EASY WAFFLE CEILING WITH I SHAPE SECTION

Generally one of the best types of ceiling in terms of technical and performance in the whole world is waffles ceiling. But the necessity of implementation of false ceilings also implementation of formatting in this ceiling, increases the cost. Also control of bar is difficult and may be covered from eyes, which these are another reasons for the lack of interest for this ceiling. It is shown that moment throughout span change direction in fixed span so the best option for one way ceiling and two way ceiling are beams with I-shaped sections that generally fix the problems and disadvantages of the T-shaped section. I-shaped sections have the maximum moment, minimum weight, slip and Sound transmission.in this floor there's no need for false ceilings and formatting. In order to achieve mentioned structural shape use different blocks and mold.

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Description
FIELD OF THE INVENTION

The invention relates generally to ceiling construction and particularly theirs component. This ceiling has called Easy waffle ceiling with I shape section which solved completely current waffle ceiling.

BACKGROUND OF THE INVENTION

Various systems of ceilings are used in the construction industry, which each one has their own advantages and disadvantages. Regarding to fixed price you must pay for ceilings, and in order to make the building more economical, building designers have invented and implemented, various systems which includes; reduce the usage of concrete and steel, reducing or elimination of form working, improving methods of constructing and increasing the quality of implementation.

Generally one of the best types of ceiling in terms of technical and functional issues is waffles ceiling in the world. But it is used less, because of overweight, slow function and high costs for implementation. However, some engineer designers believe more in slab ceiling and use it in their designs, and for its great function they use it for more important buildings such as buildings in refineries or big industrial centers.

To reduce the usage of concrete and reduce the weight of the ceiling a part of the ceiling section which is in tensile will be removed and only that part which is needed for placing longitudinal and stretching bars is preserved. This step is especially for reducing ceiling and building dead weight.

The remaining distances are chosen close enough in order that compressive and tensile concrete cross-section of the ceiling stay integrated and the ceiling does not lose its primary mode. This resulted in Design of waffles ceilings, Honeycombed, and others like them. The consumption of concrete in these kind of ceilings is about one-third of the initial consumption and, the weight of ceiling will be reduced this much. On the other hand, because of lighter ceilings the cost of implementation, consumption of the bars, and the other porter parts of building are more economic, besides this ceiling with his bending function in two directions, causes uniformly distributed load to beams. The Implement of waffles ceilings is by wooden and metal formworks. But due to high weight of these formworks, implement problems and high costs using this ceiling is not advised and is not warmly welcomed despite its advantages.

SUMMARY OF THE INVENTION

Generally one of the best types of ceiling in terms of technical and performance in the whole world is waffles ceiling. But the necessity of implementation of false ceilings also implementation of formatting in this ceiling, increases the cost. Also control of bar is difficult and may be covered from eyes, which these are another reasons for the lack of interest for this ceiling.

It is shown that moment throughout span change direction in fixed span so the best option for one way ceiling and two way ceiling are beams with I-shaped sections that generally fix the problems and disadvantages of the T-shaped section. I-shaped sections have the maximum moment, minimum weight, slip and Sound transmission.in this floor there's no need for false ceilings and formatting. In order to achieve mentioned structural shape use different blocks and mold.

To create this structural shape, the different blocks or molds can be used. These blocks can be implemented as follows:

    • 1. The whole block is made of polystyrene
    • 2. The whole block is made of gas lightweight concrete
    • 3. Using temporary plastic molds.
    • 4. Using composite molds
    • 5. Using fiberglass molds
    • 6. The blocks should be a combination of polystyrene and gas concrete

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is bending moment chart in a span with pinned connection.

FIG. 2 is bending moment chart in a span with fixed connection.

FIG. 3 is structural shapes of the ceiling.

FIG. 4 is CLC_ALC blocks used in ceiling.

FIG. 5 is flexible blocks used in ceiling.

FIG. 6 is underside of blocks have been cut like an arc or on a slant and etc.

FIG. 7 is location of spacer between CLC_ALC blocks.

FIG. 8 is blocks arrangement in plan.

FIG. 9 is spacer details.

FIG. 10 is location of bars in the spacer.

FIG. 11 is the geometry of the blocks made of gas lightweight concrete.

FIG. 12 is location of blocks.

FIG. 13 is the location of upper bars.

FIG. 14 The bottom Block is half gas concrete and half polystyrene and the upper block is made of polystyrene so spacer's height has increased.

FIG. 15 is the geometry of the spacer.

FIG. 16 is general shape of the Implemented ceiling.

FIG. 17 is gas concrete used in the ceiling.

 BRIEF DESCRIPTION OF THE PICTURES IN IMPLEMENTATION

PIC. 1 shows the location of spacer between CLC blocks.

PIC. 2 shows the usage of spacers and blocks together can be seen in plan.

PIC. 3 shows the location of bars in the spacer.

PIC. 4 shows the location of upper bars.

PIC. 5 shows I-shaped sections.

DETAILED DESCRIPTION OF THE INVENTION

Various systems of ceilings are used in the construction industry, which each one has their own advantages and disadvantages. Regarding to fixed price you must pay for ceilings, and in order to make the building more economical, building designers have invented and implemented, various systems which includes; reduce the usage of concrete and steel, reducing or elimination of form working, improving methods of constructing and increasing the quality of implementation.

Generally waffle ceiling is one the best ceiling in the world in terms of technical implementation and It is the only system which all the regulations and curriculums, have experienced it without any problem. And it is compatible with the ideals of engineering which leads this ceiling to be a good option to use in buildings. But the need of implementation of false ceilings in this type of ceiling has caused less eagerness to implement it despite its advantages.

On the other hand the implementation of this ceiling is by form working (metal, wood, etc.) that using these formworks sometimes because of high cost and difficulty in its implementation, bars is not properly worked out and it has to be considered that controlling bars is a tough task and is sometimes ignored which is why it's not very common to use this type of ceiling.

If you examine the moment chart in a span with pinned connection (FIG. 1), we will find that moment throughout the span is positive and the underside of the ceiling concrete begins to stretch. Regarding to in this ceiling underside concrete is not implemented, the function of ceiling in this span is very proper. but now if we examine the moment chart in a span with fixed connection (FIG. 2), it is shown that moment throughout the span will change directly into the opening part, which is positive and in other part negative and where the moment have changed direction, the underside of the ceiling is compressed. Since the bottom concrete is not implemented in this ceiling, inappropriate function will be observed. The best option for one-way ceiling and two-way ceiling is beams with I-shaped sections that completely fix the problems and disadvantages of the T-shaped sections and bending capacity and ceiling deflection significantly are improved so the high performance in waffles ceiling in span with fixed connection and in span with simple connection is observed.

Considering I-shaped sections have the maximum moment, minimum weight, minimum slip and sound transmission so there is no need for form working.

In Easy waffle ceiling with I shape section In addition to available benefits, mentioned problems of waffle ceilings have been solved and added on to its benefits. All these benefits are because of the structural shape of the ceiling (FIG. 3). To create this structure, different blocks or formworks can be used that it will be explained later on.

To create this structural shape, different blocks or molds can be used. These blocks can be implemented as follows:

    • 1. The whole block is made of polystyrene
    • 2. The whole block is made of gas lightweight concrete
    • 3. Using temporary plastic molds.
    • 4. Using composite molds
    • 5. Using fiberglass molds
    • 6. The blocks should be a combination of polystyrene and gas concrete
    • 7 . . . .
    • Generally In addition to the mentioned points, any molds that can create ceiling structural shape can be used. The dimensions of the blocks can be variable according to the engineer's opinions, the amount of load and the span on which ceiling is built on.

Using this blocks cause to implement flat form working which solves form working problems. And the ceiling can be implemented with any span. by applying specific elements (designed spacer) the reinforcement can be implemented and examined easier. Considering to the shape of blocks (in this type of ceiling beams are I-shaped sections), besides proper function of ceiling in spans with simple connection, the proper function in spans with fixed connection is also obvious. The weight of ceiling is reduced about 20% and it has become economic much more.

Considering the implantation of six mentioned blocks, I'm going to investigate some of them.

In number one regarding that the whole block is implemented by polystyrene, using the false ceilings is necessary.

In number two one of the things that can be considered is saturation of blocks before concreting. This step not only prevents the penetration of sap concrete into blocks, but also in the early hours, it keeps the moisture in the concrete and leads to high quality concrete.

In number six; regarding the combination of gaseous and polystyrene concrete, and there is a small contact between Gaseous concrete and blocks, thus saturation of blocks is not necessary and one of the most important advantages of this block comparing to the two previous blocks is its easiest implementation. (It will explained its implementation in details later on) more over this step reduces the errors and also there is no need for implementation of false ceiling which results in increasing the speed of process.

For better understanding, it will be explained the implementation of ceiling (with drawing figures in further pages).

    • Combination of polystyrene block and gas concrete block
    • Step1: arrangement of blocks by designed spacer.
    • In this step CLC-ALC blocks are designed by spacers, which are placed in a certain distance from each other that this distance can be varied according to the designer decision (FIG. 4).

We can have the blocks made of gas concrete and polystyrene together in 2 connected parts.

Polystyrene is considered to be above, so that its flexibility prevents cracking and even breaking in the whole block due to high pressure (FIG. 5).

As you see in FIG. 6 the underside of blocks is cut like an arc or on a slant and etc. so that after concreting, concrete penetrate under this section and maintains blocks stability. The block can be observed in different shapes (FIG. 6).

In the first place it might cross your mind that blocks are not connected suitably to concrete and the fold-down after taking off the formatting, but according to this fact that blocks are surrounded by concrete properly and lateral pressure and also remarkable connection between blocks and concrete, not only solves the problem of falling down but also increases the strength of blocks incredibly. Moreover even broken blocks will not be separated from the ceiling.

Spacers are designed in a way to prevent the transmission of fire and heat. Regarding that the location of rebar is embedded in it, they can be implemented easily. Therefore, implementation is very easy (FIG. 7).

The usage of spacers and blocks together can be seen in plan in FIG. 8.

The exact shape of spacer can be seen in the FIG. 9.

    • Step 2: Implementation of bottom rebar (longitudinal and reinforcement bars)
    • In this step according to spacer shape in which longitudinal bar and rebar are embedded, rears implementation is easily done and that's one of the reason which this ceiling is easily implemented (distances are in accordance with the regulations and all clauses of regulations are taken in to consideration for reinforcement) (FIG. 10).
    • Step 3: placing polystyrene blocks

In this step Polystyrene blocks are placed as they were built at first. The spacer is designed in such a way that the upper part of it is sharp and polystyrene blocks are placed with a small pressure (like a puzzle) which in results implementation errors go down to zero and the blocks do not move from their place (FIG. 11,12).

    • Step 4: the implantation of top bars (longitudinal and rebars and installation of pins) (FIG. 13).
    • In addition to the mentioned points, blocks can be implemented in two steps for convenience in implementation. The bottom Block is half gas concrete and half polystyrene and the upper block is made of polystyrene. It helps a much more convenient implement and increase in spacer's height (FIG. 14).
    • The use of polystyrene blocks:

In this case, regarding that the whole block is integrated and arrangement of blocks is done in a step, so the shape of designed spacer is shown in FIG. 15.

It should be mentioned Spacers are fireproofing and resistant to transmission of fire.

And the general shape of the ceiling is shown in FIG. 16.

    • The use of gas concrete blocks:

One of the things that can be considered is block saturation before concreting. This step not only prevents the penetration of sap concrete into blocks, but also in the early hours, it keeps the moisture in the concrete and leads to high quality concrete Implementation of gas concrete blocks and polystyrene blocks are similar, and there is no need for implementation of false ceiling in gas concrete blocks (FIG. 17).

    • Blocks can be implemented in two steps for convenience in implementation. The bottom Block is half gas concrete and half polystyrene and the upper block is made of polystyrene.it helps a much more convenient implement and increase in spacer's height.
    • It is very important point to mention that blocks and spacers can be built and used in all suitable shapes with different materials according to different aspects such as project manager's request, project conditions, climate conditions, transportation problems and etc. Four instant in some places like villages it may not be easy to access the designed spacers so any spacer can be used in the condition that can fulfill the designed spacer's duties which the most important one is to keep enough space between blocks as it is planned.
    • These spacers even can be built by bars in project. Blocks can be made of different materials too. Such as wood, compressed paper, or any kind of material according to the manager and engineers preference.

Features and Benefits of Easy Waffle Ceiling with I-Shape Section are as Follows:

    • It is the only system which is compatible with all the regulations, curriculums and ideals of engineering
    • The best option for one way ceiling and two ways ceiling is beams with I-shaped sections that not only completely solved problems of T-shaped section but also added some advantages to it.
    • Regarding that in this ceiling beams are I-shaped section, unlike the current waffle ceiling, proper function is observed in both span with fixed connection and simple connection.
    • Due to good structural behavior of this ceiling the minimum amount of rebar and concrete is used this ceiling.
    • The most optimized method for making the concrete ceilings light weighted is removing the extra concrete from stretching section and reaching to I-shaped section.
    • According to the different earthquake regulations there is no limit for the span length, the number of stories and shear walls.
    • Regarding that I-shaped sections have the maximum moment, minimum weight, the least slip and Sound transmission is observed.
    • Reduction of beam deflection in simple span (35%) and reduction of beam deflection in fixed span (41%) comparing to current ceiling waffle.
    • 10% increase in moment capacity in simple spans and 80% increase in moment capacity in fixed spans comparing to current waffle ceiling.
    • No need for form working.
    • By reducing the weight of the ceiling and structure, its implementation in large spans are easily possible and cheap.
    • Due to the taken measures, there is a high safety in this ceiling
    • Easy installations of tools through the ceiling reduce ceiling materials consumption and increase the useful height of building and also reduce the cost of building maintenance.
    • Good connection between wall and the ceiling.
    • Due to the flat form working in this ceiling, form working will be eliminated and make the implement easy.
    • By flat form working, any span can be implemented in this ceiling.
    • Easy reinforcement and precise, error-free implement of ceiling
    • Using a combination of polystyrene blocks and gas concrete in the ceiling, increases resistance to fire and earthquakes and this ceiling is an appropriate soundproof and thermal insulation.
    • Weight of ceiling is reduced about 20% and it has become economic much more.
    • Greatly increases the speed of implementation.
    • There is no need for false ceilings so it prevents additional costs.
    • Easily supervised
    • The possibility of implementing in variable thickness in long-span
    • The possibility of rectangle and square blocks according to the span different direction
    • The possibility of combination of ceiling with cable (in case of need and with the decision of designer)
    • There is no need for special skills so it easy done by semi-skilled workers

Claims

1- Using I-shaped sections in waffles ceilings have separated completely this ceiling from the current waffles ceilings.

2- As in claim 1, I-shaped sections can be applied with different dimensions and geometry in section (FIG. 3).

3- As in claim 1, the main innovation is ceiling structural shape that can be implemented by different methods.

4- I-shaped sections as in claim 1, have the maximum moment, minimum weight, slip and sound transmission. To make this structural section different blocks and molds can be used.

5- There are especial spacers considered to be used for reinforcing the ceiling which solve completely form working problems.

6- As in claim 5, the pins in mentioned ceiling are embedded, in a way that implementation errors go down to zero, so workers can implement it easily.

7- As in claim 5, implementation errors reduce to zero and theoric calculations match with implementation.

8- As in claim 5, the spacers are designed with special location that passes through longitudinal and reinforcement bars.

9- As in claim 5, bottom element of Spacers is fireproofing and resistant to transmission of fire.

10- According to claims 1 and 4, usage of blocks; that their dimensions are determined according to the designer and geometry of blocks causes the form working on this ceiling flattened and the ceiling can be implemented by any spans.

11- As in claim 4, to create this structural shape, the different blocks or molds can be used. These blocks can be implemented as follows:

The whole block is made of polystyrene
The whole block is made of gas lightweight concrete
Using temporary plastic molds.
Using composite molds
Using fiberglass molds
The blocks can be a combination of polystyrene and gas concrete
...

12- As in claims 5 and 11, designed pins on spacers are located inside the holes which are embedded on the blocks

13- As in claim 4, undersides of blocks are cut like an arc or on a slant or etc. So after concreting, concrete penetrate under this section and maintains blocks stability

14- As in claim 11, using a combination of polystyrene and gas concrete blocks in the ceiling, increases the resistance to fire and earthquakes and reduces the weight of the ceiling. Due to the porous blocks, this ceiling is an appropriate soundproof and thermal insulation.

15- Reduction of beam deflection in simple span (35%) and reduction of beam deflection in fixed span (41%) comparing to current ceiling waffle.

16- 10% increase in moment capacity in simple spans and 80% increase in moment capacity in fixed spans comparing to current waffle ceiling.

17- Weight of ceiling is reduced about 20% and it has become economic much more.

Patent History
Publication number: 20180142472
Type: Application
Filed: Apr 5, 2016
Publication Date: May 24, 2018
Inventor: Mansoor Aliabadi Farahani (Arak)
Application Number: 15/569,774
Classifications
International Classification: E04B 9/06 (20060101); E04B 9/04 (20060101);