectional view of a completed arch structured wall prior to removal of the air form in accordance with a representative embodiment of the present invention; 
         FIG. 12  is a perspective view of an attachment mechanism in accordance with a representative embodiment of the present invention; 
         FIG. 13A  is a perspective view of the attachment mechanism of  FIG. 12  in use in accordance with a representative embodiment of the present invention; 
         FIG. 13B  is another perspective view of the attachment mechanism of  FIG. 12  in use in accordance with a representative embodiment of the present invention; 
         FIG. 14  is a perspective view of another attachment mechanism in accordance with a representative embodiment of the present invention; 
         FIG. 15  is a perspective view of an air form and a hip form in accordance with a representative embodiment of the present invention; 
         FIG. 16  is a partial perspective view of the air form and hip form of  FIG. 15  with an arched or vaulted structure shown as a transparent structure in accordance with a representative embodiment of the present invention; 
         FIG. 17  is a perspective view of an arched or vaulted structure shown as a transparent structure to illustrate the thicknesses and boundaries of the structure in accordance with a representative embodiment of the present invention; 
         FIG. 18  as shown in parts A-C is a view of the interface between the arched or vaulted portion and hip portion of the structure of  FIG. 17  in accordance with a representative embodiment of the present invention; 
         FIG. 19  is a perspective view of a modular wall system during assembly in accordance with a representative embodiment of the present invention; 
         FIG. 20  is a partially exploded, perspective view of the modular wall system of  FIG. 19  in accordance with a representative embodiment of the present invention; 
         FIG. 21  is a perspective view of a clip of the modular wall system in accordance with a representative embodiment of the present invention; 
         FIG. 22  as shown in parts A and B is an air form or other arch structured form and form extension piece installed in a basement foundation in accordance with a representative embodiment of the present invention; 
         FIG. 23  is a cross-sectional view of a monolithic building set on a basement foundation prior to removal of the various forms of the shoring system in accordance with a representative embodiment of the present invention; 
         FIG. 24  as shown in parts A and B is a prolate form in accordance with a representative embodiment of the present invention; 
         FIG. 25  as shown in parts A through D shows the assembly of a portable hip form in accordance with a representative embodiment of the present invention; 
         FIG. 26  is a perspective view of a SPiFolding structure in accordance with a representative embodiment of the present invention; 
         FIG. 27  is a perspective view of another SPiFolding structure in accordance with a representative embodiment of the present invention; 
         FIG. 28  is a perspective view of a platform for a SPiFolding structure in accordance with a representative embodiment of the present invention; 
         FIG. 29  is a perspective view of the platform of  FIG. 28  with a ground bracket for a SPiFolding structure in accordance with a representative embodiment of the present invention; and 
         FIG. 30  as shown in parts A through B shows the assembly of modular barracks in accordance with a representative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention relates to systems and methods for providing a monolithic building. In particular, the present invention relates to systems and methods for providing a level foundation and building a monolithic building thereon, the monolithic building having a plurality of intersecting arches, one or more integrated hip structures, and a non-circular outer circumferential shaped base 
     With reference to  FIGS. 1A-1D , a monolithic building  10  is shown. In some embodiments, monolithic building  10  comprises a unitary structure having a centrally located arch structured or vault shaped apex (or simply a vault or cupola)  12  and a plurality of integrated hip structures  20 . As used herein, the term “monolithic” is understood to mean a single, integrated structure that is formed of a single unitary material and structure. The monolithic buildings and structures of embodiments of the present invention are single, unitary dome structures having various appendages or hip structures  20  that are formed concomitantly during the construction process. Thus in some embodiments, monolithic building  10  comprises two or more intersecting arches  14  forming a vault-shaped apex  12 , wherein portions of the monolithic building  10  are integrated hip structures  20 . 
     In some embodiments, hip structures  20  comprise a dormer, such as a window dormer. In other embodiments, hip structures  20  comprise at least one of a garage, a nook, an entryway, a room, or other structure having an appearance that is different from the arch structured shell, yet is itself constructed monolithically. Monolithic building  10  further comprises doors and windows to provide access to the interior of the building. In some embodiments, openings for doors, windows and/or any other needed opening are formed during the process of forming the building. For example, material is used to mask where the designer does not want concrete—such as where the window(s) or door(s) are to be located. Utilization of the masking material results in the desired void(s) in the building. 
     In other embodiments, access holes are cut into building  10  following construction of the building  10  to allow installation of doors and windows. In some embodiments, the exterior of building  10  is decorated with brick, stucco, siding or other ornamental exterior covering materials to provide a desired aesthetic look. In some embodiments, a cementitious outer construction material of building  10  is stamped, painted and/or stained to resemble a desired ornamental exterior covering material. Thus, the exterior of building  10  may be modified and decorated to match or closely resemble a desired traditional home style. 
     In other embodiments, such as the embodiment illustrated in  FIG. 1E , a parapet is formed by extending the exterior walls above the lower arch line such that the extension partially or completely hides the cupola or arch apex. The parapet can completely hide any dome like features, thus making the exterior of the building more architecturally similar to traditional or regional construction, which may be required by many nationalities. Furthermore, the application of the parapet can transform the intersection of the arches, which naturally appears to be a dome, into an elliptical or polygonal shape.  FIG. 1E  further illustrates an interior parapet that sits on the bisecting arches and adds further dimension. 
     The process for constructing or forming monolithic building  10  generally begins with a foundation. Traditional dome buildings use a circular foundation, wherein the dimensions of the circular foundation approximate the circumference of the dome&#39;s base. However, some embodiments of monolithic building  10  can utilize a rectangular or other sized foundation to support the non-circular base of building  10 . 
     In some embodiments, a laser mounting device  30 , as shown in  FIGS. 2A-3  is used to ensure that a foundation is provided that is square, plum and level. Some embodiments of laser mounting device  30  comprise an angled box having a first channel  32  and a second channel  34  for positioning mounting device  30  on the outside corner of any forming system. In some embodiments, first and second channels  32  and  34  are configured to snuggly receive nominal 2× material  50 , such as a 2×4, 2×6, 2×8, or 2×10 piece of lumber. In other embodiments, channels  32  and  34  further comprises an adjustable clamp  36  whereby the width of channels  32  and  34  may be adjusted to snuggly receive and secure larger or smaller dimensioned forming materials  52 . 
     Laser mounting device  30  further comprises a top compartment  40  for receiving a laser device  42 . One having skill in the art will appreciate that any type of laser device may be used with laser mounting device  30 , such as a dot/plumb laser, a grade laser, a manual leveling laser, a self-leveling laser, a line laser level, a pipe laser, a 180° line laser, and a 360° line laser. Laser device  42  is secured in top compartment  40  via laser vise or clamp  38 . 
     The process for setting the foundation forms starts with a first forming material  54  being attached to a second forming material  56  at their ends to roughly provide a 90° corner θ. First and second forming materials are generally secured via fasteners, such as nails or screws  58 . Laser mounting device  30  is then placed over the corner and clamps  36  are tightened thereby ensuring that the corner is maintained at 90°. Laser device  42  is then secured in top compartment  40  such that the laser beam  44  is directed along either of the first or second forming materials  54  and  56 . 
     A target card  60  having a plurality of target lines  62  is then placed on the forming material  54  adjacent to laser mounting device  30 . The position of the beam  44  relative to the target lines  62  is then recorded as a target mark. Target card  60  is then moved to the opposite end of forming material  54 , whereafter forming material  54  is adjusted  64  until beam  44  registers at the target mark on the target card  60 . The second end of forming material  54  is then secured at the desired position. At this point, the first and second ends of forming material  54  are level and aligned. This process is then repeated for each corner of the foundation forming system to provide a level and square foundation form. 
     In some embodiments, laser mounting device  30  further comprises a connection piece for compatible use with the Plastiform® system. As such, the process for building the foundation slab is simplified. This connection piece allows the form system to be suspended away from form stakes, which in turn allows for the use of a spin-screed or other large span, close edge finishing system, to be used for screeding the foundation material within the slab or foundation form. 
     Once formed, the foundation form is then filled with a foundation material by any method known in the art, thereby providing a rectangular foundation  70 , as shown in  FIG. 4 . In some embodiments, the finished concrete slab foundation receives a burnished finish which allows for floor staining and polish, thereby eliminating the need for other floor finishes in the building  10 . In other embodiments, a stamped faux tile, brick or other three-dimensional design is applied prior to the concrete setting. 
     In some embodiments, the length, width and height of foundation  70  is determined by use of a ruler or standard measuring tape. In other embodiments, foundation  70  and monolithic building  10  are constructed with the aid of coded architectural plans which utilize colors and symbols instead of numbers and words. In some embodiments, the coded architectural plans are accompanied by a set of tape measures that include matching symbols and colors. In other embodiments, the coded architectural plans are further accompanied with a video having various sections that allow those with limited or no reading skills to perform the necessary tasks to complete the monolithic building  10 . Further, in some embodiments, physical or computer generated models are further provided to assist the user in constructing the building  10 . In this way, foundation  70  and building  10  may be constructed without consideration for user education, nationality, language or sophistication. 
     Building  10  is formed with the aid of a plurality of various forms. A first step in providing these forms is to secure an air or other arch structured form to the concrete slab  70  via a modular form securing system  80 , as shown in  FIGS. 4A through 6 . In some embodiments, form securing system  80  comprises a plurality of interlocking c-channel sections  82 , such as an aluminum c-channel, which are combined in a modular fashion to provide ring approximately equal to the circumference of a desired air form  90 . In some embodiments, adjacent sections  82   a  and  82   b  are interconnected wherein a tongue  88  of section  82   b  is inserted into an opening  96  of section  82   a . Sections  82   a  and  82   b  are then secured together via a plurality of fasteners  104 .  FIGS. 4A and 4B  show straight sections  82 , which combine to form a polygon-shaped securing system  80 . Alternatively,  FIGS. 5A and 5B  show a modular form securing system  80  having arc-shaped sections  82 ′ rather than the straight sections  82  of  FIGS. 4A and 4B . The arc shaped sections  82 ′ can collectively form a circle and create a more uniform shaped vault. 
     In some embodiments, sections  82   b  are secured to foundation  70  via fasteners  84 , such as a expansive concrete anchor bolt, a wedge insert, a nail or a screw. Fasteners  84  are generally placed in sections  82   b  which are positioned closest to the perimeter edge  72  of foundation  70 . As such, fasteners  84  are located adjacent to the outer wall of the final structure  10 , as opposed to being positioned away from the wall opposite a corner  74  of the foundation  70 . Prior to securing the sections  82  to foundation  70 , a portion  92  of air form  90  is secured within the channel  86  of sections  82 , such that a part of air form  90  is secured between shoring system  80  and foundation  70 . For example, in some embodiments a rope or wire  92  is sewn into a bottom seam  98  of air form  90 , thereby providing a surface which is capable of being retained in channel  86 . Air form  90  is then connected to a fan or a plurality of fans (through a manifold system), such as a squirrel cage fan or other blower to inflate form  90 , as shown. 
       FIG. 6  illustrates a cross-sectional view of an air form or other arch structured form secured to the foundation via a modular form securing system in accordance with another representative embodiment of the present invention. 
     The air form is used for shoring and supporting the structure, including hip structures, as well as the weight of the cementitious material and reinforcing material applied to the exterior. The air form is placed as the main support structure for building  10  and therefore is placed approximately in the center of foundation  70 . The fan(s) for the air form is/are set to maintain at least a three inch water column of continuous pressure within the interior of the air form. In some embodiments, an entrance is provided that is separate from the direct flow of air by the fan system. In some embodiments, the entrance is provided at the eventual location of a door or window of building  10 , such that interior work on the building may be accomplished simultaneously with the exterior work of the building  10 . In other embodiments, such as the embodiment illustrated in  FIG. 7 , the entrance is provided through a “trap door” in the fan manifold system. In  FIG. 7 , the slide door allows a person to crawl into the air form. The hatch at the top is a pressure regulator. Weights are stacked on top of the pressure regulator to hold it shut. When the pressure builds up, it will vent out the hatch. Those of ordinary skill in the art will appreciate that embodiments of the present invention contemplate other types of pressure regulators that may be used. 
     In  FIG. 7 , the fan manifold system allows a plurality of fans to be used and provides redundancy, which ensures that the minimum pressure is provided even if one fan fails. In further embodiments, the fans are hooked up to different power sources, such as one or more city power sources, one or more generator power sources, and/or one or more other power sources so that if one power source fails, the other fan(s) are able to provide the minimum pressure. Thus, in some embodiments, a plurality of fans are used that run off a plurality of power sources. 
     Referring now to  FIG. 8 , the various forms used to construct building  10  can further comprise a plurality of hip forms  100 . In some embodiments, hip forms  100  comprise a desired three-dimensional shape which is attached or otherwise coupled to air form  90 . Thus, the outer surface  94  of air form  90  and the outer surfaces  102  of hip forms  100  provide a combined outer surface that defines the inner and outer shape, profile and/or design of monolithic building  10 . Hip forms  100  may include any desired shape or structure. For example, in some embodiments hip form  100  comprises a dormer shape. In other embodiments, hip form  100  comprises a shape reflective of a garage, a nook, an entryway, and/or a room. 
     In some embodiments, hip forms  100  comprise a system of vertical and horizontal modular pieces  110  that are interconnected via spring clips  114  and rods  116  which are manufactured to best fit the forms, as shown in  FIGS. 9 and 10 . In some embodiments, vertical and horizontal pieces  110  are sized so as to facilitate removal of hip forms through a window, door, or sliding glass door following completion of building  10 . For example, in some embodiments pieces  110  are sized such that building  10  must include an opening having a diagonal dimension of at least six feet to enable removal of the individual pieces  110  from the interior of the finished monolithic building  10 . 
     In some embodiments, the vertical and horizontal pieces  110  are configured of grids of tubular steel made to match a one foot center rebar layout, as shown in  FIGS. 9B and 9C . This system allows for rebar to be installed around the perimeter of building  10  without the use of tape measures or measuring sticks. In some embodiments, hip forms  100  are manufactured to include cutouts  122  configured to fit windows and doors of varying sizes and layouts. This allows the builder to perfectly place door and window layouts without the use of tape measures or other devices which require literacy capabilities. In some embodiments, the hip form system is used for interior applications. In some embodiments, the hip form system is used for exterior applications. In some embodiments, hip forms  100  include turnbuckle braces placed periodically around the perimeter of the air form  90  so that the assembled pieces of the shoring system  80  can stand independently. Further, in some embodiments adjacent sections are interconnected at 90° via a jig  118 , as shown in  FIG. 9C . Still further, in some embodiments arches are used to support the hip form structurally. Such use of arches to support a hip form is illustrated, by way of example, in  FIGS. 15-16 . 
     As shown in  FIG. 10 , in some embodiments, a top section  112  is provided to form various roof shapes. The top section pieces  112  are made in a similar manner as the vertical and horizontal hip form pieces, only rods  116  are placed in the end of hollow form pieces that can extend to match various roof pitches, or to vaulted air forms  90 . In some embodiments, top sections  112  further comprise a clamping mechanism whereby to allow each extension rod or tube  116  to be set at a desired extension length. Extension rods or tubes  116  can be covered with a tubular shield, such as one-inch polyvinylchloride pipe. The tubular shield then acts as a cutting guide for foam or insulation pieces which are positioned over the shields between top sections  112  and the outer surface of air form  90 . 
     Once the forms are completed, the next step in the construction process of monolithic building  10  is to cover the various forms  90  and  100  with an insulating material, such as dense or medium-dense polystyrene sheet foam. In some embodiments, liquid thermoset foam is sprayed onto the exterior surfaces of forms  90  and  100 . In some embodiments, a releasing agent is applied to outer surfaces of forms  90  and  100  prior to applying or spraying a liquid insulating material to the forms. 
     The process for applying the insulating material to the outer surfaces of forms  90  and  100  entails cutting the insulating material into shapes and sizes that correspond to the cumulative outer surface of forms  90  and  100 . Thus, a continuous layer of insulating foam is applied to the entire outer surface of forms  90  and  100 . In some embodiments, an adhesive is used to join adjacent pieces of insulating material. In other embodiments, adjacent pieces of insulating material are interconnected via rods, clips, adhesive tape, rope or some other tethering device or material. Once completed, a lattice of rebar is applied to the outer surface of the insulating material. 
     In some embodiments, the insulating material is replaced with re-usable sheeting made of a strong and often light weight material such as polycarbonate or another polymer material to act as a backing when the cementitious exterior coating is applied. The re-usable sheeting is removed along with the form system and is used over and over with the form system. 
     In some embodiments, the insulating material  120  is equipped with a rebar anchoring system  130 , as shown in  FIGS. 11A and 11B . For example, in some embodiments, a staple  130 , such as a landscape staple is melted into the insulating material  120  prior to installing the insulating material onto the outer surface of forms  90  and  100 . Staple  130  may be preheated via an open flame and subsequently pushed into insulating material  120  thereby leaving free ends  132  on the outer surface of material  120 . When applying rebar  140  to the outer surface of material  120 , rebar  140  is secured to material  120  by twisting or wrapping free ends  132  around rebar  140 . Free ends  132  are further secured by being covered and set in cementitious exterior coating material  150 . In some embodiments, staple  130  is further tied around a portion of form  100  thereby securing insulating material  120  to forms  100 . Following application of coating material  150 , staples  130  are cut thereby releasing forms  100  from insulating material  120 . The cut ends of staples  130  are then bent flat against insulating material  120  and covered by an interior finishing material, such as plaster, insulation, or another finishing material. 
     In some embodiments, it can be desirable to provide a space between the rebar  140  in the insulating material  120 . Accordingly,  FIGS. 12 ,  13 A and  13 B show a spacer  160  that can be placed between the rebar  140  in the insulating material  120 . The spacer  160  can includes a base  162  that has a substantially planar back surface that is placed against the insulating material  120 . The base  162  can be secured to the insulating material  120  via one or more holes  168  in the base  162 . Furthermore, in some embodiments, as shown in  FIG. 13B , staples  130  can extend through these holes  168 . The spacer  160  can secure the rebar  140  within one or more clips  166  (shown as clips  166   a ,  166   b , and  166   c ) coupled to arms  164  (shown as arms  164   a ,  164   b , and  164   c ) that are coupled to the base  162 . The clips  166  can be C-clips or another type of clip. Similarly the clips  166  can be replaced with another type of fastener. The arms  164  can extend away from the base  162 . Thus, in use, the arms can extends away from the insulating material  120  to provide a space between the insulating material  120  and rebar  140  that is supported by the clips on  166 . 
     As shown, the spacer  160  can be configured to hold two or more pieces of rebar  140 . Moreover, the arms  164  can have various lengths. For example, as shown, arms  164   a  and  164   c  are longer than arm  164   b . Additionally, clips  166   a  and  166   c  coupled to arms  164   a  and  164   c , respectively, are oriented at a 90° offset in relation to clip  166   b  coupled to arm  164   b . As such, clip  160  can support a vertical piece of rebar  140 , while clips  166   a  and  166   c  can support a horizontal piece of rebar  140 , or vice versa. Thus, the spacer  160  shown in  FIG. 12  can secure both a horizontal and a vertical piece of rebar  140  away from the insulating material  120 , as shown in  FIGS. 13A and 13B . Moreover, the spacer  160  can be oriented so that it supports rebar  140  at angles other than purely horizontal and purely vertical. 
     Referring to  FIG. 14 , the spacer  160  can be configured to hold only a single piece of rebar  140 . As shown, the spacer  160  can include only a single arm  164  that has only a single clip  166 . As will be understood, the spacer  160  can be oriented on the insulating material  122  to position a piece of rebar  140  within the clip  166  in any orientation, such as horizontally, vertically, or at any other angle. 
     As further shown in  FIG. 14 , the clip  166  can be shaped, sized, and/or otherwise configured to be capable of securing one or more sizes of rebar  140  within the clip  166 . As shown, the inner surface of the clip  166  includes a first inner surface that is closest to the base  164  that is shaped and sized to hold a smaller sized piece of rebar  140 . The inner surface of the clip  166  can also includes a second set of surfaces next to the first inner surface that is shaped and sized to collectively secure a larger piece of rebar  140 . Inner surface of the clip  166  can further include a third set of surfaces that is farthest away from the base  162 . This third set of surfaces can be shaped and sized to hold an even larger piece of rebar  140 , as shown. Moreover, in other embodiments the clip  166  can be configured to hold only two sizes of rebar  140 , as shown in  FIG. 11 , or be configured to hold for or more sizes of rebar  140 . 
     Referring again to  FIGS. 10A and 10B , a finishing step in the construction process for monolithic building  10  is the application of an exterior coating material  150 . As previously discussed, exterior coating material  150  generally includes a cementitious material which is rigid and weather resistant. In some embodiments, material  150  is fire resistant. In some embodiments, material  150  is applied using an air assist spray and pump. In other embodiments, material  150  is applied by hand. In some embodiments, material  150  is applied to a desired thickness via a plurality of thin coats. Once a desired thickness is achieved, forms  90  and  100  are left in place for the required cure time according to the requirements of the selected exterior coating material  150 . Once cured, forms  90  and  100  may be removed from the building structure  10 . 
     In some embodiments, a further finishing step is performed wherein a polyicocyanurate foam or urethane foam is applied to the inside and/or outside surfaces of the completed dome building  10 . This additional material is applied at one to three inches and is then covered with various elastomeric or cementitious coatings or other appropriate surfaces to achieve a desired aesthetic appearance, acoustic attenuation, and other practical needs for the structure. 
     Reference will now be made to  FIGS. 15 through 18C , which provide a detailed illustration of the construction of a building  10  having a representative hip structure  20 , and the interface between the hip structure  20  (specifically a corner structure  180 ) the arches  14  the vaulted apex  12 . Reference will first be made to  FIGS. 15 through 17 .  FIG. 15  illustrates a corner form  182  and air form  90  used in the construction of a hip structure (corner structure  180 ).  FIG. 16  illustrates a portion of the corner form  182  and an outline of the resulting hip structure  182 , arches  14 , and vaulted apex  12 .  FIG. 17  illustrates the hip structure  182 , arches  14 , and vaulted apex  12  with the corner form  182  and air form  90  removed. 
     Referring first to  FIG. 15 , a corner structure  180  is formed by a corner form  182  comprising a plurality of rods  116  provide structure to the corner form  182 . The rods  116  form an outer skeleton that approximates the ultimate shape of the inner surface of the corner structure  180 . The rods  116  are periodically spaced to provide sufficient structural support to the corner structure  180  during construction. As shown, the corner form  182  is configured and placed to lean against a portion of the air form  90 . Thus, the air form  90  supports at least a portion of the corner form  182  to prevent the corner form  182  from falling inwardly in the direction of the air form  182 . Furthermore, the rounded hip form exterior edge that is restrained by the air form prevents the corner hip roof, and thus entire corner structure from moving in the lateral direction thus giving the entire corner form incredible rigidity and structural strength. 
     In some embodiments, the corner form  182  includes one or more internal supports or internal supporting structures  184  coupled to rods  116   a  that support a roof portion of the corner structure  180 . The internal supporting structure  184  reduces or eliminates bending of these rods  116   a  due to the weight of the concrete during the formation of the corner structure  180 . As shown, the internal supporting structure  184  is oriented at an angle with respect to vertical such that its lower portions do not contact the air form  90 . Oriented at a non-horizontal angle, the internal supporting structure  184  act as a tripod having just two legs, which support the rods  116   a  that supports the roof portion of the corner structure  180 . The internal supporting structure  184  is not a tripod, since one leg would go through the air form  90 . Instead, the roof portion is supported by the air form itself to provide complete support to the roof portion of the corner form. In some embodiments, the internal supporting structure  184  includes one or more integrated arch-shaped extension rods or tubes  116   b  coupled to a plurality of vertical supporting rods or tubes  166   c  to which a single layer of wire mesh may be attached. This wire mesh acts to provide lateral support as well as a backing for the sacrificial insulation panels or re-usable solid panels. 
     As shown in  FIG. 16 , a layer of concrete and/or another material is applied to the outer surface of the corner form  182  to construct a corner structure  180 . At the same time, a layer of concrete and/or another material is applied to the outer surface of the air form  92 , forming one or more arches  14 . The corner structure  180  and arches  114  form a monolithic building  10  with a vaulted apex  12 , as previously described. In some embodiments, the one or more arches  14  are formed when two or more corner structures  180  or other hip structures  20  are included in the building  10 . These non-dome-shaped structures can convert the building  10  from a dome (which would be its shape without any hip structures) to one or more arches  10 . 
       FIG. 16  shows the building  10  as transparent to highlight the interface  186  between the corner structure and the arches  14  of the building  10 . As shown, the arches  14  extend seamlessly into the corner structure  180  rather than merely butting up against the corner structure  180  at a seam. This extension is shown as a shared (or overlapping) distance  188  in  FIG. 16 . In other words, the arches  14  and the corner structure  180  are integrally formed as a single structure. Thus, the interface  186  is seamless, since the corner structure  180  and the remainder of the building  10  are formed from a unitary material that is sprayed on or otherwise applied as a unitary layer onto the corner form  182  and air form  90 . As a result of this construction process, no seems are present between the corner structure  180  and the arches  14 . This translates into a structure that has improved load bearing and load transferring capabilities. More specifically, the corner structure  180  is integrated and formed in a monolithic fashion that allows a transfer of physical loads and lateral/shear restraint from the arches  12  through the corner structure  180 . These structural abilities stem, at least in part, from the fact that the arches  12  extend into the corners rather than simply butting against them. The resulting structural strength created from this unitary interface  186  enables the building  10  to be formed of a thinner layer of material and using less reinforcing material. 
       FIG. 17  shows a building  10  formed of two intersecting arches  14  (shown as arch  14   a  and arch  14   b ). While the building includes space for four corner structures  180 , three corner structures  180  are removed for the sake of illustration. As shown, the interface  186  between the corner structure  180  and the arches  14   a  and  14   b  is a seamless interface  186  formed by applying one or more layers across the top of the air form  90  and corner form  182  (forms are shown in  FIG. 15 ).  FIG. 18A-18C  illustrate the nature of this interface  186  by showing a building  10  similar to that of  FIG. 17 , and then by breaking away the corner structure  182  to reveal the shared distance  188  of the interface  186 , or the distance of the corner structure  180  into which the arches  14  extend into the corner structure  180  (or the structure shared by both the arches  14  in the corner structure  180 ). 
     It will be noted that a traditional dome has typically been constructed using an air form system with out-structures added in a modular process. This forms a seam between the dome and the out-structure. In contrast, the buildings  10  shown in  FIGS. 16 through 18A  have a substantial portion (e.g., about 40-70%) of the dome removed. These removals leave two or more bisecting or intersecting arches  14 . The bisecting angle of such arches can vary from about 0 to 90. The structural integrity of this arch system can be maintained with the addition of the corner structure  180  (or other hip structure  20 , as shown in  FIG. 2 ) in a monolithic process, rather than a modular process. As noted, the monolithic process forms a seamless interface between the arches  14  and the corner structure  180  that allows for a transfer of load and lateral restraints in the building  10 . 
     Reference will now be made to the interior structures of the building  10 . In some embodiments, the building can include a plumbing system, even a modular-type plumbing system. In most plumbing applications for home construction the plumbing system is built on site, or in a warehouse for manufactured homes, yet the systems are still built into the home at the time of construction. In some embodiments, a main plumbing tree for building  10  is built offsite. In some embodiments, the plumbing tree is incorporated into an interior wall of the dome building  10 , and is configured to accommodate all of the building&#39;s underground waste in a single run. This allows for the main “trunk” of the plumbing waste system to be built offsite. In other embodiments, a subsurface plumbing channel is created at a depth, for example 1-2 inches below the top of slab surface, to allow plumbing to be easily installed at a later time. 
     Above-ground plumbing for building  10  may also be built into a 6″, 2 lbs density foam wall. Block-outs are left in the base of the foam wall to “accept” a rubber connector that attaches the wall and plumbing section to the underground tree that would be buried and covered with concrete prior to the wall assembly being attached at the jobsite. In some embodiments, hard plumbing, such as PEX pipe would also be attached at this time and block-outs for these particular attachments would be made at the appropriate locations. 
     As previously discussed, for some embodiments foundation  70  is screeded using the Plastiform® system or other similar systems. For these embodiments, some will include a system of pre-marked, color coded attachments which will indicate specific locations where to place the underground electrical system in the pre-placed concrete. This conduit system, whether flex or solid, may be built in an offsite facility and coded with coloration that matches the selected slab form system. For some embodiments, the electrical conduit and wires are pre-run and designed to be interchangeable in length and layout. These features allows for ease in installation. A loom will be attached on the end of each wire length (a quick connect loom) that attaches to outlet receptacles around the exterior of the building. For some embodiments, a wireless toggle switch is used in building  10  in an effort to eliminate the difficulty of running conduit for switching lights. 
     The interior space of monolithic building  10  may be divided by any method known in the art. As shown in  FIGS. 19 through 21 , in some embodiments, a mobile wall system  300  is provided wherein the interior space of building  10  by be easily adjusted into a one, two, three, four, or more bedroom home, an office space, or even a duplex unit. Since building  10  has a completely structural, integral exterior shell, interior partition walls  302  may be easily and freely moved around the interior of the structure, with exception of the plumbing wall which is a stationary wall. However in cases where the subsurface plumbing channel is employed, all walls can be easily and freely moved so long as one or more walls (or connecting walls) that require plumbing crossover said subsurface plumbing channel. 
     A movable wall system  300  in accordance with the present invention may include a wall frame built using studs (e.g., metal studs)  306  and track, and panels (e.g., 2 foot by 8 foot panels)  308  inserted between the studs  306 . The spacing between metal studs  306  can be approximately 12, 18, 24, 30, 36, or greater than 36 inches. The height of the studs  306  can be approximately 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, or more than 10 feet. The panels  308  can have various thicknesses, such as a thickness ranging between 1-12 inches, 1-6 inches, and/or 2-4 inches. The panels  308  can be made of foam or another material. For example, the foam panels  308  can be two pound density expanded polystyrene foam panels. In some embodiments, as shown in  FIG. 19 , every two feet, two metal studs  306  can be used back to back making an “H” shape channel for retaining the foam panels  308 . 
     In some embodiments, the panels  308  are routed, or a dado is cut in the top, bottom, and side of the panel to run electrical wiring. This wiring then uses standard wiring procedures to fasten gang boxes to the studs and run the wiring. At the end of each wall a special outlet with a male plug is run that will plug into the interior side of the exterior wall receptacle. This allows for the electrical in the movable wall system  300  to become active. In some embodiments, the sturdy foam wall panels are covered with a fire resistant fabric, or a fire retardant elastomeric paint. In some embodiments, the panels are adhered to the floor surface with silicone caulking. 
     As shown in  FIGS. 19 and 20 , in some embodiments, a ceiling track system  304  is provided having a similar construction to the interior partition walls  302 , discussed above. A ceiling track system  304  may include a stud configuration having a plurality of channels in which to retain panels  308 . In some embodiments, the ends of the panels  308  are modified to include dadoes for running electrical circuitry. As such, various ceiling fixtures (such as lights, ceiling fans, fire detectors, etc.) may be changed easily, or moved around to fit various wall arrangements. The 2×8 studs  306  can be used where the ceiling spans of building  10  allow. Where the ceiling span exceeds the capabilities of a 2×4 metal stud, larger studs may be used. As shown in  FIGS. 20 and 21 , metal tabs  320  are provided on the top tracks to allow the interior partition walls  302  to be fastened to a ceiling track system  304 . The metal tab is selectively attached and detached to the ceiling track system  304 . 
     In some embodiments, building  10  further comprises a basement  170 , as shown in  FIGS. 22A ,  22 B, and  23 . Basement  170  is provided by any known method in the art. Subsequent to providing basement  170 , air form  90  is combined with an air form extension piece  190 , as shown. Air form extension piece  190  generally comprises a cylindrical air form that extends or lengthens the base of air form  90  such that air form  90  and extension piece  190  are secured to basement  170  by form securing system  80 , as discussed previously. Hip forms  100  are applied to air form  90  as previously discussed, wherein the base of hip forms  100  are supported by a surface edge  172  of basement  170 , as shown in  FIG. 23 . In some embodiments, an extruded foam coating  174  is further applied to an outer surface of basement  170 , whereby to provide insulation or act as a water barrier. 
     Referring now to  FIGS. 24A and 24B , in some embodiments, an adjustable prolate form  200  is provided. Prolate form  200  generally comprises an arched or air form section  210  having a plurality of eyelets or grommets  212  evenly spaced around the form&#39;s base perimeter. Prolate form  200  further comprises an extension base form  220  which is generally cylindrical and comprises a plurality of eyelets or grommets  222  which are evenly spaced around the form&#39;s perimeter. In some embodiments, grommets  212  and  222  are equally spaced along their respective perimeters thereby permitting the grommets to be aligned. Once aligned, grommets  212  and  222  are fastened together via a fastener  232 , such as a zip tie, a piece of rope, or a piece of wire. 
     In some embodiments, extension base form  220  further comprises a system of adjustable grommets  230  whereby the circumference of base form  220  may be selectively adjusted to match the circumference of air form  210 . A desired circumference of base form  220  is maintained by coupling adjustable grommets  230  via a fastener  232 . Unused grommets  230  are covered and sealed with an adhesive strip, such as an adhesive tape, thereby providing an airtight base form  220 . In some embodiments, the seam  240  is further sealed with an adhesive tape as may be necessary to provide an airtight form. 
     In some embodiments, air form section  210  is joined to base form  220  by interwrapping base form edge  224  with air form edge  214 . In some embodiments, a rope is sewn into edges  224  and  214  to assist in interwrapping the two edges. The interwrapped configuration of the two edges  224  and  214  is maintained by securing a fastener  232  through grommets  212  and  222 . An adhesive tape may be further applied to seam  242  and grommets  212  and  222  as necessary to provide an airtight form. 
     In some embodiments, base form  220  further comprises a rope  226  which is sewn into the base perimeter edge to facilitate securement of form  220  to basement foundation  170  via securing system  80 . In other embodiments, base form  220  further comprises a mid-rope  228  which is sewn into a pocket  234 . In some embodiments, mid-rope  228  is secured to basement foundation  170  via securing system  80  to compensate for a shallower basement depth. In some embodiments, base form  220  comprises a plurality of mid-ropes to facilitate various basement foundation depths. 
     Referring again to the hip form  100  (as previously discussed with reference to  FIGS. 8A-9 ), as shown in  FIGS. 25A through 25D , in some embodiments a trailer-based hip form  400  can be used to form a hip structure  20  (as shown in  FIGS. 1A-1D ), such as a garage for storing a vehicle or other usable space.  FIG. 25A  shows a trailer-based hip form  400  attached to a vehicle  402 . The trailer-based hip form  400  is driven to a construction site and backed into place adjacent a building  10 . The trailer-based hip form  400  includes a plurality of retractable and extendable sections (e.g., retractable side sections  404   a  and  404   b  and a retractable roof section  406 ), with each section including a plurality of rods  116 . The rods  116  can be similar to those previously described. 
       FIG. 25B  shows the trailer-based hip form  400  in place adjacent to a building  10 . At this point, the extendable sections are extended to extend the trailer-based hip form  400  so that it touches the foundation  70  and the building  10 . For example as shown, the extendable side sections  404   a  and  404   b  can be extended downward to touch the foundation  70  or the ground. Additionally, the extendable roof section  406  can extend rearwardly toward the building  10  until it contacts the building  10 . 
       FIG. 25C  shows insulating material  120  that has been applied to the trailer-based hip form  400 . The insulating material  120  can be applied the same manner as previously described with reference to  FIGS. 9 through 15 . At this point, the construction of a hip structure  20  can be finalized in the manner previously described. After the hip structures  20  is finalized, the extendable and retractable sections are retracted and the trailer-based hip form  400  is withdrawn from the hip structure  20  and driven away by the towing vehicle  402 . 
     Reference will now be made to  FIGS. 26 through 29 , which illustrate a scaffolding system that can be used in the construction and/or repair of the monolithic buildings  10  previously described. This scaffolding system is referred to as SPiFolding due to its unique properties, appearance and construction as compared to traditional scaffolding systems. The SPiFolding  500  can be configured with a shape that substantially follows the exterior or interior curvature of the building  10 . As such the SPiFolding  500  can generally be disposed within a certain distance from the surface of the building  10 . For example, the scaffolding system  500  can always be within, for example, approximately 6, 12, 18, 24, 36, 42, or 48 inches, or another dimension, of the building  10 . In a specific embodiment, the scaffolding system  500  can always be within approximately 30 inches of the building  10 , therefore not requiring a lot of safety rails since the furthest drop is only 30 inches. By allowing construction workers to move about the SPiFolding, the need for man lifts or other lifting equipment can be reduced or eliminated. 
     Once assembled, the SPiFolding  500  facilitates the installation of rebar, dormers and other exterior facades, textures, or aesthetic designs. Further, systems and methods provided herein allow for the installation of interior facades, textures, or aesthetic designs. The SPiFolding  500  provides a sturdy and secure platform from which to apply concrete, shotcrete, or another material to the building forms. The SPiFolding  500  allows multiple workers to work on the same building  10  at the same time. 
     As shown in  FIG. 26 , the SPiFolding  500  can include a series of arches  502  that can allow a complete span around the building with few or no supports other than on the ground. The SPiFolding  500  includes a set of vertical supports coupled to the arches  500 . The vertical supports can be coupled to horizontal supports to form corner scaffolding that surrounds a hip structure  100  of the building  10 . A series of horizontal supports  504  can extend horizontally between the arches  502 . Additionally, in some embodiments, each of the arches  502  can be coupled to an apex ring  506  at the top of the SPiFolding  500 . One or more open posts  508  extend upward from the perimeter of the SPiFolding  500 . These posts  508  or another such structure can be configured to receive and couple to safety rails. In some embodiments, the SPiFolding  500  can have a no-bolt design that comprises sleeves and pins to connect all sections of the arches  502  and horizontal supports  504 . 
       FIG. 27  illustrates a smaller embodiment of SPiFolding  500  than that shown in  FIG. 28 . As shown, the SPiFolding  500  can incorporate some or all of the same parts that the SPiFolding  500  of  FIG. 26 . As such, the SPiFolding  500  can be assembled to fit the size of the building. For example, the arches  502  can include multiple sections, which can be added or removed based on the desired size of the resulting SPiFolding  500 . 
     In some embodiments, the SPiFolding illustrated in  FIG. 26  is configured to correspond to and be used in association with the exterior surface of the building, and some of the parts of the SPiFolding can be adjusted or removed to result in a configuration that can be used within the building, such as the configuration shown in  FIG. 27 , 
       FIGS. 28 and 29  illustrate a platform  520  that can be selectively attached to the SPiFolding  500  of  FIGS. 26 and 27 . The platform  520  can include one or more leveling devices  522  that support one or more planks  530  in place in a relatively horizontal position. The one or more leveling devices  522  can be configured to adjust the orientation of the plank  530  automatically or manually. As shown, the leveling device  522  includes an arc-shaped member  528  having a plurality of holes therein. The arc-shaped member  528  is coupled to one or more hooks or other attachment members (not shown) that are configured to attach to the horizontal supports of the SPiFolding  500 . A locking bar  524  and locking tab  526  can be configured to lock the arc-shaped member  528  in place when one of the locking tabs  526  is inserted into a hole of the arc-shaped member  528 . The orientation of the platform  520  can thus be adjusted by moving the locking bar  524  and locking tab  526  so that the locking tab  526  can inserted into another hole of the arc-shaped member  528 . 
     As further shown in  FIGS. 28 and 29 , the platform  520  includes one or more bars  536  that are configured to hold the plank or planks  536  in place. Moreover, safety rails, which include vertical rails  534  and horizontal rails  532 , can be coupled to the platform  520 . 
     Reference will now be made to  FIGS. 30A and 30B , which illustrate modular barracks  600 . The modular barracks  600  can be used to form a temporary or permanent building. The modular barracks  600  can include a plurality of modular building units  602 . As shown, each modular building units  602  can have a substantially rectangle or base and a semicircular roof  612  to form an upside-down U-shaped side profile. Each modular building unit  602  can also include a floor surface. In some embodiments, each modular building unit  602  can include one or more openings, such as a door opening  604  or other wall opening  606 . Wall openings  606  can extend substantially the entire length of the modular building units  602  for only a portion of this distance. Two or more modular building units  602  having wall opening  606  can be placed adjacent to one another such that the wall openings face one another and the two or more modular building units  602  form a larger living space than otherwise possible with a single modular building units  602 . Thus, a modular building unit  602  can have an opening in a wall of that is disposed adjacent to a corresponding opening in a wall of an adjacent modular building unit  602 . 
     One or more of the modular building units  602  includes an overlapping portion  610  that includes an extension of the walls and roof outward from one side of the modular building unit  602 . The overlapping portion  602  can be placed above and around an adjacent modular building unit  602  to reduce the likelihood of rain, sunshine, or other foreign objects from entering into the modular building unit  602  between two adjacent units. 
     As shown in  FIG. 30A , each modular building unit  602  can be added to existing building units by being lowered in place such that the overlapping portion  602  of the new unit overlaps one of the existing units. 
     As shown in  FIG. 30B , after the module modular building units  602  are in place, a roof structure is placed over the top of all of the units. As shown, the roof structure can include a series of rails supports  620  followed by a canopy member  622 . The rail supports  620  are coupled to each modular building unit  602  using one or more fasteners. The rail supports  620  include a central rail that extends the length of the barracks, and support rails  626  thereon perpendicular to the central rail&#39;s  24  at an angle. The canopy member  622  includes a flexible member, such as a tarp, canvas, or other water impermeable material. The canopy member  622  includes a rigid member, including a sheet of material, such as would, of metal, or plastic. 
     At least some embodiments of the present invention result in zero to extremely low amounts of waste material from building such rounded vault forming structures. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.