Design, Development, and Laboratory Validation of a Low-Cost Multi-Sensor System for Bridge Structural Health...

This paper reports the design, development and laboratory validation of a low-cost multi-sensor system for bridge Structural Health Monitoring with complementary scour-related environmental sensing. The proposed sensing apparatus is intended for continuous dynamic (vibration-based) and quasi-static structural monitoring, in particular for bridge applications. It employs a distributed wired architecture comprising two custom printed circuit boards, BridgeWatch and EnvironMonitor. BridgeWatch nodes integrate MEMS accelerometers and gyroscopes, enabling acceleration measurements, quasi-static inclination estimates from gravity components, angular-rate measurements and structural surface-temperature acquisition. The EnvironMonitor node acquires wind, rainfall, air temperature, humidity and bridge water level; these variables provide environmental and hydrological context relevant to scour risk, without directly measuring riverbed elevation or scour depth. A Raspberry Pi coordinates acquisition, synchronisation and communication through RS485 and RS232 links. The hardware was implemented through custom PCB design and dedicated firmware. The principal contribution is the system-level integration of structural and environmental measurements in one open architecture. Laboratory validation comprised communication and synchronisation checks, shaker tests, a scaled structural benchmark, climatic-cell tests and environmental-input simulations. The results demonstrate functional acquisition and relevant dynamic-feature extraction under controlled conditions. These outcomes enable future full-scale in situ validation and testing on full-size case studies.