Wire Break Detection

Gain real-time insights into the health of your bridge’s cables and tensioned wires. Our advanced monitoring solutions help identify wire breaks before they escalate, preserving structural integrity and minimizing downtime.

Bridge cables, tendons, and wires endure constant stress from traffic loads, weather extremes, and everyday mechanical wear. Over time, these forces can lead to microcracks, corrosion, and eventually wire breaks. Even a single snapped wire can severely compromise structural integrity, increasing the risk to public safety and leading to expensive emergency repairs. MISTRAS Group’s proactive wire break monitoring solutions help you stay ahead of potential failures and maintain a high level of safety for both the bridge and the traveling public.

Advanced Detection Through Acoustic Emission (AE)

MISTRAS Group’s wire break monitoring solutions rely on innovative Acoustic Emission (AE) technology—a non-destructive testing (NDT) method that listens for stress waves emitted by materials undergoing deformation or fracturing. When a cable develops a microcrack or experiences a wire break event, the acoustic signals generated are captured by sensors placed at strategic points.

• Pinpoint Accuracy - By triangulating the location and intensity of acoustic signals, our system identifies the exact area of concern.
• Real-Time Insights - AE monitoring provides data-driven clarity, enabling engineers to detect issues before they escalate into structural failures.
• Faster Remediation - Early detection ensures targeted inspection and timely repairs, optimizing maintenance budgets while enhancing public safety.

Data Analytics for Reliable Results

Alongside AE technology, our wire break monitoring solutions incorporate advanced data analytics to filter out ambient noise. This specialized software distinguishes genuine anomalies—such as microcracks or break events—from everyday disturbances like wind or traffic vibrations.

• Reduced False Positives - Intelligent filtering methods allow maintenance teams to focus on actual risks, boosting overall efficiency.
• Automated Alerts - Customized alarms can be set up to notify key personnel instantly when severe wire breaks occur, enabling an immediate response.
• Real-Time Dashboards - Operators benefit from live updates that help them stay informed of any emerging issues and prioritize interventions accordingly.

Benefits of MISTRAS Group’s Wire Break Monitoring

• Enhanced Safety - Continuous monitoring mitigates the risk of sudden failures that could endanger commuters and local communities.
• Proactive Maintenance - Early issue detection lets you schedule repair work during optimal periods, reducing the likelihood of disruptive, unplanned closures.
• Extended Asset Lifespan - By addressing small-scale problems before they grow, you can preserve a bridge’s structural health and delay costly overhauls.
• Optimized Resource Planning & Budgeting - Real-time data analytics ensure minimal waste of resources, enabling focused maintenance strategies and better budget allocation.

A Holistic Approach to Bridge Condition Monitoring

Wire break monitoring often pairs well with other structural health monitoring (SHM) techniques, such as strain gauge analysis and corrosion monitoring. Together, these methods offer a comprehensive understanding of a bridge’s mechanical performance, allowing asset owners and operators to adopt a proactive rather than reactive stance.

Partnering for Bridge Integrity

MISTRAS Group has decades of experience in NDT, condition monitoring, and predictive maintenance. We collaborate closely with clients to develop customized wire break monitoring programs that consider each bridge’s unique design, usage levels, and environmental conditions. By combining targeted inspection, real-time data, and ongoing support, our mission is to help you maintain a safe, reliable infrastructure.

Continual innovation, deep technical expertise, and a commitment to exceptional service drive our wire break monitoring solutions. By leveraging our proven technologies and methods, you can minimize potential hazards, avoid substantial repair costs, and safeguard the well-being of everyone who relies on your bridge network.