Integrated Sensor Technology for Basalt-Reinforced Segmental Lining Elements

Current climate protection goals are driving research toward large-scale structural health monitoring solutions for critical, long-lifespan infrastructure, alongside the usage of low CO₂ emission materials. In this work, we present an innovative approach that combines both aspects: the use of continuous basalt fibers assembled into sustainable reinforcement structures, and low-cost measurement systems for integrated long-term condition monitoring, specifically applied to tunnel segment monitoring. As a proof-of-concept for the integration of sensor elements into basalt reinforced concrete structures, we utilized stranded steel wire to create custom strain gauge sensors for integrated strain measurements, paired with a custom-designed resistive bridge-based measurement system to evaluate the feasibility of enabling low-cost condition monitoring. Mechanical tests were conducted on basalt-reinforced concrete specimens under both tensile and compressive loading. The results indicate that the system can measure even low strain values for the sensor-enhanced structures down to approximately 5 μm/m and a standard deviation of 2.1 μm/m, achieving a sensing performance close to state-of-the-art measurement systems and externally applied standard strain gauges. The study demonstrates the potential for cost-effective condition monitoring of individual tunnel segments with sustainable basalt reinforcement. Further optimizations of the system are anticipated in future projects.