Assessment of low-cost sensors in early-age concrete: laboratory testing and industrial applications

Abstract

Concrete is an essential material in the construction industry due to its strength and versatility. However, its quality can be compromised by environmental factors during its fresh and early-age states. To address this vulnerability, various sensors have been implemented to monitor critical parameters. While high-precision sensors (e.g., piezoelectric and fiber optic) offer accurate measurements, their cost and fragility limit their widespread use in construction environments. In response, this study proposes a cost-effective, Arduino-based wireless monitoring system to track temperature and humidity in fresh and early-age concrete elements. The system was validated through laboratory tests on cylindrical specimens and industrial applications on self-compacting concrete New Jersey barriers. The sensors recorded temperature variations between 15 °C and 35 °C and relative humidity from 100% down to 45%, depending on environmental exposure. In situ monitoring confirmed the system’s ability to detect thermal gradients and evaporation dynamics during curing. Additionally, the presence of embedded sensors caused a tensile strength reduction of up to 37.5% in small specimens, highlighting the importance of sensor placement. The proposed solution demonstrates potential for improving quality control and curing management in precast concrete production with low-cost devices

The authors would like to express their gratitude for the funding provided by the project “PID2021-126405OB-C32 Alarm system for bridge management systems with BIM digital twins using artificial intelligence” funded by MICIN/AEI/10.13039/501100011033/ and “A way to make Europe” FEDER funds. Aslo, this research has been supported by the project SBPLY/23/180225/000113, funded under the call for grants for scientific research and technology transfer projects, in accordance with the Resolution of 22 March 2023. The authors gratefully acknowledge Cotubo Prefabricados, S.L. (Córdoba, La Carlota, Carretera de Posadas Km 20), a leading Spanish manufacturer of precast concrete elements since 1959, for providing laboratory access, materials, and technical support during the execution of experimental tests. Special thanks go to their staff on-site for facilitating the instrumentation of sensors and sample preparation. We also appreciate the administrative and logistical support from Cotubo, enabling the integration of industry-standard practices into our research. During the preparation of this manuscript, the authors used ChatGPT (OpenAI, GPT-3.5, version April 2024) for drafting and refining sections of the Acknowledgments; the output was reviewed and edited by all authors, who take full responsibility for its content

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