Performance and Characteristics of Sprayed Flexible Sensor for Strain Monitoring of Steel Bridges

Monitoring stress and strain at the critical details of steel bridges is essential for ensuring structural integrity. This study introduces a three‐layer flexible strain sensor produced through a spraying process, using flake‐shaped silver‐coated copper powder as the conductive filler and modified acrylic emulsion as the matrix material. The study investigated the impact of size parameters on sensor sensitivity, determining optimal dimensions of 20 mm in length, 2 mm in width, and an initial resistance value ranging from 1.0 Ω to 1.8 Ω. Analysis of the optimized sensor’s performance unveiled high sensitivity and linear response capabilities under low strain conditions with a gauge factor (GF) value of up to 25.6 and a linear correlation coefficient R 2 ≥ 0.971 under 300 με. Notably, the sensor exhibits an extremely low strain detection limit of 0.005% and a broad response range spanning from 0.005% to 0.19% strain. It demonstrates swift response and recovery times of 500–800 ms, showcases directional strain response, exhibits good repeatability, and endures durability tests (withstanding 3000 cycles). Furthermore, a fitting formula is proposed to accurately depict the strain and relative resistance change relationship across a wide response range. The study and initial application of this sensor’s sensing characteristics and performance signify its potential for practical engineering applications.