Smart and autonomous monitoring of cracking in concrete structures with PZT sensor array-based hybrid sensing

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Detecting microcracks in concrete structures is crucial for maintaining structural integrity; however, current methods often lack the precision, objectivity, and sensitivity needed for early-stage detection and monitoring. This study introduces a pioneering hybrid sensing approach that combines coherent and incoherent ultrasonic wave fields with surface-mounted PZT-based sensors, significantly advancing the state-of-the-art. The sensors are positioned at specified locations on a notched concrete beam and operated in the actuator-receiver (AR) mode, allowing for the manipulation of fracture width at the notch to achieve distinct degrees of damage. By evaluating the ultrasonic waves received from various AR configurations, we developed robust damage indices: the attenuation factor and diffusivity ratio. These indices provide objective metrics for evaluating the degree of damage, addressing the limitations of existing techniques. Key results demonstrate that the attenuation factor can detect crack widths as small as 10 µm at a 120 kHz frequency, surpassing traditional methods. Nevertheless, its sensitivity diminishes if the crack width exceeds 100 µm. Additionally, the diffusivity ratio remains sensitive to cracks beyond 200 µm and shows a substantial 40 % decrease even for non-visible fractures, offering a comprehensive assessment of fracture propagation. These advancements not only enhance early detection and monitoring precision but also offer a deeper understanding of fracture mechanics, paving the way for improved structural health monitoring and maintenance strategies.