Feasibility of Magnetically Docked Aerial Ultrasonic Inspection for Steel Bridges

Steel bridge infrastructure requires regular crack inspection to ensure structural safety. In current practice, ultrasonic inspection is labour-intensive, costly, and often disruptive, because inspectors need physical access to elevated or hard-to-reach bridge components. This project investigates the feasibility of a magnetically docked aerial platform equipped with an ultrasonic sensing system for crack inspection on steel bridges.
The project combines aerial robotics, passive magnetic docking, and ultrasonic sensing in one mechatronic inspection concept. Rather than developing a field-ready autonomous drone system, this one-year KIEM HighTech project focuses on a feasibility study under controlled laboratory conditions. The central question is whether a magnetically docked aerial platform can provide sufficiently stable positioning, sensor contact, and measurement quality to enable reliable and repeatable crack detection on steel surfaces.
The project has three objectives:
define the technical requirements and feasibility boundaries of the concept;
develop a functional laboratory prototype integrating the aerial platform, docking mechanism, and ultrasonic sensor;
validate the concept on SHM Next’s steel test structure by comparing drone-based measurements with a reference sensor.
The project will deliver a validated feasibility assessment, including strengths, limitations, and go/no-go conditions for further development. If successful, the project will provide the basis for follow-up research and innovation towards safer inspection work, reduced operational disruption, and improved maintenance of steel bridge infrastructure.