Extend the lifetime of infrastructure with smart monitoring
How Villari’s certified wireless crack detection technology transforms aging steel infrastructure by safely extending asset lifetime and optimizing maintenance.
At a glance
In the railway infrastructure sector, ensuring the structural integrity of bridges is key to ensure safety and operational efficiency. Bridges, especially critical members like the main girder, must be closely monitored for any damage or deformation, as these issues can lead to expensive repairs and possible downtime.
Customer
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Industry
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Challenge
A truck collision damaged a railway bridge’s main girder, raising concerns about crack growth and safety. Traditional repair would have caused excessive downtime and costs.
Solution
Villari implemented a continuous monitoring system on the deformed flange with minimal installation. The sensors detect crack growth by tracking changes in real time.
Key Benefits
1. Reduced downtime
2. Early damage detection
3. Fast, non-intrusive installation
Challenge
A railway bridge in the Netherlands faced a significant challenge after a truck collided with its structure, causing visible deformation to the bottom flange of the main girder, a critical component of the bridge. The deformation raised concerns about potential crack growth and initially a repair was scheduled. However, it would result in excessive downtime and substantial expenses, making it a costly solution.
Solution
To avoid unplanned downtime and expensive repairs, Villari collaborated with the bridge’s owner to implement a continuous monitoring system. The sensors were strategically placed on the deformed flange, a process that required minimal installation time and no surface preparation. The sensor system detects crack growth by monitoring changes in the ferro-magnetic field of the steel structure, providing real-time data on any structural developments.
"
It's a pleasure to collaborate with the Villari team, who are not only knowledgeable but also flexible in their approach.
The dashboard they provide offers us a clear overview of the status of the most critical stress points."
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Results
The implementation of Villari’s sensor system unlocked a new level of data-driven asset management and maintenance. A continuous stream of data provides instant alerts when cracks start to develop. Maintenance costs and downtime were reduced and the EOL for each asset could now be precisely assessed and increased in 15%, through the valuable data acquired.
10 minutes
Installation time / sensor
48 hours
Maximum response time
Up to 4.000
Measurements per year / sensor
Cost reduction
Reduced monitoring cost
Key Numbers
10 minutes
Installation time / sensor
48 hours
Maximum response time
Up to 4.000
Measurements per year / sensor
Cost reduction
Reduced monitoring cost
Key Numbers
Key Numbers
48 hours
Maximum response time
10 minutes
Installation time / sensor
48 hours
Maximum response time
10 minutes
Installation time / sensor
Want to learn more?
Are you ready to take your asset management and
maintenance strategy to the next level?