In order to appreciate this simplistic structure each step must be analyzed :




   Church arhitects and general contractors know how difficult, time consuming and costly the construction of a dome can be when using conventional framing techniques with copper cladding, or other standard methodologies.
   A revolutionary technique has now been developed by Metro Cast Corporation which permits the creation of large prefabricated dome sections that can be quickly and economically assembled in place at a job site.
   This innovative casting procedure utilizes a high strength precast polymer concrete combined with custom designed stud framing members to create interlocking sections that insure positive watertight joints.
   The 22' diameter dome for All Saints Greek Orthodox Church in Canonsburg, PA is an example of the unique capabilities of polymer concrete in dome construction.
It was completely installed in only three working days.
   The project architect, Mr. John Krusienski of Domianos Brown Andrews Architects wrote the manufacturer upon completion of the project : "Your ability to fabricate this entire dome in only four (4) sections with a tight interlocking joint detail facilitated and accelerated completion of the total project. The dome color is exactly the shade we wanted and uniformity is excellent. From both a cost and performance point of view, we feel your new innovative polymer concrete system offers an effective approach to future dome construction."
 
 

   Dome divided into 4 sections

   Diameter = 22' - 0"

   Radius = 11' - 0"

   Wt. per sqft = 15 lb./sqft.

   Total sqft = 790 sqft.

   Total weight = approx. 12,000 lb.
 
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   Initially, a skeletal dome shape is formed in four sections and pre-erected so as to check alignment and fit and
to simulate the finished shape.

 
Plywood is then attached from the inside to create the casting mold.
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Each section is then placed face up. The mold surface is finished to a desired smooth texture and coated with parting agents.
 
Working from the side as well as utilizing a platform - like gantry, the polymer concrete matrix is applied by skilled trawlers who at times can be considered artisans for performing this tedious and demanding task. Specially designed inserts are the cast into it along with fiberglass reinforcement.
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Performed galvanized structural steel trusses are then permanently welded to the cast-in inserts.
 
After a twenty-four hour ambient temperature cure, the entire unit is lifted from the mold by a
hi-low truck and set aside until all the other sections are completed.
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The units are then test assembled.
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All surfaces are checked for any imperfections. The joining of each of the four spherical pieces is tested for water tightness and accuracy and then dis-assembled, placed on a low-bed trailer and transported to the job site, in this case a distance of 300 miles.
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The dome sections were lifted and placed onto the structural base, utilizing a simple lightweight crane. All on-site assembly work was done from the inside. Thus, the world's first prefabricated polymer concrete dome is now gracing this edifice in Pennsylvania, a symbol of the versatility and creativity possible with polymer concrete.
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Similar polymer concrete technique can be utilized and applied for use in creating arches and domes of almost any size or contour in segments to fit design criteria.