AI-Integrated Graphene-Modified Polymer Interfaces for Real-Time Crack Detection and Autonomous Healing in Smart Concrete Structures

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Year : 2026 | Volume : 14 | 03 | Page :
    By

    E. Afreen Banu,

  • D. Jyothi Swarup,

  • K.R.Saranya,

  • M.Revathi,

  • Kedri Janardhana,

  • C.Karthikeyan,

  • N.Meenatchi,

  • Nellore Manoj Kumar,

  • D. Vijayalakshmi,

  1. Assistant Professor, Department of Computer Engineering, Shah & Anchor Kutchhi Engineering College, Mumbai, Maharashtra, India
  2. Associate Professor, Department of Civil Engineering, St.Ann’s College of Engineering and Technology, Chirala, Andhra Pradesh, India
  3. Assistant Professor, Department of Computer Science and Engineering, SRM Institute of Science and Technology, Tiruchirappalli, Tamil Nadu, India
  4. Assistant Professor, Department of Computer Science Engineering, S.A.Engineering College, Chennai, Tamil Nadu, India
  5. Assistant Professor, Department of Electrical Engineering, Faculty of Engineering, Dayalbagh Educational Institute (Deemed to be University), Agra, Uttar Pradesh, India
  6. Associate Professor, Department of Mechanical Engineering, Panimalar Engineering College, Chennai, Tamil Nadu, India
  7. Assistant Professor, Department of Mathematics, R.M.K. Engineering College, Chennai, Tamil Nadu, India
  8. Adjunct Professor, Department of Mathematics, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences (SIMATS), Chennai, Tamil Nadu, India
  9. Assistant Professor, Department of Physics, School of Basic Sciences, Vels Institute of Science Technology and Advanced Studies, Chennai, Tamil Nadu, India

Abstract

This study presents the design and development of a graphene-reinforced multifunctional polymer composite interface engineered for structural reinforcement, self-sensing, and autonomous healing applications in cementitious systems. A thermosetting polymer matrix embedded with graphene nanoplatelets (0.25–1.5 wt.%) was developed to establish a conductive polymer nano-composite network. Electrical characterization confirmed a distinct percolation threshold at ~0.6–0.8 wt.%, beyond which a sharp increase in conductivity was observed due to the formation of interconnected graphene pathways within the polymer matrix. The composite exhibited stable piezoresistive behaviour, enabling detection of micro-cracks as small as 30 µm through resistance variation. The incorporation of graphene significantly enhanced load transfer efficiency and interfacial adhesion, resulting in improved mechanical performance. Compressive strength increased from 32 MPa to 45 MPa (~40% improvement), while fracture toughness improved from 0.8 MPa√m to 2.1 MPa√m due to effective crack-bridging and energy dissipation mechanisms within the composite interphase. The integration of microencapsulated healing agents within the polymer matrix enabled autonomous crack repair, achieving healing efficiencies of 80–85%, demonstrating the capability of the polymer composite to function as a self-repairing material system. Furthermore, the conductive polymer composite interface was integrated with machine learning algorithms to enable real-time structural health monitoring, achieving detection accuracy exceeding 95%. The results highlight the synergistic role of polymer matrix engineering, graphene reinforcement, and multifunctional composite design in developing next-generation smart materials. The proposed system establishes polymer composites as a viable platform for multifunctional structural applications combining mechanical enhancement, sensing, and self-healing capabilities.

Keywords: AI-integrated, graphene-reinforced, polymer composite, micro-crack, percolation threshold

How to cite this article:
E. Afreen Banu, D. Jyothi Swarup, K.R.Saranya, M.Revathi, Kedri Janardhana, C.Karthikeyan, N.Meenatchi, Nellore Manoj Kumar, D. Vijayalakshmi. AI-Integrated Graphene-Modified Polymer Interfaces for Real-Time Crack Detection and Autonomous Healing in Smart Concrete Structures. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
E. Afreen Banu, D. Jyothi Swarup, K.R.Saranya, M.Revathi, Kedri Janardhana, C.Karthikeyan, N.Meenatchi, Nellore Manoj Kumar, D. Vijayalakshmi. AI-Integrated Graphene-Modified Polymer Interfaces for Real-Time Crack Detection and Autonomous Healing in Smart Concrete Structures. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=243179


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Ahead of Print Subscription Original Research
Volume 14
03
Received 11/04/2026
Accepted 30/04/2026
Published 07/05/2026
Publication Time 26 Days
30

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