Pod Assembly Floor
Rolling steel jigs, overhead gantry crane, polished slab. The line builds 1B / 2B / 3B pod modules in parallel.
Where every dome begins.
A captive 15,000 sq ft modular plant in or near Polk County, Florida — co-located with the flagship community to eliminate freight, lead time, and supply-chain risk. Built first to deliver our 150 units. Built to last as a standalone manufacturing business.
Why Captive Manufacturing
We own the line. We own the cost.
Modular factories typically serve dozens of clients. Ours serves one — until the flagship is built.
01
Stabilized unit cost
Captive production fixes blended cost at $163K–$229K per unit — insulated from contractor markups and labor scarcity.
02
Community comes first
Year 1–3.5 capacity is reserved exclusively for the 150 Polk units. No external orders compete with the flagship build.
03
Then it pivots
By Year 4 the factory becomes its own profit center: custom dome kits and B2B ADUs adding ~$1.7M/yr to corporate NOI.
The Facility at Completion
Four bays. One continuous line.
Renderings of the plant at full tool-up. The Polk County site is chosen to co-locate within trucking distance of the flagship.
Airform & Shotcrete Bay
On-site airform inflation, structural rebar grid, and sprayed shotcrete shell — the monolithic dome cures in place.
Interior Pod Fabrication
Insulation, plumbing rough-in, electrical, kitchens, and finishes — all completed before the pod ever leaves the floor.
Staging Yard & Loading Dock
Solar carport, dome airforms, materials staging, and dock-high doors sized for 53-ft trailers to the community site next door.
Production Flow
Five steps from jig to keys.
Step 01
Steel jig assembly
Pod frames sized & welded on rolling jigs.
→Step 02
Airform inflation
On-site at the slab — circular ring beam set.
→Step 03
Shotcrete shell pour
Rebar grid + monolithic concrete spray.
→Step 04
Pod fabrication
Insulation, MEP, kitchens, finishes — at factory.
→Step 05
Delivery & set
Trucked next door, craned onto slab inside shell.
How a Dome Home is Built
Layer by layer. Slab to skyline.
Every unit moves through the same eight-step sequence — from the poured slab to the finished, storm-rated residence.
Step 01
Prepare Foundation
Circular slab poured with embedded plumbing and electrical.
Step 02
Inflate Airform
Flexible airform anchored and inflated to dome shape.
Step 03
Steel Reinforcement
Rebar mesh tied across the inside of the airform.
Step 04
Shotcrete Shell
High-strength concrete sprayed in multiple passes.
Step 05
Cure & Remove
Shell cures monolithically. Airform deflates and is removed.
Step 06
Pod Installation
Factory-built interior pods craned in and anchored.
Step 07
Insulation & Finishes
Spray-foam, drywall, fixtures and interior finishes.
Step 08
Complete Dome Home
A finished, hurricane-rated residence ready for keys.
The 7-Layer Shell
Seven layers. One continuous skin.
- 01Interior finish
Smooth plaster or drywall — paint-ready.
- 02Interior insulation
Spray foam, R-20 to R-30+.
- 03Rebar reinforcement
High-tensile steel mesh grid.
- 04Concrete shell
Shotcrete, 6–8″ thick monolithic.
- 05Exterior insulation
Reflective thermal barrier.
- 06Waterproof membrane
Blocks moisture intrusion.
- 07Elastomeric finish
UV-resistant, flexible exterior.
Dome vs. Traditional
Same lot. Two very different outcomes.
Category
TerraSphere Dome
Traditional Wood Frame
Structural shell
✓Solid monolithic concrete
✕Wood frame with hundreds of joints
Wind behavior
✓Aerodynamic — wind flows over
✕Box shape — wind hits & lifts
Roof failure risk
✓No attic, no uplift surface
✕Attic uplift is the #1 failure point
Fire resistance
✓Non-combustible concrete shell
✕Highly flammable wood + asphalt
Mold / rot / pests
✓Impervious to all three
✕Susceptible across the lifespan
Expected lifespan
✓100+ years
✕20 – 50 years
Insurance cost
✓Lower premiums
✕Higher premiums
Year-round energy
✓Thermal mass — up to 70% savings
✕Constant HVAC load
15,000
sq ft footprint
150
Polk flagship units
~60
B2B units / yr (post-pivot)
42
Months to deliver flagship
Factory Lifecycle
Two phases. One asset that pays twice.
Phase A · Months 0 – 42
Build the 150 Polk units
100% of capacity feeds the flagship community. The factory exists to lock in cost and timeline — it is a construction tool with a corporate envelope around it.
- · 50 STR (Airbnb) units delivered first — cash flow by Month 18
- · 50 LTR units delivered Months 19–30
- · Final 50 LTR units delivered Months 31–42
Phase B · Year 4+
Pivot to B2B & custom kits
With the community delivered, the line pivots to external revenue. Same crew. Same tooling. New buyers.
- Custom Landowner Kits$120K–$180K · ~$45K profit / unit · ~20 / yr
- B2B Developer ADUs$65K–$85K · ~$20K profit / unit · ~40 / yr
- ~$1.7M / yr factory NOIStandalone enterprise value ≈ $13.6M at 8× multiple
Location
In or near Polk County, Florida.
The factory is sited within trucking distance of the flagship community in the Davenport / Haines City corridor. Co-location eliminates freight cost, removes inter-state regulatory complexity, and lets the same crew shuttle between fabrication bay and on-site shotcrete bay in a single day.