IoT crack monitoring in roof structures
Sensor-based monitoring for roof areas
Monitoring of roof areas with sensors
Our crack monitoring system – where precision meets practicality
The Infrasolute system is based on linear displacement sensors with inductive measurement technology and a resolution of up to 0.003 mm. The sensors continuously detect even microscopic movements in cracks within concrete components at freely selectable intervals.
- Connection to gateway: wired or integrated
- Measurement frequency: adjustable from seconds to hourly intervals
- Data transmission: via NB-IoT / LTE-M to the Infrasolute cloud platform
- Installation: screwed or bonded, with a reusable mounting system
- Power supply: selectable between mains power, solar, or long-life battery
From the field: Crack monitoring in a supermarket
Based on this analysis, a structure-integrated building monitoring concept was developed, enabling continuous, high-resolution measurement of crack opening widths – a crucial contribution to condition monitoring and the structural safety of the building.
The sensor system (5 displacement sensors) was connected via cable to a central data acquisition gateway. The cable lengths were custom-fabricated for the project and laid according to the pre-planned sensor positions by the engineering firm. The sensors were specifically arranged along the structurally relevant crack paths, which had been mapped in advance.
Specially developed crack sensors with linear displacement transducers (10 mm measurement range, 0.003 mm resolution) based on inductive technology were used. The high resolution allows for the detection of even microstructural movements in concrete components. This enables reliable measurement of thermally induced expansions or quasi-static crack openings. Installation was carried out by the engineering firm Bröggelhoff using mechanical fastening with counter brackets as well as bonding to the concrete surface, ensuring long-term stability of the measurement positions. A zero-point calibration was performed after installation to interpret all subsequent measurements relative to the installation state.
The measurement frequency of the sensors is configurable via the gateway and allows flexible adjustment depending on requirements.
The gateway serves as the central acquisition and transmission unit and is powered by mains electricity (230 V AC). Thanks to its built-in electronics based on a low-power microcontroller with NB-IoT (Narrowband Internet of Things), energy consumption is minimal. Narrowband offers a particularly robust and wide-coverage mobile communication standard with high building penetration, making it ideal for stationary monitoring applications. For this project, a measurement frequency of 15 minutes was selected. Data transmission is carried out via NB-IoT or alternatively LTE-CAT-M to the Infrasolute cloud platform. All sensors are connected to the gateway using IP68-protected plug-and-play connectors.
In addition to crack movements, the gateway also transmits an integrated temperature value, which serves to interpret thermal influence factors.
The recorded measurement data consists of:
- Timestamp (UTC)
- Measurement value from the displacement sensor (in mm)
- Ambient temperature (at the gateway)
All data is end-to-end encrypted and stored on the Infrasolute monitoring platform. The platform offers a wide range of functionalities:
- Zero-point calibration from the time of installation
- Interactive plan integration: display of live values on stored building plans
- Alarm management: configurable thresholds for each sensor including multi-level alarm levels
- PDF reporting: generate reports for any time period at the push of a button
- CSV export: for further analysis in Excel
- Power supply monitoring: continuous monitoring of the power supply with outage alarms
- Advanced visualization: time series analysis, zoom functions, difference comparison
Flexible system configuration
In general, customers have the following configuration options:
- Choice of power supply:
- Solar
- Long-life battery
- Mains power
- Execution variant:
- 1 displacement sensor integrated into the gateway
- Multiple displacement sensors wired to the gateway
- Mounting method:
- Screwing (recommended)
- Bonding
No matter which variant is chosen – all are reusable thanks to the smart mounting solution.
Project partner: Ingenieurberatung Bröggelhoff GmbH
Ingenieurberatung Bröggelhoff GmbH, based in Oldenburg, is a renowned company specializing in structural engineering, building inspection, and building physics. With over 30 years of experience and an interdisciplinary team of structural engineers and expert consultants, the firm provides services for both new constructions and existing buildings throughout Germany.
As part of this project, Bröggelhoff was responsible for:
- the structural assessment of the roof construction
- the identification of critical and representative crack locations
- the positioning and installation of the sensor system
- the coordination with the monitoring partner Infrasolute
This collaboration enabled the implementation of a technically sound and future-proof monitoring system.
Your benefits with Infrasolute
- Early warning system through proactive alerts
- Plug-and-play: easy installation, even in existing structures
- Flexible configuration of power supply and mounting
- Long-term stability thanks to low-maintenance design
- Digital platform for managing all measurement points
Areas of application for crack monitoring
Our systems are ideally suited for:
- Bridges, tunnels, underground parking structures
- Industrial and logistics halls
- High-rise buildings & renovation projects
- Buildings with recurring crack formation
Let us advise you!
Benedikt Seuss is your personal contact and advisor in the field of intelligent concrete structures.
