Design and laboratory evaluation of a low-cost, portable sensor-based system for pavement condition monitoring

Abstract

Effective pavement condition monitoring is essential for road safety, maintenance planning, and sustainability. However, traditional monitoring systems are costly and complex, limiting their widespread deployment by road authorities. High cost and complexity encouraged the development of more affordable monitoring tools. Most of these existing low-cost monitoring systems rely on single-sensor configurations or simplified data processing methods, which limit their robustness and adaptability under real-world conditions. This study addresses this gap by developing a novel, low-cost, portable monitoring device for monitoring surface characteristics. This solution integrates multiple sensors (laser distance, accelerometer and temperature-humidity) into a single system supported by Internet of Things connectivity, with a total component cost under €100. The system addresses key barriers to adoption by offering an affordable and scalable solution suitable for municipalities, road maintenance contractors, infrastructure agencies, and smart city planners. Validation under laboratory controlled conditions using a Wheel Track machine demonstrates the device’s ability to reliably detect surface irregularities, measure environmental effects, and assess changes in surface texture and geometry under controlled conditions. The impact of environmental humidity on sensor performance was also quantified. These results confirm the system’s technical feasibility and measurement reliability. Given its affordability and modular design, the tool holds significant promise for enabling more frequent, data-driven road maintenance, ultimately reducing long-term infrastructure costs.