IoT-based three-dimensional crack monitoring sensor
From micro-fractures to structural behaviour - transform cracks into intelligent data for continuous, three-dimensional monitoring.
A Revolution in Structural Damage Detection
The IoT-based 3D Crack Monitoring Sensor represents a new generation of intelligent sensing technology designed for real-time assessment of structural health.
Unlike traditional crack gauges or manual inspection methods, this sensor provides continuous, high-resolution, three-dimensional data on crack propagation — accessible remotely via a secure cloud interface.
Why the IoT Crack Monitoring Sensor?
Monitoring cracks in critical masonry structure and infrastructure - such as bridges, tunnels, heritage structures, and retaining walls - is essential for ensuring their safety and longevity.
Conventional inspection methods are often time-consuming, invasive, and provide only periodic data. Our innovative IoT sensor overcomes these challenges by combining precision 3D sensing, real-time data transmission, and wireless connectivity into a single compact device.
Key Features:
- Three-Dimensional Crack Measurement: Captures opening, sliding, and out-of-plane movement with sub-millimetre precision
- IoT Connectivity: Real-time data transmission
- Highly Customizable Design: Tailored to specific monitoring requirements — including sensor form factor for different structural geometries, measurement range according to crack width, and sampling frequency adjustable from high-speed dynamic monitoring to long-term periodic measurements
- Battery-Powered and Solar-Compatible: Enables long-term operation
- Compact & Weatherproof Design: Suitable for indoor and outdoor environments
- Easy Installation & Calibration
How IoT-sensor Works
This next-generation sensor is ideal for both infrastructure asset management and heritage preservation, providing precise, non-invasive, and data-driven insights.
Step-by-Step Process:
- Installation — Sensors are mounted along cracks or joints of interest
- Calibration — Initial reference position recorded and linked to a project dashboard
- Data Collection Setup — Crack dimensions, mortar lines, block contours
- Continuous Monitoring — Real-time 3D displacement data streamed to the cloud
- Analytics & Alerts — Detects abnormal crack developments exceeding user-defined thresholds, sending notifications to stakeholders
- Visualization & Reporting — Interactive 3D dashboards display crack evolution over time
Applications:
This next-generation sensor is ideal for both infrastructure asset management and heritage preservation, providing precise, non-invasive, and data-driven insights.
Application Areas Include:
- 3D structural crack monitoring in masonry arch bridges and other masonry structures
- Long-term deformation tracking
- Heritage façade preservation and crack propagation analysis
- Predictive maintenance planning for critical assets
We also offer customized sensor development tailored to specific monitoring requirements. Our team can design sensors with bespoke form factors, measurement ranges, and mounting configurations to perfectly match the conditions of each monitoring case.
By offering reliable, continuous monitoring, the system reduces maintenance costs, prevents unexpected failures, and supports data-driven asset management - contributing to sustainability and Net Zero objectives.
Case Study – Masonry Triplet Testing
Let’s take a look at one of the applications of using the IoT sensor to monitor shear displacement of a mortar joint in a masonry triplet:
The sensor was attached to the surface of the masonry triplet by magnets.
The setup enables non-invasive monitoring while providing high-resolution displacement measurements suitable for both research testing and real asset monitoring.
Let’s Build Smarter Structures Together
Through innovative remote sensing techniques, advanced imaging technology, and state-of-the-art data analytics, we offer customized solutions aimed at diagnosing, preserving, and enhancing the resilience of masonry structures against the challenges posed by time and environmental factors.
Our commitment goes beyond mere preservation; we strive to empower the future of architectural conservation through meticulous attention to detail, innovative methodologies, and a deep respect for cultural heritage.
Get In Touch
Have questions or need assistance? Contact us to learn more about how we can support your project with our expertise.