Netted inlay masonry structure for repairing local low brick wall and construction method thereof

Abstract

The application relates to a kind of sandwich embedded patching masonry structures for repairing local low-level brick wall and its construction method, the structure includes original wall, new masonry, mortar layer and hot-dip galvanized steel wire mesh, the new masonry is built at the position to be repaired of the original wall from the both sides of wall through the mortar layer, the steel wire mesh is anchored to the original wall, the steel wire mesh is layered inlaid in the connecting interface of new masonry and original wall using "one-side building bottoming-pasting net wrapping mortar-two-side closing embedding" process, is wrapped and clamped in vertical direction by multiple mortar layers, forms three-dimensional reinforcing framework through original wall and new masonry.The beneficial effects of the application are: (1) excellent structural performance; (2) complete preservation of style; (3) economy and convenient construction; (4) good durability.

Description

Technical Field

[0001] This invention belongs to the field of building engineering technology, and specifically relates to a repair and reinforcement structure and construction method for localized damage to the walls of traditional low-rise brick masonry (red brick, blue brick) buildings in rural areas and towns. Background Technology

[0002] Traditional technical problems: A large number of low-rise brick-built houses constructed in the mid-to-late 20th century remain in rural areas and towns across my country. These buildings are mostly constructed with clay bricks, and due to long-term use and environmental erosion, they commonly suffer from localized brick weathering, efflorescence, and detachment. Traditional repair methods mainly fall into two categories: one is "repairing the original structure," which involves removing damaged bricks and replacing them in situ with new bricks and mortar; the other is "overall reinforcement," such as applying steel mesh to one or both sides of the wall before plastering (the steel mesh mortar surface layer method).

[0003] The shortcomings of existing technology:

[0004] First, the shortcomings of the "original patching method": This method relies solely on the bonding force between the mortar and the new and old bricks to transfer stress. The interface is weak and prone to cracking and falling off again due to factors such as temperature and humidity changes and shrinkage. It has poor durability and cannot fundamentally enhance the integrity of the wall.

[0005] Secondly, there are shortcomings of the overall reinforcement method (such as wire mesh plastering): While this method can significantly improve the overall strength of the wall, it completely covers the original brick facade, severely damaging the traditional appearance and local texture of the building. This method is unacceptable for old buildings that are not cultural relics or historical buildings but have historical value and local characteristics. In addition, the durability of the plaster layer itself, the risk of cracking, and the coordination with the old wall also need to be considered.

[0006] Thirdly, economic efficiency and applicability: Existing mature reinforcement technologies (such as shotcrete panel walls and carbon fiber cloth reinforcement) are mostly designed for modern structures or important cultural relics buildings. They have problems such as high cost, strong construction expertise, and complex equipment, and cannot be economically and easily promoted and applied in the vast rural areas where there is a lack of special funds and professional technicians.

[0007] Conclusion: Currently, there is a lack of a repair technique that can effectively repair and reinforce localized damage to traditional low-rise brick walls, while preserving the original brick facade appearance, and is also simple and cost-effective. Therefore, a new technical solution is needed to address this issue. Summary of the Invention

[0008] In summary, to overcome the shortcomings of the existing technology, the technical problem to be solved by the present invention is to provide a mesh-filled masonry structure and its construction method for the repair of rural low-rise brick walls. It is a local repair technology for rural brick walls that is structurally reasonable, easy to construct, economical and practical. The core is to overcome the defects of traditional patching methods, such as poor adhesion and poor durability, while avoiding the damage to the original appearance of the building caused by large-area plastering and reinforcement, so as to achieve the repair goal of "restoring the old as before and improving the function".

[0009] The technical solution of this invention to solve the above-mentioned technical problems is as follows: a mesh-inserted masonry structure for repairing low-rise brick walls in rural areas, comprising the original wall, new masonry, mortar layers, and hot-dip galvanized steel wire mesh. The new masonry is constructed from both sides of the wall through the mortar layers at the location on the original wall to be repaired. The steel wire mesh is anchored to the original wall, and during the construction of the new masonry, the steel wire is pressed in layers and wrapped in multiple layers of mortar, thereby forming a three-dimensional reinforcing skeleton in the vertical direction, held by multiple layers of mortar and penetrating between the new masonry and the original wall. In some possible implementations, the hot-dip galvanized steel wire mesh is connected to the location on the original wall to be repaired using cement nails and washers.

[0010] In some possible implementations, the gasket is a two-piece design with a three-hole connecting and limiting structure.

[0011] In some possible implementations, the hot-dip galvanized wire mesh covers the area to be repaired on the original wall, and each side of the hot-dip galvanized wire mesh extends beyond the outline of the area to be repaired on the original wall by a predetermined distance, with the extended portion tightly adhering to the cross-section of the intact brick wall at the area to be repaired.

[0012] The present invention also provides a construction method for constructing the above-mentioned mesh-filled masonry structure for the repair of rural low-rise brick walls, comprising the following steps:

[0013] Step 1: First, precisely, safely, and neatly chisel away and clean the damaged parts of the wall to form a repair area with clear boundaries, a solid base, and in accordance with size restrictions. Then, according to traditional masonry requirements, interlocking joints should be reserved, and temporary supports should be set up for large openings to ensure construction safety and interface bonding conditions.

[0014] Step 2: Select and cut hot-dip galvanized steel wire mesh according to the size of the repair area. Use cement nails and special stainless steel washers to firmly anchor the steel wire mesh to the original wall. Fold and extend the edges and fix them to form a rigid connection system between the steel wire mesh and the original wall without loosening and with full coverage.

[0015] Step 3: Using a construction method that combines single-sided layered masonry with simultaneous wire mesh embedding, starting from the bottom of the repair area, first lay at least two courses of bricks on one side to form a base layer; then, press the wire mesh in this area tightly against the inner side of the already laid bricks and cover the mesh surface with adhesive mortar; then, simultaneously lay bricks of the corresponding height on the other side of the wire mesh, so that the wire mesh is completely wrapped and embedded in the mortar layer between the bricks on both sides;

[0016] Step 4: Repeat step 3 until the repair area is sealed by masonry, so that the wire mesh is fixed by multiple layers of mortar in the vertical direction.

[0017] Some possible implementation methods also include step 5, which involves uniformly grouting the newly built wall according to the traditional style of the original wall, fully moistening and curing the newly built wall, and finally spraying a colorless penetrating waterproofing agent to complete the appearance repair, strength guarantee and durability improvement.

[0018] The beneficial effects of this invention are:

[0019] (1) Excellent structural performance: By embedding the wire mesh as a "skeleton" completely inside the newly built brickwork and tightly bonding it with the mortar, a three-dimensional reinforcement system is provided for the repair area. This structure significantly improves the integrity and shear and tensile strength between the new and old brickwork, solves the problem of weak bonding and easy detachment of the interface in the traditional patching method, and forms a permanent repair structure that is tightly integrated with the original wall.

[0020] (2) Complete preservation of appearance: The restoration process does not involve any form of external plastering or covering. The newly built bricks, colors and mortar joints can be consistent with the original wall. From the appearance, it is basically impossible to distinguish the repair traces. The original facade texture, masonry craftsmanship and historical and cultural information of the building are perfectly preserved, and the protection requirement of "not changing the original state" is achieved.

[0021] (3) Economic efficiency and ease of construction: The main materials are red bricks (or blue bricks), ordinary mortar and low-specification steel wire mesh, which are inexpensive and easy to obtain. The construction process is mainly based on traditional masonry techniques, which do not require large-scale professional equipment or complex technology. Ordinary bricklayers can implement it with simple guidance, which is extremely suitable for promotion in rural areas where special funds and professional technology are lacking.

[0022] (4) Good durability: The steel wire mesh treated with hot-dip galvanizing process has good corrosion resistance. After being completely wrapped by dense mortar, it is in an alkaline protective environment, which greatly extends its service life and ensures the durability of the reinforcement effect. Attached Figure Description

[0023] Figure 1 Process the detailed drawing of the damaged area;

[0024] Figure 2To cut a large-scale drawing of wire mesh to the appropriate size;

[0025] Figure 3 for Figure 2 Enlarged view of A;

[0026] Figure 4 for Figure 2 Sectional view 1-1;

[0027] Figure 5 for Figure 4 Enlarged view of B;

[0028] Figure 6 A schematic diagram of a gasket with a limiting structure (three holes connected in "one piece and two sets");

[0029] Figure 7 For the restoration of the rear wall elevation drawing;

[0030] Figure 8 for Figure 7 Sectional view 2-2;

[0031] Figure 9 To remove broken bricks and create a regular repair area diagram;

[0032] Figure 10 Diagram of the temporary support system for the top of the wall opening;

[0033] Figure 11 Diagram showing the layout and anchoring of the wire mesh;

[0034] Figure 12 Detailed diagram of steel wire mesh fixed with cement nails and stainless steel washers;

[0035] Figure 13 A schematic diagram of the progressive construction process of "new brick laying + wire mesh mortar wrapping".

[0036] Figure 14 A diagram illustrating the color and texture coordination between new and old bricks.

[0037] Figure 15 Image showing the application of a colorless, penetrating waterproofing agent to the entire wall surface;

[0038] Figure 16 This is a schematic diagram showing the effect after the modification. Detailed Implementation

[0039] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0040] This invention first provides a mesh-embedded masonry structure for repairing low-rise brick walls in rural areas. It includes the original wall, new masonry, mortar layers, and hot-dip galvanized steel wire mesh. The new masonry is constructed from both sides of the original wall at the location to be repaired, through the mortar layers. The steel wire mesh is anchored to the original wall. During the construction of the new masonry, the steel wire is pressed in layers and wrapped within multiple mortar layers, thus forming a three-dimensional reinforcing skeleton vertically, held by multiple mortar layers and penetrating both the new and original masonry. This ensures a tight fit between the steel wire mesh and both the original and new masonry, with no exposed areas. Specifically, the steel wire mesh is embedded in layers at the interface between the new and original masonry using a "single-sided masonry base - mesh wrapping with mortar - double-sided closed embedding" process. It is vertically wrapped and held by multiple mortar layers, forming a three-dimensional reinforcing skeleton penetrating both the new and original masonry. Using built-in hot-dip galvanized steel wire mesh as a connecting skeleton, a mechanical interlocking and binding system is formed between the new and old masonry and inside the masonry, thereby achieving high-strength, integrated repair of locally damaged walls without changing the visual effect of the facade.

[0041] The hot-dip galvanized steel wire mesh is connected to the location on the original wall to be repaired via cement nails and washers. Preferably, the washers are two sets of one piece with a three-hole connecting structure and a limiting structure.

[0042] The hot-dip galvanized steel wire mesh covers the area to be repaired on the original wall, and each side of the hot-dip galvanized steel wire mesh extends beyond the outline of the area to be repaired on the original wall by a predetermined distance, with the extended portion tightly attached to the cross-section of the intact brick wall at the area to be repaired.

[0043] The present invention also provides a construction method for constructing the above-mentioned mesh-filled masonry structure for the repair of rural low-rise brick walls, comprising the following steps:

[0044] Step 1, Treatment of damaged areas

[0045] First, precisely chisel away any damaged or efflorescent old bricks within the wall, and remove any loose bricks and mortar from the surrounding area to create a regularly defined repair area. When demolishing the old wall, leave toothed joints of the same specifications around the wall opening, following the original masonry method. The size and spacing of the toothed joints should match the requirements of the old wall construction. Clean the wall opening and joints of debris until a solid masonry base is exposed, ensuring a tight fit between the old and new masonry.

[0046] The length of a single wall opening should not exceed 1.0 meter, and the width should not exceed 0.6 meters. If it is at a wall corner, the length and width of the opening should be reduced by 20% to prevent a decrease in structural stability at the corner. If the opening is close to a wooden beam support point, ensure that the opening is at least 0.3 meters from the bottom of the beam to prevent affecting its load-bearing stability. If the area of ​​the wall opening after removal exceeds 0.5 square meters, a temporary support system must be constructed using wooden planks and timber before repair. The support must be reliably connected to the surrounding wall structure to prevent deformation or collapse of the wall during repair. Figure 1 As shown.

[0047] Step 2, Wire Mesh Arrangement and Anchoring

[0048] Cut hot-dip galvanized steel wire mesh of appropriate size according to the dimensions of the repair area (mesh size should be 10mm×10mm or larger, and the maximum should not exceed 20mm×20mm; the wire diameter should not be less than 1.2mm, and is recommended to be 2.0mm-3.0mm). In the brick wall joints along the vertical and horizontal directions of the repair area, use M7.5×72mm cement nails + 1.0mm thick, 15mm×60mm stainless steel washers (2 nails per washer, nail spacing ≤25mm, washer spacing ≤150mm) to tightly adhere and fix the wire mesh to the original wall. The stainless steel washers are designed with three interconnected holes and a limiting structure, with two sets per washer, facilitating adjustment of the cement nail positions according to the site conditions.

[0049] The edges of the hot-dip galvanized steel wire mesh are folded inwards from the gasket, and a length of at least 100mm is tightly fitted to the surrounding intact brick wall section. The ends are fixed with cement nails and gaskets to ensure a tight and secure fit between the wire mesh and the wall section. Figure 2-6 As shown.

[0050] Step 3: Single-sided masonry base construction - mesh reinforcement and mortar application - double-sided closed embedding

[0051] The key steps are as follows:

[0052] ① Starting from the bottom of the repair area, first lay 2 to 3 courses of bricks on one side (about 120mm-200mm high) to form a base layer.

[0053] ② Attach the pre-laid and anchored wire mesh tightly to the inner side of the newly laid brickwork (i.e. the side facing the other side to be laid), and cover the mesh surface with adhesive mortar.

[0054] ③ Then, on the other side of the wire mesh, bricks of the corresponding height are laid simultaneously. The mortar is squeezed to fill the brick joints, and the wire mesh is completely wrapped and embedded in the mortar layer between the bricks on both sides.

[0055] Step 4: Repeat the process of "single-sided masonry → mesh application and grouting → masonry closure on the opposite side".

[0056] Repeat step 3, "single-sided masonry → mesh application and mortar covering → opposite-side masonry closure," constructing layer by layer upwards until the repaired area is completely sealed. Through this process, the wire mesh is vertically separated by multiple layers of horizontally divided mortar, which then wrap and clamp it, forming a three-dimensional reinforcing skeleton between the new and old masonry and within the new masonry.

[0057] Steps 3 and 4: Throughout the entire masonry process, it is necessary to ensure that the materials of the newly laid bricks, the mortar ratio, and the staggered joint method are consistent with the original wall, so as to achieve uniformity in structural performance and appearance of the repaired wall.

[0058] Step 5, Grout joint treatment and maintenance

[0059] After the masonry work is completed, the joints should be grouted according to the original architectural style. The junction between the old and new walls and the newly constructed sections should be moistened and cured as needed. After cleaning the old and new wall surfaces, apply two coats of a colorless, penetrating waterproofing agent to enhance the wall's waterproofing performance. Figure 7 and 8 As shown.

[0060] Example

[0061] Take, for example, a single-story red brick house built in the 1970s in a rural village in southern my country. On the east side of the building, about 0.5 meters from the ground, an irregular area of ​​about 0.5 square meters of bricks has weathered and fallen off due to long-term rain erosion.

[0062] The repair steps are as follows:

[0063] Step 1, Diagnosis and Cleaning

[0064] ① Carefully diagnose the wall to ensure that the damage is limited to a localized area and that the main structure of the wall is stable.

[0065] ② Using a small pneumatic pick and hand tools, carefully chisel away all weathered and cracked bricks, starting from the point of detachment and working outwards, until the surrounding area consists entirely of structurally intact bricks. After cleaning, the repair area will form a rectangle approximately 0.96 x 0.48 meters on each side, with a depth equal to the wall thickness of 240 mm. Clean the exposed old brick surfaces and grout lines in the repair area with a stiff brush and a high-pressure water gun, ensuring no loose dust or debris remains. Figure 9 As shown.

[0066] ③ To prevent wall deformation or collapse during the repair process, a temporary support system is constructed using wooden planks and timber, such as... Figure 10 As shown.

[0067] Step 2, Netting and Anchoring

[0068] ① Cut a piece of hot-dip galvanized steel wire mesh (20mm x 20mm mesh, Φ2.5mm wire diameter) approximately 1.16m x 0.68m in area, ensuring it covers the entire internal outline of the area to be repaired, extending at least 100mm beyond each side. Figure 11 As shown.

[0069] ② In the intact brickwork or mortar joints above, below, and on both sides of the edge of the repair area, use M7.5×72mm cement nails + 1 thick 15mm×60mm stainless steel shims (2 nails per shim, nail spacing ≤25mm) to fix the taut wire mesh to the original wall (shim spacing ≤150mm).

[0070] ③ Fold the excess wire mesh from the pad inwards to ensure it fits snugly against the surrounding intact brick wall surface, with a length of at least 100mm. Secure the ends with cement nails and pads to enhance the fit between the wire mesh and the wall surface. Figure 12 As shown.

[0071] Step 3, laying new bricks and clamping them with wire mesh.

[0072] ① Single-sided masonry base: Starting from the bottom of the repaired opening, first complete two courses of bricks on one side (the thickness of a single course of bricks is about 60mm, and the total thickness is about 120mm). When masonry, ensure that the mortar fullness of the joint is ≥80% and the vertical deviation of the bricks is ≤2mm.

[0073] ② Wire mesh positioning and mortar coating: After completing the masonry on one side, attach the pre-set wire mesh tightly to the inner side of the newly laid brick, ensuring that the gap between the wire mesh and the brick is ≤5mm; then evenly apply a bonding mortar with a thickness of about 10mm to the surface of the wire mesh to completely cover the wire mesh grid.

[0074] ③ Double-sided closure and fixation: Immediately lay two courses of bricks on the other side of the wire mesh. During the laying process, lightly press the bricks to make the wire mesh completely embedded in the middle mortar layer of the bricks on both sides, ensuring that the wire mesh is covered by mortar from top to bottom and has no exposed parts.

[0075] Step 4, proceed with construction in a cyclical manner.

[0076] Repeat step 3, "lay two courses of bricks on one side → tightly attach the wire mesh and mortar → lay two courses of bricks on the other side," for each completed cycle (total laying height approximately 120mm). Check that the centering deviation of the wire mesh is ≤10mm, until the repaired opening is completely sealed. The wire mesh must be held and fixed by the bricks and mortar throughout the process, with no exposed areas. Figure 13 As shown.

[0077] In steps 3 and 4, the newly laid bricks must be joined to the surrounding existing bricks using a standard staggered T-joint pattern; the color and texture of the new bricks must match the original building, with priority given to using existing bricks from the original building. If existing bricks are unavailable, new bricks of the same specifications and color must be custom-made locally. Figure 14 As shown.

[0078] Step 5, Grouting and Maintenance

[0079] ① After the entire wall is completed, fill the last part of the repair area with mortar or a special grout that resembles the appearance of the old wall, and then uniformly grout the joints between the old and new mortar. The grouting style should be consistent with the original wall (such as flat joints or recessed joints).

[0080] ② After construction is completed, the newly built wall should be watered for at least 7 days in dry weather to prevent the mortar from losing water and cracking too quickly.

[0081] ③ After curing, clean both the old and new walls, and spray two coats of colorless penetrating waterproofing agent evenly to enhance the wall's waterproofing performance. Figure 15 As shown.

[0082] Final Result Assessment: After restoration, the new wall blends seamlessly with the original wall in appearance. The built-in wire mesh, mortar, and bricks form a high-strength composite structure, firmly bonded to the original wall, fully achieving the intended functional and aesthetic preservation goals. Figure 16 As shown.

[0083] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A mesh-reinforced masonry structure for repairing low-rise brick walls in rural areas, characterized in that, The structure includes the original wall, new masonry, mortar layers, and hot-dip galvanized steel wire mesh. The new masonry is built from both sides of the wall through the mortar layers at the location where the original wall is to be repaired. The steel wire mesh is anchored to the original wall. During the construction of the new masonry, the steel wire is pressed in layers and wrapped in multiple layers of mortar, thereby forming a three-dimensional reinforcing skeleton in the vertical direction that is held by multiple layers of mortar and runs through the new masonry and the original wall.

2. The mesh-filled masonry structure for repairing low-rise brick walls in vernacular architecture according to claim 1, characterized in that, The hot-dip galvanized steel wire mesh is connected to the location on the original wall to be repaired via cement nails and shims.

3. The mesh-filled masonry structure for repairing low-rise brick walls in vernacular architecture according to claim 2, characterized in that, The gasket is a two-piece design with a three-hole connecting and limiting structure.

4. The mesh-filled masonry structure for repairing low-rise brick walls in vernacular architecture according to claim 1, characterized in that, The hot-dip galvanized steel wire mesh covers the area to be repaired on the original wall, and each side of the hot-dip galvanized steel wire mesh extends beyond the outline of the area to be repaired on the original wall by a predetermined distance, with the extended portion tightly attached to the cross-section of the intact brick wall at the area to be repaired.

5. A construction method for constructing the mesh-filled masonry structure for repairing low-rise brick walls as described in any one of claims 1 to 4, characterized in that, Includes the following steps: Step 1: First, precisely, safely, and neatly chisel away and clean the damaged parts of the wall to form a repair area with clear boundaries, a solid base, and in accordance with size restrictions. Then, according to traditional masonry requirements, interlocking joints should be reserved, and temporary supports should be set up for large openings to ensure construction safety and interface bonding conditions. Step 2: Select and cut hot-dip galvanized steel wire mesh according to the size of the repair area. Use cement nails and special stainless steel washers to firmly anchor the steel wire mesh to the original wall. Fold and extend the edges and fix them to form a rigid connection system between the steel wire mesh and the original wall without loosening and with full coverage. Step 3: Using a construction method that combines single-sided layered masonry with simultaneous wire mesh embedding, starting from the bottom of the repair area, first lay at least two courses of bricks on one side to form a base layer; then, press the wire mesh in this area tightly against the inner side of the already laid bricks and cover the mesh surface with adhesive mortar; then, simultaneously lay bricks of the corresponding height on the other side of the wire mesh, so that the wire mesh is completely wrapped and embedded in the mortar layer between the bricks on both sides; Step 4: Repeat step 3 until the repair area is sealed by masonry, so that the wire mesh is fixed by multiple layers of mortar in the vertical direction.

6. The mesh-filled masonry structure for repairing low-rise brick walls in vernacular architecture according to claim 5, characterized in that, It also includes step 5: uniformly grouting the new wall according to the traditional style of the original wall, fully moistening and curing the newly built wall, and finally spraying a colorless penetrating waterproof agent to complete the appearance repair, strength guarantee and durability improvement.

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