Manufacturing of CFRP Plate Coupled with Large Range FBG
Mingxia Li1,*, Haowei Xu1, Ruiqi Li1, Bo Song2, Wanxu Zhu1,*
1 School of Civil Engineering, Guilin University of Technology, Guilin, China
2 China Huaneng Zhasainuoer Coal Industry Co., Ltd., Hulunbuir, China
* Corresponding Author: Mingxia Li. Email: 
; Wanxu Zhu. Email: 
(This article belongs to the Special Issue: AI-driven Monitoring, Condition Assessment, and Data Analytics for Enhancing Infrastructure Resilience)
Structural Durability & Health Monitoring https://doi.org/10.32604/sdhm.2026.075587
Received 04 November 2025; Accepted 20 January 2026; Published online 21 February 2026
Abstract
Conventional fiber Bragg grating (FBG) sensors used for tensile monitoring have a limited measurement range and therefore cannot cover the entire service stage of prestressed carbon-fiber-reinforced polymer (CFRP)–strengthened members. In this study, a smart CFRP plate is developed by embedding a wide-range FBG sensor in a prestressed CFRP plate. Based on strain-transfer theory for the grating region, an analytical expression for the average strain-transfer rate is derived and then used to inversely design the groove geometry and bonding parameters; the resulting groove size is 0.5 mm × 0.5 mm. During bonding, a tensile force of 0.3Pc is applied and maintained, where Pc denotes the theoretical ultimate tensile capacity of the plate, so that the embedded FBG remains in tension and potential slack at the bonded interfaces is eliminated. Three CFRP specimens (100 mm × 2 mm, width × thickness) are fabricated, and three rounds of cyclic calibration followed by monotonic tensile tests are conducted. In accordance with national standards for static performance, the sensitivity, hysteresis, linearity, repeatability, and root-sum-square (RSS) combined accuracy are quantified. The measured FBG strain sensitivity agrees well with the theoretical value of 1.21 pm/με. The measurable strain range reaches approximately 12,088.71 με, covering about 90% of the working interval up to the theoretical ultimate load of the member. The static performance indices are as follows: hysteresis ≤ 0.94%, linearity ≤ 0.57%, repeatability ≤ 2.82%, and overall accuracy ≤ 2.95%. The proposed approach markedly extends the monitoring range while maintaining accuracy, enabling continuous strain monitoring of CFRP-strengthened members from normal service to the pre-ultimate stage and meeting engineering requirements for both a wide range and high precision.
Keywords
Whole-stage monitoring; intelligent CFRP plate; FBG sensor; tension test; stress strain
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