Claude-skill-registry defect-detection-ai
AI-powered construction defect detection using computer vision. Identify cracks, spalling, corrosion, and other defects in concrete, steel, and building components from images and video.
install
source · Clone the upstream repo
git clone https://github.com/majiayu000/claude-skill-registry
Claude Code · Install into ~/.claude/skills/
T=$(mktemp -d) && git clone --depth=1 https://github.com/majiayu000/claude-skill-registry "$T" && mkdir -p ~/.claude/skills && cp -r "$T/skills/data/defect-detection-ai" ~/.claude/skills/majiayu000-claude-skill-registry-defect-detection-ai && rm -rf "$T"
manifest:
skills/data/defect-detection-ai/SKILL.mdtags
source content
AI Defect Detection
Overview
This skill implements deep learning-based defect detection for construction quality control. Analyze images and video to automatically identify structural and surface defects, classify severity, and generate inspection reports.
Detectable Defects:
- Concrete: Cracks, spalling, honeycombing, efflorescence
- Steel: Corrosion, weld defects, deformation
- Masonry: Mortar deterioration, displacement
- Finishes: Surface defects, coating failures
- MEP: Insulation damage, pipe corrosion
Quick Start
import torch import torch.nn as nn from torchvision import transforms, models from PIL import Image from dataclasses import dataclass from typing import List, Dict, Tuple from enum import Enum class DefectType(Enum): CRACK = "crack" SPALLING = "spalling" CORROSION = "corrosion" HONEYCOMBING = "honeycombing" EFFLORESCENCE = "efflorescence" DEFORMATION = "deformation" SURFACE_DAMAGE = "surface_damage" NO_DEFECT = "no_defect" class SeverityLevel(Enum): MINOR = "minor" MODERATE = "moderate" SEVERE = "severe" CRITICAL = "critical" @dataclass class DefectDetection: defect_type: DefectType confidence: float severity: SeverityLevel bounding_box: Tuple[int, int, int, int] # x1, y1, x2, y2 area_ratio: float # Defect area as ratio of image # Simple classifier using pretrained model class SimpleDefectClassifier: def __init__(self, num_classes: int = 8): self.model = models.resnet18(pretrained=True) self.model.fc = nn.Linear(self.model.fc.in_features, num_classes) self.model.eval() self.transform = transforms.Compose([ transforms.Resize((224, 224)), transforms.ToTensor(), transforms.Normalize([0.485, 0.456, 0.406], [0.229, 0.224, 0.225]) ]) self.classes = list(DefectType) def predict(self, image_path: str) -> DefectDetection: """Classify defect in image""" image = Image.open(image_path).convert('RGB') input_tensor = self.transform(image).unsqueeze(0) with torch.no_grad(): outputs = self.model(input_tensor) probs = torch.softmax(outputs, dim=1) confidence, predicted = torch.max(probs, 1) defect_type = self.classes[predicted.item()] return DefectDetection( defect_type=defect_type, confidence=confidence.item(), severity=self._estimate_severity(confidence.item()), bounding_box=(0, 0, image.width, image.height), area_ratio=1.0 ) def _estimate_severity(self, confidence: float) -> SeverityLevel: if confidence > 0.9: return SeverityLevel.CRITICAL elif confidence > 0.7: return SeverityLevel.SEVERE elif confidence > 0.5: return SeverityLevel.MODERATE else: return SeverityLevel.MINOR # Usage classifier = SimpleDefectClassifier() # result = classifier.predict("concrete_image.jpg") # print(f"Defect: {result.defect_type.value}, Confidence: {result.confidence:.2%}")
Comprehensive Defect Detection System
Object Detection Model
import torch import torch.nn as nn from torchvision import transforms from torchvision.models.detection import fasterrcnn_resnet50_fpn from PIL import Image import numpy as np from dataclasses import dataclass, field from typing import List, Dict, Tuple, Optional from datetime import datetime import json @dataclass class BoundingBox: x1: int y1: int x2: int y2: int @property def width(self) -> int: return self.x2 - self.x1 @property def height(self) -> int: return self.y2 - self.y1 @property def area(self) -> int: return self.width * self.height @property def center(self) -> Tuple[int, int]: return ((self.x1 + self.x2) // 2, (self.y1 + self.y2) // 2) @dataclass class DetectedDefect: defect_id: str defect_type: DefectType confidence: float severity: SeverityLevel bounding_box: BoundingBox area_sqm: Optional[float] = None dimensions_mm: Optional[Tuple[float, float]] = None metadata: Dict = field(default_factory=dict) @dataclass class InspectionResult: inspection_id: str image_path: str timestamp: datetime location: str element_type: str defects: List[DetectedDefect] overall_condition: str recommended_actions: List[str] class DefectDetectionModel: """Deep learning defect detection with object detection""" DEFECT_CLASSES = { 1: DefectType.CRACK, 2: DefectType.SPALLING, 3: DefectType.CORROSION, 4: DefectType.HONEYCOMBING, 5: DefectType.EFFLORESCENCE, 6: DefectType.DEFORMATION, 7: DefectType.SURFACE_DAMAGE } def __init__(self, model_path: str = None, device: str = 'cpu'): self.device = torch.device(device) # Initialize Faster R-CNN self.model = fasterrcnn_resnet50_fpn(pretrained=True) # Modify for our classes num_classes = len(self.DEFECT_CLASSES) + 1 # +1 for background in_features = self.model.roi_heads.box_predictor.cls_score.in_features self.model.roi_heads.box_predictor = FastRCNNPredictor(in_features, num_classes) if model_path: self.model.load_state_dict(torch.load(model_path, map_location=self.device)) self.model.to(self.device) self.model.eval() self.transform = transforms.Compose([ transforms.ToTensor() ]) def detect(self, image_path: str, confidence_threshold: float = 0.5, pixels_per_mm: float = None) -> List[DetectedDefect]: """Detect defects in image""" image = Image.open(image_path).convert('RGB') image_tensor = self.transform(image).to(self.device) with torch.no_grad(): predictions = self.model([image_tensor]) pred = predictions[0] defects = [] for i in range(len(pred['boxes'])): score = pred['scores'][i].item() if score < confidence_threshold: continue label = pred['labels'][i].item() box = pred['boxes'][i].cpu().numpy() defect_type = self.DEFECT_CLASSES.get(label, DefectType.SURFACE_DAMAGE) bbox = BoundingBox( x1=int(box[0]), y1=int(box[1]), x2=int(box[2]), y2=int(box[3]) ) # Calculate dimensions if scale provided dimensions_mm = None if pixels_per_mm: width_mm = bbox.width / pixels_per_mm height_mm = bbox.height / pixels_per_mm dimensions_mm = (width_mm, height_mm) severity = self._classify_severity(defect_type, bbox, image.size) defects.append(DetectedDefect( defect_id=f"DEF-{i:04d}", defect_type=defect_type, confidence=score, severity=severity, bounding_box=bbox, dimensions_mm=dimensions_mm )) return defects def _classify_severity(self, defect_type: DefectType, bbox: BoundingBox, image_size: Tuple[int, int]) -> SeverityLevel: """Classify defect severity based on type and size""" image_area = image_size[0] * image_size[1] defect_ratio = bbox.area / image_area # Severity thresholds by defect type thresholds = { DefectType.CRACK: {'critical': 0.1, 'severe': 0.05, 'moderate': 0.02}, DefectType.SPALLING: {'critical': 0.15, 'severe': 0.08, 'moderate': 0.03}, DefectType.CORROSION: {'critical': 0.2, 'severe': 0.1, 'moderate': 0.05}, DefectType.HONEYCOMBING: {'critical': 0.1, 'severe': 0.05, 'moderate': 0.02}, DefectType.DEFORMATION: {'critical': 0.05, 'severe': 0.02, 'moderate': 0.01} } t = thresholds.get(defect_type, {'critical': 0.15, 'severe': 0.08, 'moderate': 0.03}) if defect_ratio >= t['critical']: return SeverityLevel.CRITICAL elif defect_ratio >= t['severe']: return SeverityLevel.SEVERE elif defect_ratio >= t['moderate']: return SeverityLevel.MODERATE else: return SeverityLevel.MINOR class FastRCNNPredictor(nn.Module): """Custom predictor for Faster R-CNN""" def __init__(self, in_channels, num_classes): super().__init__() self.cls_score = nn.Linear(in_channels, num_classes) self.bbox_pred = nn.Linear(in_channels, num_classes * 4) def forward(self, x): scores = self.cls_score(x) bbox_deltas = self.bbox_pred(x) return scores, bbox_deltas
Crack Analysis System
import cv2 import numpy as np from typing import List, Tuple, Dict class CrackAnalyzer: """Specialized crack detection and measurement""" def __init__(self): self.min_crack_length = 10 # pixels self.min_crack_width = 2 # pixels def detect_cracks(self, image_path: str, pixels_per_mm: float = 1.0) -> List[Dict]: """Detect and measure cracks in image""" # Load image image = cv2.imread(image_path) gray = cv2.cvtColor(image, cv2.COLOR_BGR2GRAY) # Enhance contrast clahe = cv2.createCLAHE(clipLimit=2.0, tileGridSize=(8, 8)) enhanced = clahe.apply(gray) # Edge detection edges = cv2.Canny(enhanced, 50, 150) # Morphological operations to connect crack segments kernel = np.ones((3, 3), np.uint8) dilated = cv2.dilate(edges, kernel, iterations=1) closed = cv2.morphologyEx(dilated, cv2.MORPH_CLOSE, kernel) # Find contours contours, _ = cv2.findContours(closed, cv2.RETR_EXTERNAL, cv2.CHAIN_APPROX_SIMPLE) cracks = [] for i, contour in enumerate(contours): # Filter by length arc_length = cv2.arcLength(contour, False) if arc_length < self.min_crack_length: continue # Get bounding box x, y, w, h = cv2.boundingRect(contour) # Calculate crack properties length_px = arc_length width_px = self._estimate_crack_width(gray, contour) # Convert to mm length_mm = length_px / pixels_per_mm width_mm = width_px / pixels_per_mm # Classify crack crack_type = self._classify_crack(length_mm, width_mm, contour) cracks.append({ 'crack_id': f"CRACK-{i:04d}", 'type': crack_type, 'length_mm': length_mm, 'width_mm': width_mm, 'bounding_box': (x, y, x + w, y + h), 'contour': contour.tolist(), 'severity': self._get_crack_severity(width_mm, length_mm), 'orientation': self._get_crack_orientation(contour) }) return cracks def _estimate_crack_width(self, gray_image: np.ndarray, contour: np.ndarray) -> float: """Estimate average crack width""" # Create mask for contour mask = np.zeros(gray_image.shape, dtype=np.uint8) cv2.drawContours(mask, [contour], -1, 255, 1) # Distance transform dist = cv2.distanceTransform(mask, cv2.DIST_L2, 5) # Get average distance (half-width) nonzero = dist[dist > 0] if len(nonzero) > 0: return np.mean(nonzero) * 2 return 0 def _classify_crack(self, length_mm: float, width_mm: float, contour: np.ndarray) -> str: """Classify crack type""" # Fit line to get orientation [vx, vy, x, y] = cv2.fitLine(contour, cv2.DIST_L2, 0, 0.01, 0.01) angle = np.arctan2(vy, vx) * 180 / np.pi if abs(angle) < 20 or abs(angle) > 160: orientation = "horizontal" elif 70 < abs(angle) < 110: orientation = "vertical" else: orientation = "diagonal" # Check for pattern (simplified) if width_mm > 3: return "structural_crack" elif orientation == "horizontal" and length_mm > 100: return "settlement_crack" elif orientation == "diagonal": return "shear_crack" else: return "shrinkage_crack" def _get_crack_severity(self, width_mm: float, length_mm: float) -> str: """Determine crack severity based on dimensions""" # Based on ACI 224R guidelines if width_mm > 1.0: return "critical" elif width_mm > 0.4: return "severe" elif width_mm > 0.2: return "moderate" else: return "minor" def _get_crack_orientation(self, contour: np.ndarray) -> float: """Get crack orientation angle""" [vx, vy, x, y] = cv2.fitLine(contour, cv2.DIST_L2, 0, 0.01, 0.01) return float(np.arctan2(vy, vx) * 180 / np.pi) def generate_crack_report(self, cracks: List[Dict]) -> Dict: """Generate summary report of detected cracks""" if not cracks: return {'message': 'No cracks detected'} total_length = sum(c['length_mm'] for c in cracks) max_width = max(c['width_mm'] for c in cracks) severity_counts = {} for c in cracks: sev = c['severity'] severity_counts[sev] = severity_counts.get(sev, 0) + 1 return { 'total_cracks': len(cracks), 'total_length_mm': total_length, 'max_width_mm': max_width, 'avg_width_mm': sum(c['width_mm'] for c in cracks) / len(cracks), 'by_severity': severity_counts, 'by_type': self._group_by_type(cracks), 'most_severe': max(cracks, key=lambda c: c['width_mm']) } def _group_by_type(self, cracks: List[Dict]) -> Dict: """Group cracks by type""" grouped = {} for c in cracks: t = c['type'] if t not in grouped: grouped[t] = [] grouped[t].append(c['crack_id']) return grouped
Inspection Report Generator
from datetime import datetime import pandas as pd class DefectInspectionSystem: """Complete defect inspection and reporting system""" def __init__(self, detection_model: DefectDetectionModel): self.model = detection_model self.crack_analyzer = CrackAnalyzer() self.inspections: List[InspectionResult] = [] def perform_inspection(self, image_path: str, location: str, element_type: str, pixels_per_mm: float = None) -> InspectionResult: """Perform complete inspection on image""" # Detect defects defects = self.model.detect(image_path, pixels_per_mm=pixels_per_mm) # Additional crack analysis for concrete if element_type.lower() in ['concrete', 'slab', 'wall', 'column', 'beam']: cracks = self.crack_analyzer.detect_cracks(image_path, pixels_per_mm or 1.0) # Add detailed crack info to relevant defects for defect in defects: if defect.defect_type == DefectType.CRACK: for crack in cracks: # Check if crack overlaps with defect bbox if self._boxes_overlap(defect.bounding_box, crack['bounding_box']): defect.metadata['crack_details'] = crack break # Determine overall condition overall_condition = self._assess_overall_condition(defects) # Generate recommendations recommendations = self._generate_recommendations(defects, element_type) result = InspectionResult( inspection_id=f"INS-{datetime.now().strftime('%Y%m%d%H%M%S')}", image_path=image_path, timestamp=datetime.now(), location=location, element_type=element_type, defects=defects, overall_condition=overall_condition, recommended_actions=recommendations ) self.inspections.append(result) return result def _boxes_overlap(self, box1: BoundingBox, box2: Tuple) -> bool: """Check if two bounding boxes overlap""" x1_1, y1_1, x2_1, y2_1 = box1.x1, box1.y1, box1.x2, box1.y2 x1_2, y1_2, x2_2, y2_2 = box2 return not (x2_1 < x1_2 or x2_2 < x1_1 or y2_1 < y1_2 or y2_2 < y1_1) def _assess_overall_condition(self, defects: List[DetectedDefect]) -> str: """Assess overall structural condition""" if not defects: return "Good" severity_scores = { SeverityLevel.MINOR: 1, SeverityLevel.MODERATE: 2, SeverityLevel.SEVERE: 3, SeverityLevel.CRITICAL: 4 } max_severity = max(severity_scores[d.severity] for d in defects) total_defects = len(defects) if max_severity >= 4 or total_defects > 10: return "Critical - Immediate attention required" elif max_severity >= 3 or total_defects > 5: return "Poor - Repairs needed" elif max_severity >= 2 or total_defects > 2: return "Fair - Monitor and plan repairs" else: return "Good - Minor issues only" def _generate_recommendations(self, defects: List[DetectedDefect], element_type: str) -> List[str]: """Generate repair recommendations""" recommendations = [] # Group defects by type defect_groups = {} for d in defects: t = d.defect_type if t not in defect_groups: defect_groups[t] = [] defect_groups[t].append(d) # Generate recommendations by defect type for defect_type, group in defect_groups.items(): max_severity = max(d.severity for d in group) if defect_type == DefectType.CRACK: if max_severity in [SeverityLevel.CRITICAL, SeverityLevel.SEVERE]: recommendations.append( f"Structural engineer assessment required for {len(group)} crack(s). " f"Consider epoxy injection or structural repair." ) else: recommendations.append( f"Seal {len(group)} minor crack(s) with appropriate sealant." ) elif defect_type == DefectType.SPALLING: recommendations.append( f"Remove loose concrete and apply repair mortar to {len(group)} spalling area(s). " f"Check reinforcement for corrosion." ) elif defect_type == DefectType.CORROSION: recommendations.append( f"Treat {len(group)} corrosion area(s). Clean rust, apply rust converter, " f"and protective coating." ) elif defect_type == DefectType.HONEYCOMBING: recommendations.append( f"Fill {len(group)} honeycomb area(s) with non-shrink grout. " f"Investigate concrete placement procedures." ) elif defect_type == DefectType.EFFLORESCENCE: recommendations.append( f"Clean efflorescence from {len(group)} area(s). " f"Investigate and address moisture source." ) if not recommendations: recommendations.append("Continue regular inspection schedule.") return recommendations def export_inspection_report(self, inspection_id: str, output_path: str) -> str: """Export inspection report to Excel""" inspection = next( (i for i in self.inspections if i.inspection_id == inspection_id), None ) if not inspection: raise ValueError(f"Inspection {inspection_id} not found") with pd.ExcelWriter(output_path, engine='openpyxl') as writer: # Summary summary = pd.DataFrame([{ 'Inspection ID': inspection.inspection_id, 'Date': inspection.timestamp.strftime('%Y-%m-%d %H:%M'), 'Location': inspection.location, 'Element Type': inspection.element_type, 'Overall Condition': inspection.overall_condition, 'Total Defects': len(inspection.defects), 'Image': inspection.image_path }]) summary.to_excel(writer, sheet_name='Summary', index=False) # Defects if inspection.defects: defect_data = [{ 'Defect ID': d.defect_id, 'Type': d.defect_type.value, 'Severity': d.severity.value, 'Confidence': f"{d.confidence:.1%}", 'Location (x,y)': f"({d.bounding_box.x1}, {d.bounding_box.y1})", 'Size (w×h)': f"{d.bounding_box.width}×{d.bounding_box.height}", 'Dimensions (mm)': d.dimensions_mm if d.dimensions_mm else 'N/A' } for d in inspection.defects] pd.DataFrame(defect_data).to_excel(writer, sheet_name='Defects', index=False) # Recommendations rec_data = [{'#': i+1, 'Recommendation': r} for i, r in enumerate(inspection.recommended_actions)] pd.DataFrame(rec_data).to_excel(writer, sheet_name='Recommendations', index=False) return output_path def get_defect_statistics(self, start_date: datetime = None, end_date: datetime = None) -> Dict: """Get defect statistics across inspections""" filtered = self.inspections if start_date: filtered = [i for i in filtered if i.timestamp >= start_date] if end_date: filtered = [i for i in filtered if i.timestamp <= end_date] all_defects = [] for inspection in filtered: all_defects.extend(inspection.defects) if not all_defects: return {'message': 'No defects found in period'} # Statistics by_type = {} by_severity = {} for d in all_defects: t = d.defect_type.value s = d.severity.value by_type[t] = by_type.get(t, 0) + 1 by_severity[s] = by_severity.get(s, 0) + 1 return { 'period': { 'start': start_date.isoformat() if start_date else 'all', 'end': end_date.isoformat() if end_date else 'all' }, 'total_inspections': len(filtered), 'total_defects': len(all_defects), 'by_type': by_type, 'by_severity': by_severity, 'avg_defects_per_inspection': len(all_defects) / len(filtered) if filtered else 0 }
Model Training
import torch from torch.utils.data import Dataset, DataLoader from torchvision import transforms import os from PIL import Image class DefectDataset(Dataset): """Dataset for training defect detection model""" def __init__(self, root_dir: str, annotations_file: str, transform=None): self.root_dir = root_dir self.annotations = self._load_annotations(annotations_file) self.transform = transform or transforms.Compose([ transforms.Resize((800, 800)), transforms.ToTensor() ]) def _load_annotations(self, path: str) -> List[Dict]: """Load COCO-format annotations""" import json with open(path, 'r') as f: data = json.load(f) return data['annotations'] def __len__(self): return len(self.annotations) def __getitem__(self, idx): ann = self.annotations[idx] image_path = os.path.join(self.root_dir, ann['image_file']) image = Image.open(image_path).convert('RGB') if self.transform: image = self.transform(image) # Prepare target boxes = torch.tensor(ann['boxes'], dtype=torch.float32) labels = torch.tensor(ann['labels'], dtype=torch.int64) target = { 'boxes': boxes, 'labels': labels } return image, target def train_defect_model(train_dataset: DefectDataset, val_dataset: DefectDataset, num_epochs: int = 10, batch_size: int = 4, learning_rate: float = 0.005): """Train defect detection model""" device = torch.device('cuda' if torch.cuda.is_available() else 'cpu') # Initialize model model = fasterrcnn_resnet50_fpn(pretrained=True) num_classes = 8 # 7 defect types + background in_features = model.roi_heads.box_predictor.cls_score.in_features model.roi_heads.box_predictor = FastRCNNPredictor(in_features, num_classes) model.to(device) # Data loaders train_loader = DataLoader(train_dataset, batch_size=batch_size, shuffle=True, collate_fn=lambda x: tuple(zip(*x))) val_loader = DataLoader(val_dataset, batch_size=batch_size, shuffle=False, collate_fn=lambda x: tuple(zip(*x))) # Optimizer optimizer = torch.optim.SGD(model.parameters(), lr=learning_rate, momentum=0.9, weight_decay=0.0005) # Training loop for epoch in range(num_epochs): model.train() total_loss = 0 for images, targets in train_loader: images = [img.to(device) for img in images] targets = [{k: v.to(device) for k, v in t.items()} for t in targets] loss_dict = model(images, targets) losses = sum(loss for loss in loss_dict.values()) optimizer.zero_grad() losses.backward() optimizer.step() total_loss += losses.item() avg_loss = total_loss / len(train_loader) print(f"Epoch {epoch+1}/{num_epochs}, Loss: {avg_loss:.4f}") return model
Quick Reference
| Defect Type | Detection Method | Typical Severity |
|---|---|---|
| Crack | Edge detection + CNN | Varies by width |
| Spalling | Object detection | Moderate-Severe |
| Corrosion | Color + texture analysis | Moderate-Critical |
| Honeycombing | Object detection | Severe |
| Efflorescence | Color analysis | Minor-Moderate |
ACI 224R Crack Width Guidelines
| Width (mm) | Condition | Exposure |
|---|---|---|
| < 0.1 | Acceptable | Any |
| 0.1 - 0.2 | Acceptable | Dry |
| 0.2 - 0.4 | Repair recommended | Humid |
| > 0.4 | Repair required | Any |
| > 1.0 | Structural concern | Any |
Resources
- PyTorch: https://pytorch.org
- OpenCV: https://opencv.org
- ACI 224R: Crack control in concrete
- DDC Website: https://datadrivenconstruction.io
Next Steps
- See
for construction progress analysisprogress-monitoring-cv - See
for safety defect integrationsafety-compliance-checker - See
for model-based quality controlbim-validation-pipeline