System and method for strengthening lightweight ceilings

Abstract

The present invention is directed to a method of reinforcing a waffle-structure ceiling having vertical members. The method includes drilling a hole through the vertical members and through a continuous upper layer covering the vertical members. Then, a reinforcing pin is inserted into the hole such that the shear stresses on the vertical member are transferred to the pin.

1 . A method of reinforcing a waffle-structure ceiling comprising vertical members, around forms between the vertical members and a continuous upper layer covering the vertical members and filler, the method comprising:
 drilling a hole through the vertical members and at least partially through the upper layer, and   inserting a reinforcement pin into the hole such that shear stresses on the vertical member are transferred to the pin.   
     
     
         2 . The method of  claim 1 , wherein the ceiling further comprises a continuous lower layer. 
     
     
         3 . The method of  claim 1 , wherein the forms are fabricated from tinplate. 
     
     
         4 . The method of  claim 1 , wherein the forms include a lightweight insulating material. 
     
     
         5 . The method of  claim 1 , wherein the lightweight insulating material comprises expanded polymer foam. 
     
     
         6 . The method of  claim 5 , wherein the expanded polymer foam is selected from the list consisting of polystyrene, polyurethane and polypropylene foams. 
     
     
         7 . The method of  claim 1 , wherein the drilling is from above and the hole passes through the upper layer and into the vertical member. 
     
     
         8 . The method of  claim 7 , wherein the hole passes into a lower layer and is a blind hole. 
     
     
         9 . The method of  claim 7 , wherein the hole passes through the lower layer and is a through hole. 
     
     
         10 . The method of  claim 7 , wherein an adhesive is injected into the hole and shear stresses on the vertical members are transferred to the pin via the adhesive. 
     
     
         11 . The method of  claim 1 , wherein the hole is a-through hole and the adhesive is provided in excess such that a blob of adhesive is formed beyond the farther surface from a point of injection. 
     
     
         12 . The method of  claim 1 , wherein a plate is threaded around an end of the pin. 
     
     
         13 . The method of  claim 1 , wherein the hole is drilled from below and passes through the vertical member and into an upper layer covering the vertical member. 
     
     
         14 . The method of  claim 1 , wherein the structure comprises a lower layer and the hole is drilled from below, through the lower layer and into the vertical member. 
     
     
         15 . The method of  claim 14  wherein the hole is drilled into an upper layer. 
     
     
         16 . The method of  claim 14  wherein the hole is a through hole, drilled through the upper layer. 
     
     
         17 . The method of  claim 1  further comprising threading a protruding end of the reinforcing pin through a metal plate and locking in place. 
     
     
         18 . The method of  claim 17  wherein locking comprises welding the pin to the plate. 
     
     
         19 . The method of  claim 17  wherein locking comprises, bending over a protruding end of the vertical pin. 
     
     
         20 . The method of  claim 17  wherein the protruding end of the pin is threaded and locking comprises applying a bolt onto the bar. 
     
     
         21 . The method of  claim 1  further comprising a preliminary step of locating the vertical member. 
     
     
         22 . The method of  claim 21  wherein locating the vertical member is selected from the list of visible observance, distance measurement, infra red emittance mapping, vibration mapping and drilling exploratory holes. 
     
     
         23 . A retro-reinforced waffle ceiling structure comprising substantially vertical pins passing through vertical members and at least one external layer of concrete; the pin coupled to the vertical member to combat shear stresses in the vertical member. 
     
     
         24 . The retro-reinforced waffle ceiling structure of  claim 23 , wherein the at least one external layer of concrete includes an upper floor covering the vertical member. 
     
     
         25 . The retro-reinforced waffle ceiling structure of  claim 23 , wherein the at least one external layer of concrete includes a lower layer contacting the undersurface of the vertical member. 
     
     
         26 . The retro-reinforced waffle ceiling structure of  claim 23 , wherein the at least one external layer comprises reinforced concrete. 
     
     
         27 . The retro-reinforced waffle ceiling structure of  claim 23 , wherein the substantially vertical pin comprises a reinforcement bar of mild steel with ribbing coupled to the vertical member by an epoxy. 
     
     
         28 . The retro-reinforced waffle ceiling structure of  claim 23 , wherein a metal plate is positioned over a protruding end of the vertical pin and either the pin is bent over to engage the plate, the bar is welded to the plate or the bar is threaded and a nut is threaded onto the thread.