Structural Health Monitoring System for Suramadu Bridge Using FBG Sensors and OPC UA
Challenges
Developing a scalable and future-proof structural health monitoring system (SHMS) for one of Indonesia’s longest bridges—Jembatan Suramadu. The system must support more than 190 distributed Fiber Bragg Grating (FBG) strain sensors, deliver real-time data acquisition, and publish results to a centralized server for continuous evaluation.
Haliatech Solution
A flexible and programmable system based on LabVIEW and OPC UA architecture to acquire, process, and transmit strain data from multiple FBG interrogators to a Fujitsu cloud server. Haliatech developed the solution to ensure rapid configuration, easy scalability, and real-time visualization for structural diagnostics.
Suramadu Bridge spans over 5 kilometers and experiences high mechanical stress due to environmental loads and dynamic traffic. Monitoring its structural integrity is essential to ensure safety and long-term durability. The system developed by Haliatech integrates:
- 190+ FBG strain sensors, installed across critical points on the bridge
- FBG interrogator hardware with optical demodulation
- LabVIEW-based real-time acquisition and visualization software
- OPC UA server communication for publishing data to a central monitoring platform
Key Features:
- Real-Time Strain Monitoring from 190+ FBG sensors
- Integrated OPC UA Publishing to remote server (Fujitsu)
- Minimal Effort to Expand – Add new sensors/interrogators with ease
- Highly Programmable using LabVIEW for custom functions and alarms
- Modular Architecture that supports future upgrades and data fusion (e.g. with force sensors)
Technical Architecture
The architecture was designed with flexibility and extensibility in mind. Core components include:
- LabVIEW Platform: Main engine for sensor communication, data handling, and UI
- OPC UA Technology: Allows secure, real-time, platform-independent data sharing to the cloud
- FBG Interrogators: Devices that convert optical signals from fiber sensors to usable data
- Distributed Sensor Arrays: Installed on bridge towers, deck, and expansion joints
This architecture allows stakeholders to:
- Analyze long-term deformation patterns
- Trigger alerts if strain thresholds are exceeded
- Archive data for predictive maintenance and research
Next Development Phase – Load Monitoring
In collaboration with Kementerian PUPR, the project will evolve into a Bridge Load Monitoring System using force sensors. This upgrade aims to complement strain data with live load data from vehicles and environmental factors, creating a holistic structural health platform.
Benefits:
- Scalable Design: New FBG sensors can be added with minimum changes to the system
- Centralized Monitoring: Data is visualized and logged remotely from the control center
- Cloud Integration: OPC UA enables future AI and analytics-based health predictions
- Long-Term Reliability: FBG sensors offer immunity to electromagnetic interference and harsh weather
Haliatech is proud to be trusted in enhancing the safety of Suramadu Bridge through advanced sensor integration and smart data infrastructure. For further discussion about SHMS or NI-LabVIEW based optical solutions, reach us at sales@haliatech.com
References:
