WO2021116779A1

WO2021116779A1 - Flat two-stage heeled waffle ceiling

Info

Publication number: WO2021116779A1
Application number: PCT/IB2020/053598
Authority: WO
Inventors: Mansoor ALIABADI FARAHANI; Mehdi Mousavi; Kaveh EBRAHIMI; Kianoush GHAZVINI; Poriya MIRZAEI
Original assignee: Aliabadi Farahani Mansoor
Priority date: 2019-12-08
Filing date: 2020-04-16
Publication date: 2021-06-17

Abstract

A flat two-stage heeled waffle ceiling and a method of constructing the ceiling are provided. The ceiling includes low blocks (102), upper blocks (104), low reinforcements (103), upper reinforcements (105) and spacers (106). The lower blocks (102) are then arranged in designated locations and placed at appropriate distances using the spacers (106). The spacers (106) should be used to create the appropriate distance between the lower blocks (102). The lower reinforcements (103) are placed at a distance between the lower blocks (102) and to provide minimum standard concrete cover on the lower blocks (102). Then the upper blocks (104), which form the section in the lower blocks (102), are placed on top of them and spaces between the upper blocks (104) are maintained by the spacers.

Description

Title of Invention: flat two-stage heeled waffle ceiling

[0001] [This Application is filed and provided based on 3 local Applications, at IRAN'S

Islamic Republic of Iran Intellectual Property Center

[0002] A: No. 139850140003008144 dated on Dec 8, 2019. [0003] B: No. 139850140003008237 dated on Dec 10, 2019. [0004] C: No. 139850140003008279 dated on Dec 11 , 2019.

Technical Field

[0005] The invention is a technique for the construction of building ceilings in the field of construction and civil engineering.

Background Art

[0006] A ceiling is an overhead interior surface that covers the upper limits of a room. It is not generally considered a structural element, but a finished surface concealing the underside of the roof structure or the floor of a story above. Ceilings can be decorated to taste, and there are many fine examples of frescoes and artwork on ceilings especially in religious buildings. The most common type of ceiling is the dropped ceiling, which is suspended from structural elements above. Panels of drywall are fastened either directly to the ceiling joists or to a few layers of moisture-proof plywood which are then attached to the joists. Pipework or ducts can be run in the gap above the ceiling, and insulation and fireproofing material can be placed here. Alternatively, ceilings may be spray painted instead, leaving the pipework and ducts exposed but painted, and using spray foam. A subset of the dropped ceiling is the suspended ceiling, wherein a network of aluminum struts, as opposed to drywall, are attached to the joists, forming a series of rectangular spaces. Individual pieces of cardboard are then placed inside the bottom of those spaces so that the outer side of the cardboard, interspersed with aluminum rails, is seen as the ceiling from below. This makes it relatively easy to repair the pipes and insulation behind the ceiling, since all that is necessary is to lift off the cardboard, rather than digging through the drywall and then replacing it. Other types of ceiling include the cathedral ceiling, the concave or barrel-shaped ceiling, the stretched ceiling and the coffered ceiling. Coving often links the ceiling to the surrounding walls. Ceilings can play a part in reducing fire hazard, and a system is available for rating the fire resistance of dropped ceilings.

[0007] Different ceiling systems are used in the building industry, each with its own advantages and disadvantages. As ceilings account for a relatively large share of the cost of a building, designers of buildings have designed and implemented a variety of systems to make them more economical. These efforts include savings on concrete and steel, reduction or elimination of molding, improvement of construction methods and construction quality. In general, a waffle ceiling is one of the best and most desirable type of ceiling in terms of technical function and performance. In recent years, improvements have been made to fix some of the problems with the construction of waffle ceilings. For example, the use of stay-in place molds instead of temporary ones facilitates construction and eliminates the difficulty of removing molds. However, even in these methods, non-heeled sections are still used which are of poor structural performance at deflections, especially at negative deflections, just like the elimination of the lower flange of I- shaped beams due to construction restrictions.

Summary of Invention

[0008] Components and construction technique for flat two-stage heeled waffle ceiling includes components and process of constructing a flat waffle ceiling in which problems encountered during construction are eliminated by the use of integrated filling blocks leading to high speed, accuracy and high quality. This purpose is to convert non-heeled sections into heeled sections through using concrete ductility properties. In this construction technique, first the mold under the ceiling, quite aligned and leveled, is fixed. The lower blocks are then arranged in designated places according to the layout design and spaced to appropriate and precise distances using a spacer. The lower blocks are laid on the surface of the molds with concrete casting indentation embedded below and around them for the concrete to enter in order to join and reinforce the joint. Spacers of appropriate and durable material are embedded between the lower blocks to provide proper spacing for preventing the blocks from moving around. The lower reinforcements are then placed on the spacers and between the lower blocks to create horizontal distances between the blocks on one hand and provide for a minimum standard coverage of concrete on the other hand. At this point, it is easy to examine the placement of bars and lower blocks because of the low height of the blocks. Then, the upper blocks, forming the section on the lower blocks, are placed on top of them, and using spacers, the distance between the upper blocks is maintained. The upper blocks are designed with specified appropriate spaces for concrete coverage and suitable locations for the placement of upper reinforcements. By placing the upper reinforcements in specified locations, the upper blocks can no longer be displaced and concrete can be cast on the entire surface. Required numbers of spacers can be used for each block. The spacers, having specified seats for the bars to be placed and fixed in them, maintain standard distances between the bars and the molds, so that in addition to providing proper alignment and order, prevent their displacement and increase the speed and quality of construction. The spacers, made of durable material and holes in them for concrete passage, allow for utmost quality, precision and speed of concrete casting. The number of seats for the placement of the bars, their distance and dimensions of spacers can be varied. Due to the form designed for the filling blocks at the lower part, existence of heels in this part and the integrated bonding of the ceiling due to the integrated concrete casting on the filling blocks, this type of ceiling has a higher flexural efficiency than non-heeled sections. Construction filling blocks can be manufactured from any suitable materials.

Technical Problem

[0009] Problems with conventional waffle ceilings include:

[0010] Problems with fixing and removing molds.

[0011] Obligations to create non-heeled structural sections due to the limitations in the construction of conventional waffle ceilings.

[0012] Limited flexural efficiency of the ceilings with non-heeled sections

[0013] Calculation limitations of deflection and vibration control in non-heeled sections.

[0014] Difficult reinforcement and inspection operations during construction due to the height of the integrated blocks. [0015] Slow construction speed and need for skill and expertise.

[0016] Errors and low accuracy in construction.

[0017] Difficult placement and fixing of filling blocks.

[0018] Unwanted displacement of filling blocks during ceiling concrete casting.

[0019] Difficulty in adhering to concrete coatings of bars according to the standard

[0020] Reduction of the structure quality.

[0021] Permeation of oil from greasy molds to ceiling round bars

[0022] Difficulty in maintaining the standard distance between the bars.

[0023] Difficulty in maintaining precise width of ceiling joists.

Solution to Problem

[0024] Includes components and process of constructing a flat waffle ceiling in which problems encountered during construction are eliminated by the use of integrated filling blocks, leading to high speed, accuracy and high quality. The purpose is to convert non-heeled sections into heeled sections through using concrete ductility properties. In this construction technique, first the mold under the ceiling, quite aligned and leveled, is fixed. The lower blocks are then arranged in designated places according to the layout design, and spaced to appropriate and precise distances using spacers. The lower blocks are laid on the surface of the mold with concrete casting indentations embedded below and around them, into which concrete enters and strengthens the joint. Spacers of appropriate and durable material are embedded between the lower blocks to provide proper spacing for preventing the blocks from moving around. The lower reinforcements are then placed on the spacers and between the lower blocks to create horizontal distances between the blocks on one hand and provide for a minimum standard coverage of concrete on the other hand. At this point, it is easy to inspect the placement of bars and lower blocks because of the low height of the blocks. Then, the upper blocks, forming the section on the lower blocks, are placed on top of them and using spacers the space between the upper blocks is maintained. The upper blocks are designed with specified appropriate spaces for concrete coverage and suitable locations for upper reinforcements placement. By placing the upper reinforcements in specified locations, the upper blocks can no longer be displaced and concrete can be cast on the entire surface

Advantageous Effects of Invention

[0025] Easy placement of lower reinforcements due to low height of the lower block

[0026] Possibility of following concrete cover requirements as per the standard through the entire ceiling.

[0027] Possibility to create different structural forms for joists due to the possibility of forming blocks

[0028] Reduction of construction errors

[0029] Remarkably easy and fast construction

[0030] No need for removing molds due to using stay-in-place molds

[0031] Possibility to use dropped ceiling

[0032] Sound and heat insulation

[0033] Elimination of unintentional worker errors in non-compliance with standard cover.

[0034] Elimination of the possibility of lower rebar contact with possibly greasy molds [0035] Easy reinforcement and accurate flawless ceiling construction [0036] Easy inspection of construction works.

[0037] Improved flexural efficiency, deflection and vibration of the ceiling

[0038] Better function at negative deflection areas

[0039] Lighter and more economical

[0040] Ceiling high moment of inertia

[0041] More rigidity against vibration

[0042] More resistance against fires than waffles with temporary molds [0043] Employment of best structural forms for ceiling elements [0044] Possibility to incorporate slab with cable [0045] No rebar movement [0046] No displacement of filling blocks during construction and concrete casting [0047] Full concrete cover under rebar

[0048] No penetration of air and moisture into the rebar as well as protection of the rebar against fire.

[0049] Increased quality of concrete casting

[0050] Well-ordered, fast and high precision block placement

[0051] Remarkably easy and fast construction

Brief Description of Drawings Fig.1

[0052] [Fig.1 ] Three-dimensional drawing of the construction process

Fig.2

[0053] [Fig.2] Three-dimensional drawing of components layout

Fig.3

[0054] [Fig.3] Three-dimensional drawing of components layout

Fig.2

[0055] [Fig.4] Three-dimensional drawing of the lower block

Fig.2

[0056] [Fig.5] Three-dimensional drawing of the upper block

Fig.2

[0057] [Fig.6] Illustration of the layout and construction of flat heeled waffle ceiling

Fig.2

[0058] [Fig.7] Three-dimensional drawing of the spacer

Description of Embodiments

[0059] Components and construction technique for the flat two-stage heeled waffle ceiling includes components and process of constructing a flat waffle ceiling, which eliminates problems encountered during construction by employing integrated filling blocks leading to high speed, accuracy and high quality. This is achieved by converting non-heeled sections into heeled sections through using concrete ductility properties. Based on the drawings 1 to 6, first the under ceiling mold (101), quite aligned and leveled, is fixed. The lower blocks are then arranged on the blocks in designated places according to the layout design, and spaced to appropriate and precise distances from each other using the spacer (106). The lower blocks are laid on the surface of the mold with concrete casting indentations (107) embedded below and around them, into which concrete enters and strengthens the joints. Spacers are used to produce appropriate distances between the lower blocks. The spacers have to be of appropriate and durable material to prevent the blocks from moving around. Then, lower reinforcements (103) are placed on the spacers and between the lower blocks. The spacer preserves the horizontal distances between the blocks and between the rebar and molds. Then, the upper blocks (104) from the section laid on the lower block (108) are placed on top of them and the distance between the upper blocks is sustained using spacers. The upper block is designed in a manner in which appropriate space for concrete casting (109) and suitable location for the placement of upper reinforcement (110) are specified. By placing the upper reinforcements (105) in the specified location, the upper blocks can no longer be displaced and concrete can be cast on the entire surface. Based on the drawing No.7 the spacer is provided with the spacer base (114) underneath creating the standard distance between the mold (101) and the lower reinforcement (103). Moreover, there are block connection clamps (112) on the sides allowing the block to be fixed in place. Filling blocks retainer (113) is employed for creating standard distance between blocks in case of 2-piece blocks which upon using block and mold spacer (111) maintains its standard distance from the mold and is fixed also through strengthening corner spacer 116. The locations for the placement of the bars (115) are embedded on the spacer, in which bars are placed and fixed. Moreover, the spacer is provided with concrete penetration space (117) in it for letting the concrete underneath and maintaining the quality of concrete casting. Examples

[0060] Components and construction technique for the flat two-stage heeled waffle ceiling includes components and process of constructing a flat waffle ceiling, which eliminates problems encountered during construction by employing integrated filling blocks leading to high speed, accuracy and high quality of construction. This is achieved by converting non-heeled sections into heeled sections through using concrete ductility properties. In this technique, first the mold under the ceiling, quite aligned and leveled is fixed. The lower blocks are then arranged in designated places according to the layout design, and spaced to appropriate and precise distances using a spacer. The lower blocks are laid on the surface of the mold with concrete casting indentation embedded below and around them into which concrete enters and strengthens the joint. Spacers are used between the lower blocks to provide proper distance. The spacers have to be of appropriate and durable material to prevent the blocks from moving around. The lower reinforcements are then placed on the spacers and between the lower blocks to observe horizontal distances between the blocks on one hand and provide for a minimum coverage of concrete as per standard on the other hand. At this point, inspecting the placement of bars and lower blocks can be easily carried out due to the low height of the blocks. Then, the upper blocks, from the section on the lower blocks, are placed on top of them, and using spacers the distance between the upper blocks is maintained. The upper block is designed in a manner in which appropriate space for concrete casting and suitable location for the placement of upper reinforcement are specified. By placing the upper reinforcements in specified locations, the upper blocks can no longer be displaced and concrete can be cast on the entire surface.

Industrial Applicability

[0061 ] Components and construction technique for the flat two-stage heeled waffle ceiling is a technique used for constructing structural ceilings for different places required to be carried out in short periods, high precision and quality and under restrictions of architectural space.

Reference Signs List

[0062] 101. Flat mold [0063] 102. Lower block

[0064] 103. Lower reinforcement

[0065] 104. Upper block

[0066] 105. Upper reinforcement

[0067] 106. Spacer

[0068] 107. Concrete indentation

[0069] 108. Section on the lower block

[0070] 109. Concrete casting space

[0071] 110. Upper reinforcement placement locations

[0072] 111. Block and mold spacer

[0073] 112. Block connection clamps

[0074] 113. Filling blocks retainer

[0075] 114. Spacer base

[0076] 115. Rebar placement location

[0077] 116. Strengthening corner spacer

[0078] 117. Concrete transfer space

Claims

[Claim 1] Components and construction technique for the flat two-stage heeled waffle ceiling includes components and process of constructing a flat waffle ceiling, which eliminates problems encountered during construction by employing integrated filling blocks leading to high speed, accuracy and high quality of construction. The purpose is to convert non-heeled sections into heeled sections through using concrete ductility properties and includes components such as mold, lower block, upper block, lower reinforcements, upper reinforcements and spacer.

[Claim 2] According to claim 1 , there are lower blocks constructed at the beginning on flat molds.

[Claim 3] According to claim 2, the lower block is lightweight type and can be made of polystyrene, aerated lightweight concrete, plastic molds, composite molds, fiberglass molds, polystyrene blend, gypsum block, fiber concrete, aerated concrete or any other suitable material.

[Claim 4] According to claim 2, the dimensions of the lower block can be varied, produced and constructed based on the need and design.

[Claim 5] According to claim 2, the lower block has indentations underneath and on the sides for concrete entrance to produce strength. The dimensions and shape of the indentation can be designed and modified.

[Claim 6] According to claim 2, it is possible to create various deigns on the block if needed because of the placement of the lower block on the flat mold.

[Claim 7] According to claim 1 , there are spacers to maintain proper distance between the blocks and the lower reinforcement with the molds which increase accuracy, speed and quality of the construction.

[Claim 8] According to claim 7, spacers can be designed, produced and constructed in desired dimensions from any high strength material for maintaining distance between the blocks.

[Claim 9] According to claim 7, the spacer has a base as protrusions underneath to maintain distance with the mold and possibility of concrete entrance below the spacer which can vary in shape and number depending on the dimensions and standard distance.

[Claim 10] According to claim 9, protrusions are of such shapes which have the least contact with the mold, and based on the standard it is possible to change this shape.

[Claim 11] According to claim 7, the spacer is equipped with filling block retainers maintaining the distance between the blocks.

[Claim 12] According to claim 7, the spacer is usable in single-piece or multi-piece blocks.

[Claim 13] According to claim 7, the spacer has connection clamps to blocks which fix the blocks in place and prevent them from moving.

[Claim 14] According to claim 13, clamps can be designed and produced in different shapes depending on the block.

[Claim 15] According to claim 7, there are grooves on spacers for the placement of bars.

[Claim 16] According to claim 15, the grooves are in standard dimensions in which the bars are enclosed and prevented from displacement.

[Claim 17] According to claim 15, the grooves can be designed, manufactured and constructed in accordance with the standard based on the size and number of the reinforcements.

[Claim 18] According to claim 7, the spacer is designed with spaces for concrete transfer and filling of various parts and high quality concrete casting.

[Claim 19] According to claim 18, concrete transfer spaces can be designed and created in various shapes.

[Claim 20] According to claim 17, the spacer can be constructed in different numbers and in different shapes.

[Claim 21] According to claim 1 , the upper blocks are employed for filling purposes in the ceiling with the designed dimensions.

[Claim 22] According to claim 21 , the upper blocks may be of polystyrene, polyethylene, aerated concrete, LECA (lightweight expanded clay aggregate), slag or any other material in solid or hollow forms with similar and appropriate function.

[Claim 23] According to claim 21 , dimensions of the upper blocks can be designed, manufactured and constructed in any shapes according to the needs and dimensions of the ceiling.

[Claim 24] According to claim 21 , the upper block at the bottom may have a block shoe with the dimensions of the lower block located exactly on the lower block during construction.

[Claim 25] According to claim 21 , the upper block has grooves to create concrete cover underneath the reinforcements, which can be fitted in various dimensions and shapes or eliminated completely and carried out by another cover element.

[Claim 26] According to claim 21 , the locations of reinforcement placement on the upper block can be specified to speed up the placement of the reinforcements with precision.

[Claim 27] According to claim 26, the location of the reinforcement placement can be specified by cutting, creating a protrusion or any other method.

[Claim 28] According to claim 21 , in case a solid upper block is used, it is possible to cut and use this block in other different plans.

[Claim 29] According to claim 21 , the upper blocks are designed and manufactured and constructed in the biggest possible shape and dimensions to allow for creating maximum space and least concrete casting.

[Claim 30] According to claim 21 , since the upper blocks are enclosed between the lower blocks and the upper reinforcement and also the base designed for the spacer, there would be no displacement, and concrete casting can be easily and rapidly carried out.

[Claim 31] According to claim 1 , any part of this method can be designed, manufactured and constructed, with the possibility of using other suitable materials of different shapes and dimensions.