Wood grain fair-faced concrete repairing and re-carving construction method

Abstract

The invention relates to a wood grain bare concrete repairing and recarving construction method, which comprises the following steps of: a, performing three-dimensional scanning on an original bare concrete surface needing to be repaired to obtain a bare concrete surface digital model containing surface wood grain texture, concave depth and knot position; b, delineating a restoration area; c, the surface texture in the repairing area is repaired, and the repaired surface texture in the repairing area is connected with the surface texture of the original surrounding area; d, a wood grain template is manufactured according to the surface texture in the repairing area; e, chiseling and removing the repair area, and cleaning the chiseled and removed repair area; f, the repairing area is filled with concrete, and the wood grain formwork is arranged outside the repairing area in a supported mode; and g, after the concrete in the repairing area is solidified, the wood grain formwork is dismantled, and the concrete is cured. According to the method, the building wood grain fair-faced concrete wall surface can be rapidly repaired with high quality, and it can be guaranteed that wood grains of new concrete and old concrete can be mutually connected.

Description

Technical Field

[0001] This invention relates to a construction method for wood grain fair-faced concrete, specifically a construction method for the repair and replication of wood grain fair-faced concrete. Background Technology

[0002] In the process of protecting historical buildings and industrial heritage, some old buildings have walls made of wood-grain exposed concrete. Due to environmental impacts or human damage, there are a lot of surface damage on these walls. In order to preserve the original appearance of the building as much as possible while ensuring the overall aesthetics, it is necessary to carry out repair work on the wood-grain exposed concrete walls.

[0003] Currently, the repair of wood-grain exposed concrete walls generally involves manual labor. After filling the damaged areas with concrete, the wood grain structure is manually drawn. This method is inefficient and difficult to use for repairing high sections of the wall. Because it relies heavily on the skill level of the repair personnel, the wood grain texture replication often results in low accuracy and poor realism, leading to a less aesthetically pleasing overall finish. While some existing techniques use wood grain templates to create wood grain patterns on exposed concrete surfaces, these produce fixed and repetitive textures that cannot match the original wood grain texture during repair, easily creating noticeable "patches" that compromise the overall aesthetics and the integrity of historical traces, resulting in poor overall appearance. Furthermore, the connection strength between the concrete filling and the original wall is relatively low in existing techniques, leading to cracking, bulging, and detachment after a period of time, failing to guarantee repair quality.

[0004] Therefore, there is an urgent need for a method that can quickly and effectively repair wood-grain exposed concrete walls, and ensure that the wood grain textures of the new and old concrete can be seamlessly integrated. Summary of the Invention

[0005] The purpose of this invention is to provide a method for repairing and replicating wood grain exposed concrete, so as to solve the problems of low efficiency, difficulty in guaranteeing repair quality, and mismatch between the repair area and the original wood grain texture in the existing wood grain exposed concrete repair construction.

[0006] This invention is achieved as follows: a method for repairing and replicating wood grain exposed concrete, comprising the following steps: a. Perform a 3D scan on the original fair-faced concrete surface that needs to be repaired to obtain a digital model of the fair-faced concrete surface, including the surface wood grain texture, the depth of the depressions, and the location of the knots; b. Delineate the repair area; c. Repair the surface texture within the repair area so that the surface texture within the repair area is seamlessly integrated with the original surface texture of the surrounding area. d. Create a wood grain template based on the surface texture of the repair area; e. Remove the damaged area and clean the area after removal; f. Fill the repair area with concrete and set up the prepared wood-grain template in the repair area; g. After the concrete filling the repair area has solidified, remove the wood-grain formwork and cure the concrete.

[0007] Furthermore, in step b, large defect areas, concentrated defect regions, or independent small defect areas are divided into repair areas, and the outline of the repair area is rectangular.

[0008] Furthermore, in step a, a 3D scanner is used to scan and obtain point cloud data of the fair-faced concrete surface, which is then processed to form a digital model of the fair-faced concrete surface.

[0009] Furthermore, in step c, the missing texture areas are manually designed and supplemented, and the supplemented textures are connected with the surrounding original textures.

[0010] Furthermore, in step c, for the original fair-faced concrete surface with repeating wood grain texture, the complete wood grain texture corresponding to the repair area is selected to repair the surface texture within the repair area.

[0011] Furthermore, in step g, after removing the template, defects at the edges and inside the repair area are repaired.

[0012] Furthermore, step h is also included: after the concrete in the area to be repaired has dried sufficiently, a protective layer is applied to the overall fair-faced concrete surface.

[0013] Furthermore, the wood grain template includes a main body, a textured area on the front side of the main body, and an outer bonding surface around the textured area.

[0014] Furthermore, a protruding positioning portion is provided at one or both ends of the lower edge of the textured area.

[0015] Furthermore, in step e, the repair area is chiseled away, with the edges cut into neat right angles or tongues, to a depth that exposes at least a clean, solid concrete base. The bonding surface is roughened, cleaned, and rinsed with high-pressure water.

[0016] This invention creates a corresponding wood grain template for the area requiring repair. After the original concrete in the repair area is removed and cleaned, new concrete is filled in, and the wood grain texture is pressed onto the surface using the template. Because the wood grain texture on the template is designed and manufactured using high-precision equipment, it effectively ensures that the new wood grain texture in the repair area seamlessly integrates with the original texture. The concrete in the repair area bonds effectively with the original wall, preventing cracking, bulging, and peeling later on. This invention effectively guarantees the quality of wood grain exposed concrete repair and replication. Attached Figure Description

[0017] Figure 1 This is a flowchart of the present invention.

[0018] Figure 2 This is a structural diagram of the wood grain template of the present invention.

[0019] Figure 3 This is a schematic diagram illustrating the use of the wood grain template of this invention.

[0020] In the diagram: 1. Fair-faced concrete; 2. Repair area; 3. Wood grain template; 3-1. Main body; 3-2. Textured area; 3-3. Outer bonding surface; 3-4. Positioning part. Detailed Implementation

[0021] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] like Figure 1 As shown, the method for repairing and replicating wood grain fair-faced concrete 1 provided by the present invention specifically includes the following steps.

[0024] a. Perform a 3D scan on the original fair-faced concrete surface 1 that needs to be repaired to obtain a digital model of the fair-faced concrete surface 1 that includes the surface wood grain texture, depression depth, and knot location.

[0025] A 3D scanner was used to perform a high-resolution scan of the surface of the exposed concrete 1 that needs to be repaired. After obtaining the point cloud data of the surface of exposed concrete 1 using structured light scanning or laser scanning, a digital model of the surface of exposed concrete 1 was formed through processing.

[0026] Before scanning, select an intact location on the surface of fair-faced concrete 1 and affix positioning marks. Corresponding positioning marks will also be formed in the digital model of the surface of fair-faced concrete 1. The location of repair area 2 can be determined based on the positioning marks.

[0027] b. Delineate the repair area 2.

[0028] Observe the surface of the fair-faced concrete 1 and delineate the repair area 2. Specifically, large defect areas (maximum length greater than 10cm), concentrated local defect areas, or independent small defect areas (maximum length less than or equal to 10cm) are divided into repair areas 2. The outline of repair area 2 is generally rectangular. All defects within repair area 2 are completely located within the outline of repair area 2, and the edge of the defect should generally be more than 5mm away from the outline of repair area 2.

[0029] The rectangular repair area 2 facilitates the accurate positioning of its edges and subsequent chiseling work, as well as the positioning of the wood grain template 3 during installation. The minimum distance between the outline of the repair area 2 and the edge of the defect is required to ensure effective removal of internally extending cracks and other defects during chiseling work, thus guaranteeing the quality of the repair.

[0030] c. Repair the surface texture within repair area 2 so that the surface texture within repair area 2 is seamlessly integrated with the original surface texture of the surrounding area.

[0031] In the digital model of the fair-faced concrete 1 surface, repair area 2 is selected. For the parts of the repair area 2 with missing texture, manual repair is carried out. When repairing, it should be ensured that the supplemented texture is connected with the surrounding original texture.

[0032] Given that the wood grain on the original fair-faced concrete 1 surface is randomly distributed and non-repeating, the missing texture in the repair area 2 will be supplemented by redesign. The design should take into account the overall distribution of wood grain on the original fair-faced concrete 1 surface and the direction of the surrounding wood grain texture.

[0033] If the knots on the overall wood grain are evenly distributed, and based on the knot distribution, it is inferred that there should be knot texture in the missing areas, knot texture can be added to the missing areas. Alternatively, if it is determined from the direction of the surrounding wood grain that there is no knot texture in the missing areas, long strips of texture can be added to these areas to connect the broken wood grain textures.

[0034] For some buildings that use a repetitive wood grain texture, the complete wood grain texture corresponding to the repair area 2 on the original surface of the fair-faced concrete 1 is selected in the digital model of the fair-faced concrete 1 surface. The selected wood grain texture is used to cover the wood grain texture of the repair area 2, and fine-tuning is made to make the wood grain texture in the repair area 2 connect with the surrounding wood grain texture.

[0035] d. Create a wood grain template 3 based on the surface wood grain texture within the repair area 2.

[0036] Based on the wood grain texture obtained in step c, export the forward wood grain template 3 within the repair area 2. For repair areas 2 with a length greater than 1m, divide the repair area 2 into multiple rectangular sub-areas, and create corresponding wood grain templates 3 for each sub-area for repair. Number the wood grain templates 3 during processing. For repair areas 2 with a length less than 1m, generally one corresponding wood grain template 3 is sufficient.

[0037] like Figure 2 , Figure 3 As shown, the wood grain template 3 includes a main body 3-1. A textured area 3-2 is provided on the front of the main body 3-1. The size of the textured area 3-2 is consistent with the corresponding repair area 2 or a sub-area of ​​the repair area 2. An outer bonding surface 3-3 is provided around the textured area 3-2. The outer bonding surface 3-3 contacts the outer ring of fair-faced concrete 1 of the repair area 2 during formwork erection. Designed protrusions are distributed on the textured area 3-2. The height of the protrusions is consistent with the depth of the wood grain. The protrusions are pressed into the concrete surface to form the corresponding wood grain texture.

[0038] Wood grain template 3 can be made of wood boards, resin boards, etc., and processed with a high-precision engraving machine to ensure the forming quality of wood grain.

[0039] In order to ensure the positional accuracy of the wood grain template 3 quickly when it is in place, a protruding positioning part 3-4 is provided at one or both ends of the lower edge of the texture area 3-2. The protrusion height of the positioning part 3-4 is greater than that of the texture area 3-2.

[0040] The positioning part 3-4 is generally cylindrical, and the positioning part 3-4 is tangent to the two right-angled sides of the lower part of the texture area 3-2.

[0041] e. Remove the repair area 2 and clean the removed repair area 2.

[0042] Remove the 2nd repair area by chiseling it out, cutting the edges into neat right angles or tongues and grooves, exposing at least a clean and solid concrete base layer as the bonding surface. Roughen and clean the bonding surface, and rinse it with high-pressure water to maintain its cleanliness.

[0043] f. Fill the repair area 2 with concrete and set up the wood grain template 3 in the repair area 2.

[0044] Low-slump concrete can be used to fill the repair area 2, making the filled concrete flush with the surface of the fair-faced concrete 1. Then, a wood grain template 3 is erected, and its position is carefully positioned to ensure accuracy. Specifically, the positioning part 3-4 of the wood grain template 3 is inserted into the concrete filling the repair area 2, and the position of the wood grain template 3 is adjusted so that the positioning part 3-4 is against the right angle of the rectangular repair area 2. A vibrator is then used to vibrate and press the wood grain template 3 on its back to compact the concrete in the repair area 2 and create the wood grain texture.

[0045] g. After the concrete filling area 2 has solidified, remove the wood grain formwork 3 and cure the concrete.

[0046] After removing the wood grain template 3, repair the defects at the edge and inside of the repair area 2, and fill the pits formed by the positioning part 3-4 with concrete.

[0047] After demolding, a special curing agent of the same color is sprayed on for curing to form a protective film, preventing moisture from evaporating too quickly and causing contamination, and unifying the gloss of the new and old concrete surfaces.

[0048] After the concrete has dried fully (usually after 28 days), apply a transparent, breathable, high-performance protective agent (such as silane / siloxane impregnating agent) to the entire surface to improve its resistance to pollution and weathering, and to further unify the appearance.

[0049] This invention creates a corresponding wood grain template 3 for the repair area 2. After the original concrete in the repair area 2 is removed and cleaned, new concrete is filled in, and the wood grain texture is pressed onto the surface using the fabricated wood grain template 3. Because the wood grain texture on the template 3 is designed and manufactured using high-precision equipment, it effectively ensures that the new wood grain texture in the repair area 2 can seamlessly integrate with the original wood grain texture. The concrete in the repair area 2 can effectively bond with the original wall, preventing cracking, bulging, and peeling later on. This invention effectively guarantees the quality of the repair and replication of wood grain exposed concrete 1.

[0050] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for repairing and replicating wood grain exposed concrete, characterized in that, Includes the following steps: a. Perform a 3D scan on the original fair-faced concrete surface that needs to be repaired to obtain a digital model of the fair-faced concrete surface, including the surface wood grain texture, the depth of the depressions, and the location of the knots; b. Delineate the repair area; c. Repair the surface texture within the repair area so that the surface texture within the repair area is seamlessly integrated with the original surface texture of the surrounding area. d. Create a wood grain template based on the surface texture of the repair area; e. Remove the damaged area and clean the area after removal; f. Fill the repair area with concrete and set up the prepared wood-grain template in the repair area; g. After the concrete filling the repair area has solidified, remove the wood-grain formwork and cure the concrete.

2. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, In step b, large defect areas, concentrated defect regions, or independent small defect areas are divided into repair areas, and the outline of the repair area is rectangular.

3. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, In step a, a 3D scanner is used to scan and obtain point cloud data of the fair-faced concrete surface, which is then processed to form a digital model of the fair-faced concrete surface.

4. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, In step c, the missing texture areas are manually designed and supplemented, and the supplemented textures are connected with the surrounding original textures.

5. The method for repairing and replicating wood grain fair-faced concrete according to claim 4, characterized in that, In step c, for the original fair-faced concrete surface with repeating wood grain texture, the complete wood grain texture corresponding to the repair area is selected to repair the surface texture within the repair area.

6. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, In step g, after removing the template, defects at the edges and inside the repair area are repaired.

7. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, It also includes steps h. After the concrete in the area to be repaired has dried completely, apply a protective layer to the overall fair-faced concrete surface.

8. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, The wood grain template includes a main body, a textured area on the front of the main body, and an outer bonding surface around the textured area.

9. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, A protruding positioning part is provided at one or both ends of the lower edge of the textured area.

10. The method for repairing and replicating wood grain fair-faced concrete according to claim 1, characterized in that, In step e, the repair area is chiseled away, with the edges cut into neat right angles or tongues, to a depth that exposes at least a clean, solid concrete base. The bonding surface is roughened, cleaned, and rinsed with high-pressure water.

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