HyPar Thin Shell Concrete Roof

The basic form is made as follows but can be adjusted to suit any building design. These specifications were taken from the book Latex Concrete Habitat by Dr. Albert Knott and Dr. George Nez. Other researchers and builders propose slight differences to the framing details and mix design, but the general process is the same.

The Edge Members: four poles with two slightly longer than the other two, and fastened so that the two longer poles meet at one corner. That corner can be lifted and propped on a post.

The Screen Surface: Posts are marked in 1′ (30cm) segments and then 1′ wide strips of fiberglass fly-screen are wrapped from one side of the frame to the other in both directions, layering them on so that they overlap by 6″ and stapling down to the frame.

Coating and Surface: The first coat is a latex slurry mixture of latex liquid and portland cement and water and brushed on to the surface using long-handled brushes. The next layer is a latex mortar mixture made of latex slurry and sand and applied until the surface is about 1cm thick.

Other Considerations: The surface can be used for roofs, arched shelters, and walls, and additional strength provided by adding additional layers of fabric and mortar. The surface can also be perforated for smokestacks and skylights. Only hand tools are required to build the structure and electricity is not essential. It is possible to construct the roof first before the walls and the roof structure is so light that it can be lifted onto the walls afterward or can have separate columns supporting it.

Technical support may be provided by the trained builder of the system.

The complete lifecycle is unknown, but there are HyPar structures that have been standing for over 20 years. Tests have shown that quality assurance is important in the construction of HyPar roofs because deterioration can happen if details or the mix is done poorly.

Testing of the system is being performed separately and does not relate to the projects that have or are currently being completed by implementers of the system. Research has been performed for the material science of the HyPar shell to determine the optimal mix design and structural performance during an earthquake.

The roof is lightweight and would therefore not be fatal to occupants if damaged by an earthquake. Workers would be subject to general dangers of a construction site including working with sharp tools. Construction does not require the use of large machinery.