Low-cost versatile optical fiber sensor for structural health monitoring of reinforced concrete structures

Reinforced concrete structures form the backbone of civil infrastructure due to their durability, longevity, affordability, and availability. However, aging concrete poses challenges, with decay often beginning internally and becoming visible only at advanced stages, leading to costly repairs, restricted functionality, and safety risks. To address these challenges, sensors are crucial for enhancing infrastructure resilience and optimizing repairs. This study employs multimode optical fibers to monitor concrete curing, water ingress, relative humidity (RH), cement paste carbonation, and rebar corrosion. Four sensors monitor changes in reflection at the fiber tip of a 600 μm multimode fiber (MMF) using LEDs and photodiodes, connected via a fiber bundle containing two 200 μm MMF. Variations in the refractive index around the fiber tip are used to monitor water throughout the concrete lifecycle, including curing, RH changes and water intrusion. Colorimetric changes in a cement paste layer and an iron-thin film are used to monitor carbonation and corrosion. The curing sensor is temperature-independent and correlates strongly with cumulative heat release from cement hydration (R=0.95). The RH sensor monitors up to and beyond 100% RH, detecting water intrusion. The corrosion sensor detects early corrosion stages and distinguishes between reflection losses from corrosion and mechanical changes. The layer of cement paste for carbonation monitoring increases reflected intensity by 17% due to carbonation, with 63% of the increase occurring in 80 minutes in a 3% CO₂ atmosphere. The broad monitoring scope and low implementation cost make this sensor a unique option among commercially available solutions for structural health monitoring of reinforced concrete.