Ceiling openings are necessary to create space for pipes, cables or stair openings. It is currently common practice to use timber cut to size to create customised ceiling openings before the concrete is applied. The resulting opening is often not adequately secured and therefore harbours considerable safety risks: people can trip and fall in, and objects such as tools or building materials can fall through and cause damage. In short, there is currently a lack of standard systems that make it possible to work on ceiling breakthroughs without the risk of falling.

Air-filled protection and acoustic warning

Civil engineer Robin Becker addressed this problem in his doctoral thesis at the Chair of Construction Management and Economics under the supervision of Prof Dr Manfred Helmus. In collaboration with the Wuppertal engineer and idea generator Burkhard Krüger, he further developed his existing patent for the production of ceiling breakthroughs and carried out a technical feasibility study to test the practical suitability of the system.

The result consists of a hollow body made of fabric foil, which is filled with air to completely seal the ceiling opening during the work process. After concreting, the system remains in the concrete and serves as a breakthrough protection. In this form, it can also be used as a stepping surface. What's more, an integrated pressure sensor continuously monitors the air pressure inside the body to ensure safety at all times. "If there is a sudden drop or increase in pressure - due to excessive load or damage to the hollow body, for example - the system emits an acoustic signal. Employees are warned and can leave the area in good time," says Becker.

Flexible, safe, sustainable

Different versions of the system mean that both round and square openings in various sizes are possible. In addition to improved occupational safety, the system also sets an example for sustainability: it is reusable and therefore reduces waste on construction sites.