Intelligent Bio-Based Sensor Fabric Revolutionizes Asphalt Monitoring

WPB states that a new technology developed by scientists at the Fraunhofer Institute and its industry partners is revolutionizing road asphalt monitoring and maintenance. Traditionally, road rehabilitation decisions have been made primarily based on what can be observed on the surface, neglecting the most critical condition of the asphalt base layer beneath. The new system offers a continuous, non-destructive means of sensing early indication of structural distress deep in the pavement—a capability only heretofore gained through invasive, discrete sampling procedures.

This advanced surveillance technology places a bio-based sensor material into the asphalt itself, allowing for ongoing monitoring of the inner condition of the material. The material, consisting of natural flax fibers infused with conductive wires, functions as an extremely resistant and sensitive sensing network. Supported by artificial intelligence, data collected from this in-place material allows real-time evaluation of road performance, providing engineers and officials with detailed knowledge of road infrastructure health and life expectancy.

As time goes on, asphalt is subjected to severe traffic loading stresses and environmental factors, leading to microcracking and subsurface damage that cannot be observed by regular inspections. The suggested sensor-driven solution eliminates the need for destructive core sampling, which is time-consuming, costly, and often exacerbates road deterioration. The system, however, constantly observes and processes stress, strain, and deformation data, enabling one to predict expected failures before they happen and are visible or critical.

The essence of this innovation lies in the intelligent carrier cloth—a knitted fabric produced from flax and sensor yarns with a thickness of less than one millimeter. In production, the conductive wires are smoothly integrated within the fabric, offering both mechanical strength and electrical functionality. The result is a material strong enough to bear heavy loads during installation and resistant to wear caused by traffic and weathering over long periods of time. Embedded in asphalt, this cloth is an internal diagnostic layer that records changes in electrical resistance proportional to the pavement's structural integrity.

All data gathered by the onboard sensors is transmitted to a roadside unit that stores and transfers the data for machine learning-based analysis. With advanced computational methods, the system can study these readings to determine the current condition of the road and even predict the rate of degradation. Predictive analysis makes intelligent, data-driven scheduling of maintenance possible, and road authorities can respond prior to the damage escalating—peak cost and efficacy.

A web platform displays the inspected information so that road engineers, construction planners, and other concerned stakeholders can access it. This web interface is designed to consolidate all information about infrastructure health and maintenance planning and create greater transparency and better decision-making throughout the entire road management cycle.

Initial field trials in an industrial testing zone have already validated the technology's success. Under the truck loads, the sensor cloth successfully recognized deformations and separated axle configurations with incredible accuracy under field conditions.

By incorporating sustainable materials, digitalization, and AI, this bio-based sensor system represents a leap of revolution towards intelligent, sustainable road infrastructure management. Not only does it set the bar higher on the precision of monitoring, but it also allows for long-term planning and unlocks the avenues to a new generation of pro-active, green-road maintenance.

By WPB

Asphalt, Bitumen, Market