Bio-based fabric with integrated sensors continuously monitors asphalt road conditions
By Anna Lissel, Fraunhofer-Gesellschaft – Edited by Gaby Clark, Reviewed by Robert Egan
Roads endure constant stress from heavy traffic and environmental exposure, leading over time to cracks and structural defects. While larger cracks are visible, micro-cracks and damage to deeper asphalt layers are not detectable to the naked eye. Current inspection methods rely on drilling core samples—an invasive, time-consuming, and localized process that damages the road further and requires lane closures. This often results in inefficient resurfacing efforts, as underlying issues remain hidden.
To address these challenges, researchers at the Fraunhofer Institute for Wood Research, Wilhelm-Klauditz-Institut (WKI), together with partners in the SenAD2 project, are developing a non-destructive, continuous monitoring system to assess asphalt road health and forecast degradation.
Sensor Fabric Innovation
At the heart of the system is a bio-based fabric made of flax fibers interwoven with ultra-thin conductive wires (<1mm). The conductive elements are seamlessly integrated during weaving, producing a robust material resistant to slippage or damage during road construction. The fabric withstands the weight of heavy machinery such as trucks and pavers, ensuring durability during installation and use.
Produced with a double rapier loom at Fraunhofer WKI, the fabric is available in 50cm widths and can be manufactured in virtually unlimited lengths. Once embedded in the asphalt base, the fabric continuously measures strain-induced changes in electrical resistance, which correlate with the road’s structural condition.
Data Collection and AI Analysis
The conductive fabric connects to measurement units positioned roadside. These units record resistance changes, transmit the data to analysis software, and use AI-based algorithms to assess road integrity and predict future deterioration. Results are visualized on an online dashboard, making information accessible to road authorities, businesses, and local communities.
This system enables early detection of hidden damage and supports predictive maintenance planning, reducing unnecessary resurfacing and optimizing budgets.
Field Trials Underway
Following successful laboratory feasibility tests, researchers are conducting industrial zone trials using a full-width demonstrator road segment. Initial results confirm that the sensor fabric can withstand installation conditions and environmental stresses, while delivering accurate, continuous monitoring.
Fraunhofer WKI scientist Christina Haxter emphasized: “Our goal is to enable continuous monitoring of road conditions over time and provide forecasts for degradation. While this won’t make roads last longer, it will make monitoring and maintenance far more effective.”
If widely deployed, this bio-based sensor fabric could revolutionize road management by making infrastructure maintenance more sustainable, cost-efficient, and less disruptive for traffic.
