Ring-Shaped Polyvinylidene Fluoride Piezoelectric Sensor for Real-Time Surface Crack Monitoring in Reinforced Concrete Beams

Real-time monitoring of surface cracks in reinforced concrete (RC) beams is critical to structural safety and service performance evaluation. Current structural crack monitoring still faces prominent scientific and technical bottlenecks: conventional unidirectional sensors cannot achieve multi-directional collaborative sensing, rigid piezoelectric materials exhibit poor compatibility with the large deformation of concrete, and there is a lack of quantitative mapping relationships from sensing signals to crack parameters, making it difficult to simultaneously measure crack width, angle, and morphology. This paper presents a novel ring-shaped piezoelectric sensor based on polyvinylidene fluoride (PVDF) and an annular piezoelectric sensing mechanism for real-time monitoring of crack angle, width, and morphology. The sensor incorporates a laminated structure with four strip sensing units for multi-directional strain detection. Experiments were conducted on RC beams under various loading conditions, and finite element analysis was performed using COMSOL Multiphysics. An innovative crack damage index (B) was introduced to assess structural damage quantitatively. Results demonstrate high sensor sensitivity and stable output. Voltage signals increase both with crack width and crack angle, showing responses of 0.045 mV, 0.041 mV, and 0.023 mV for crack angles of 60°, 45°, and 30°, respectively, at a crack width of 9 mm. Strong consistency between experimental and simulation data validates the effectiveness of the mechanism in monitoring the direction, width, and types of cracks. The crack damage index B exhibits a positive correlation with the structural stress response, enabling a quantitative assessment of damage. This study is applicable to the prestressed concrete box girders and T-beams commonly used in large-span bridges, which are typically with a main span of 20–50 m, a beam length of 6–30 m, a section height of 1.2–2.5 m, and designed for Grade C35–C50 concrete. The findings provide a practical foundation for real-time crack monitoring in large-scale bridge beam members.