CONCRETE AND MASONRY RESTORATION AND ORNAMENTATION METHOD AND APPARATUS
20170051522 ยท 2017-02-23
Inventors
Cpc classification
G05B19/402
PHYSICS
International classification
E04G23/02
FIXED CONSTRUCTIONS
Abstract
A method for restoration of concrete and cementitious surfaces is provided which employs the determined positions of existing fissures in a concrete surface, along with channels to be formed into the concrete surface, to form an image or indicia in the concrete surface such as stone and grout lines. Either a manually drawn platform with a channel forming tool can be employed to move the tool along a pathway to form the channels, or a self-propelled platform may be employed which is computer controlled to form the channels in the proper determined positions to yield the image in combination with the original fissures which are filled during the operation.
Claims
1. A method for restoration of concrete and cementitious surfaces, comprising: determining the position of fissures in a concrete surface within a perimeter edge defining a surface area; determining placement positions for channels in said concrete surface to form indicia therein in combination with said fissures; using said placement positions to determine a guide for positioning of said channels in said concrete surface; and positioning said guide upon said concrete surface to define a pathway for employment of a tool to form said channels in said placement positions upon said concrete surface.
2. The method for restoration of concrete and cementitious surfaces of claim 1, additionally comprising: positioning said guide upon said concrete surface by placing visible lines upon said concrete surface.
3. The method for restoration of concrete and cementitious surfaces of claim 1, additionally comprising: filling said fissures with filler material to a point where a top surface of said filler material is at an elevation slightly below an elevation of said concrete surface; forming said channels into said concrete surface; and affixing an overlay surface to cover both said top surface of said filler material and said channels whereby said channels in combination with said top surface of said fissures have an appearance of grout lines surrounding areas of said concrete surface.
4. The method for restoration of concrete and cementitious surfaces of claim 2, additionally comprising: filling said fissures with filler material to a point where a top surface of said filler material is at an elevation slightly below an elevation of said concrete surface; forming said channels into said concrete surface; and affixing an overlay surface to cover both said top surface of said filler material and said channels, whereby said channels in combination with said top surface of said fissures have an appearance of grout lines surrounding areas of said concrete surface.
5. The method for restoration of concrete and cementitious surfaces of claim 1, additionally comprising: forming a digital image of said position of fissures in a concrete surface within said perimeter edge, and storing said digital image in electronic memory of a computer; employing software running in said electronic memory which is adapted for determining said placement positions for said channels in said concrete surface to form said indicia therein, in combination with said fissures; employing software running in said electronic memory to determine said guide for positioning of said channels in said concrete surface, based on said placement positions; communicating said guide to electronic memory of a computing device on a motorized platform operatively engaged with said tool; and employing software running on said computing device on said motorized platform to use said guide for positioning of said channels, to drive said motorized platform upon said concrete surface and form said channels with said tool.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate some, but not the only or exclusive examples of embodiments and/or features of the invention. It is intended that the embodiments and figures disclosed herein are to be considered illustrative, rather than limiting.
[0025] In the drawings:
[0026]
[0027]
[0028]
[0029]
[0030]
[0031]
[0032]
[0033]
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[0037]
[0038]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
[0039] In this description, any directional prepositions if employed, such as up, upwardly, down, downwardly, front, back, first, second, top, upper, bottom, lower, left, right and other such terms refer to the device or depictions as such may be oriented are describing such as it appears in the drawings and are used for convenience only. Such terms of direction and location are not intended to be limiting or to imply that the device herein has to be used or positioned in any particular orientation.
[0040] Now referring to drawings in figures herein, wherein similar components are identified by like reference numerals, the present subject matter relates to a method, process, and system to remediate and/or beautify cracked concrete surfaces, in a cost-effective and sustainable way, minimizing the resources utilized to provide a replaced surface and obviate the need to replace a concrete body. This technique can create a genuine or more natural rough edge than most manufactured products. In the method herein, recesses and lines are formed in the concrete to form an image or pattern thereupon, and in doing so, to incorporate cracks into a pattern.
[0041] The recesses may form patters or lines and all can vary in depth, width and length, depending on the desired image or pattern to be imparted to the surface, as well as the budget for such surfacing. Using either the manual or automated device herein to employ the method herein disclosed, skilled and even semi-skilled users can make masonry surfaces appear as stones set individually. Using the automated system herein employing the self-propelled platform which is autonomous and will move the platform and mount, according to an electronic map held in electronic memory, the tool employed can impart virtually any image or design into any horizontal or vertical surface.
[0042] The self-propelled system herein for imparting recesses and lines into the surface can accomplish such in a matter of hours using onboard computer memory and software running therein configured to steer the platform and if needed translate the mount to form the pattern in the driveway which has been predetermined as shown in
[0043]
[0044] At any particular position 14 along each crack 11, it has a width W the distance between opposite sides 16 and 18. Each crack 11 forming a fissure has a depth D. The depth D corresponds to the height of a fissure sidewall 24. Such fissure sidewalls 24 are usually irregular and may be disposed at any one of a number of angles with respect to a vertical axis at different positions along the length D. The intersection of the upper surface 12 and such a sidewall 24 is referred to as a corner 26. The term corner as used herein is used for convenience in description. In virtually all cases, the corner 26 will be a rounded rough edge rather than an intersection of planes.
[0045]
[0046] As can be discerned, this prior art method of repair does virtually nothing to improve curb appeal or value of a property. The visual redundancy of cracks running through the concrete and the discolored repairs, makes the cracks particularly noticeable to the naked eye.
[0047]
[0048] As shown, in all modes of the system herein, the group 30 is used as the basis for a design of a pattern for formation into the surface. By this employment of the group 30 of fissures 10 to incorporate them in a pattern 40, the original fissures 10 are visually transformed from an eyesore to part of a design. The pattern 40 extending from and around the original group 30 of fissures, is formed of lines 44 laid out to simulate borders of set stone. The lines 44 define individual areas 46 bounded by lines 44 which as depicted simulate a stone surface, however in the automated mode of
[0049] In the method herein employing the device shown, the guide 229 may be formed by lines 44 may be imparted to the surface in any of a number of ways and provide a path for the user to follow with the tool. In one mode of the method herein, the lines may be drawn or otherwise temporarily formed such as with tape, onto the surface. Faintly depicted or inscribed lines will be sufficient to allow further process steps using the manual mode of the method herein and the device as in
[0050]
[0051] Shown in
[0052] Shown in
[0053] The overlay material 130 also provides a vehicle for receiving color for the areas 46 (
[0054] High gloss sealers may be slippery. Acrylic sealers are generally preferred. The acrylic sealers may be blended with epoxies, polyurethane, or silicones to improve performance, durability, and water resistance. Other types of topical sealers for driveways are polyurethane, epoxies, and penetrating resins. Generally, epoxy or polyurethane sealers cost considerably more than acrylics and they tend to be higher build, and thus more slippery. They also don't allow for moisture vapor to move out of the concrete. It's important that sealers used on exterior concrete allow the passage of both air and moisture. Penetrating sealers are made of specialty resins such as silicones, siloxanes, and silanes that penetrate into the concrete and form a chemical barrier to water, oil, and other common contaminants.
[0055] Shown in
[0056] Shown in
[0057] As shown in
[0058] A rack and pinion 218 allows for translation of the distal end of the engraving tool 210 toward and away from the surface 12 to render deeper or shallower channels 144 or lines, and for lifting the distal end of the engraving tool 210 above the surface 12 to move it to another point to be channeled. A drive gear 220 allows for this translation by hand rotation or motorized rotation as in the mode of the system herein in
[0059] Shown in
[0060] Shown in
[0061] Shown in
[0062] As depicted in
[0063] Using a photo, or other means for depicting the fissures 10 within the perimeter 230 and actual or electronic graph lines 232 positioned within the perimeter 230 in a virtual depiction of the surface 12, the positioning of channels 144 can be determined by the user, or by software adapted to employ the existing fissures 10 within the perimeter 230, and plot and depict positions on the surface 12 where channels 144 are to be placed to yield the desired indicia thereon, such as the depicted stone with grout indicia.
[0064] Once the determined position of the channels 144 is calculated, the guide 229 may be formed and positioned upon the surface 12 for use as a pathway with the manual platform 204 as in
[0065] Thereafter, with the guide 29 positioned on the surface 12, in the manual operation of the method herein, the user will use the platform 204 of
[0066] In a particularly preferred mode of the system herein, the mount 202 with the power tool 208 of choice engaged therewith, which has the engraving tool 210 of choice, is engaged with a self-propelled platform 205. As shown the self propelled platform 205 has wheels 224 which are operatively engaged with electric motors 240 which will propel the platform 205 forward and rearward and in turns required, to follow an electronic guide 229 held in memory of a computing device 246. The positioning of the engraving tool 210 upon the surface 12 to impart the channels 144 desired to form the indicia is handled by the computer 246 controlling the motors 240 to move the engraving tool 210 upon the surface 12 along the guide held in electronic memory.
[0067] The self propelled platform 205 will start from a known position upon the surface 12 which may either be input to the computer 246, or determined using an electronic location sensor such as a GPS receiver 247 communicating the terrestrial position of the platform 205 to the computer 246 which will use that information to drive the platform 205 using the motor or motors 240 on the surface 12. This mode of the method and device herein, like the others will allow the user to mount an existing power tool 208 on the mount 202. As shown in
[0068] It should be noted that while the method and apparatus herein is described for imparting channels 244 or recesses into a surface 12 which is generally horizontal, it could be employed to impart indicia into vertically disposed surfaces using either a platform 204 or 205 which is supported to move in a vertical orientation, or, by positioning an moveable arm (not shown) in between the platform 204 or 205 and the mount 202. Where the computerized system is employed similar to that of
[0069] A control cable assembly 240 extends from the handle 226 to the channel tool 200 to allow a user to control functions of the channel tool 200. The channel tool 200 is secured to a mounting bracket 246 mounted on the cart 220. The mounting bracket 246 comprises a height adjusting assembly slide assembly 248. The slide assembly 248 allows for selection of the height of the cutting element 214. The slide assembly 246 may include vertically displaced detents or a ratchet, for example. A spring-loaded or totally manual height adjustment may be provided. Height may also be adjusted by adjustable height wheel mounting. In this manner, the cutting element 214 may be disengaged from the surface 12 or lowered to produce a selected depth of the channel 144. The control cable assembly 240 is operated by the user to control the slide assembly 248.
[0070] The present subject matter is not limited to the specific methods stated above. Other options for creating an appearance of authentic set-stone on a masonry or concrete may use selected subsets of the steps described above. Preference and budget will dictate which steps should be used. Areas of high visibility will be most appealing and authentic if more steps are performed. [0071] In a more rigorous method the user will:
[0072] 1. Grind or scarify surface where necessary for evenness and safety.
[0073] 2. Create channel in existing cracks, if applicable; if not, then create channels that will serve as control joints to future cracking.
[0074] 3. Place stop channels, cardboard furring strips, foam (or other material that can be removed easily after overlay and texturing procedure).
[0075] 4. Prepare surface using recommended materials for optimal performance of overlay material.
[0076] 5. Apply overlay and stamp or texture which may be tinted with coloring.
[0077] 6. Apply colors to desired result.
[0078] 7. Apply sealer to protect color work from being clouded by grout material. This makes for easier cleanup after grouting.
[0079] 8. Outline desired patterns to be turned into channels. This can be accomplished by scoring lines, chalking, taping, or other. An experienced artist can perform this task without using outlines and can achieve a desired appearance.
[0080] 9. Use power tool to create complimentary additional channels that will be grouted.
[0081] 10. Apply grout and use typical grout-cleanup methods commonly used.
[0082] 11. After grout is cured, another coat of sealer is applied. [0083] In a more basic method than those described above, the user will:
[0084] 1. Grind or scarify surface only if necessary for evenness and safety.
[0085] 2. Apply color to surface for desired result.
[0086] 3. Apply sealer to protect color work from being clouded by grout material. This makes for easier cleanup after grouting.
[0087] 4. Instead of creating deep channels with invention, use at shallow depth to create the appearance of grout rather than actually applying grout. This does not yield as authentic a result as actually applying grout does, but allows a quick-fix and saves a lot of work. Further, when rendering indicia into the surface which is a photo or drawing or the like, the channels may simply be small dot-like recesses formed into the surface which when viewed from afar, appear as the intended photo image or drawing.
[0088] Finally, in a simple but effective method of the system herein,
[0089] a) the position of the fissures will be determined upon the surface;
[0090] b) the placement positions for channels is determined which in combination with the fissures, will form the desired image or indicia into the surface;
[0091] c) a guide determined using the placement position for channels and imparted to the surface;
[0092] d) the guide is employed by a user to impart the channels in the placement positions on the surface using a powered tool to form the channels in the placement positions;
[0093] e) the original fissures may be filled with filler material.
[0094] In employing the guide to impart the channels to the surface, the user may use a wheeled platform to pull the powdered tool, or if a robotic platform is employed, a computer navigation system on the platform will drive and steer the platform, to form the channels using the guide which is stored in electronic memory.
[0095] While all of the fundamental characteristics and features of the surface repair and remediation system herein have been shown and described herein, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be apparent that in some instances, some features of the invention may be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should also be understood that upon reading this disclosure and becoming aware of the disclosed novel and useful device and system herein disclosed, that various substitutions, modifications, and variations may occur to and be made by those skilled in the art, without departing from the spirit or scope of the invention. Consequently, all such modifications and variations and substitutions, as would occur to those skilled in the art are considered included within the scope of the invention as defined by the following claims.