Automated Crack Width Measurement in 3D Models: A Photogrammetric Approach with Image Selection

Structural cracks can critically undermine infrastructure integrity, driving the need for precise, scalable inspection methods beyond conventional visual or 2D image-based approaches. This study presents an automated system integrating photogrammetric 3D reconstruction with deep learning to quantify crack dimensions in a spatial context. Multiple images are processed via Agisoft Metashape to generate high-fidelity 3D meshes. Then, a subset of images are automatically selected based on camera orientation and distance, and a deep learning algorithm is applied to detect cracks in 2D images. The detected crack edges are projected onto a 3D mesh, enabling width measurements grounded in the structure’s true geometry rather than perspective-distorted 2D approximations. This methodology addresses the key limitations of traditional methods (parallax, occlusion, and surface curvature errors) and shows how these limitations can be mitigated by spatially anchoring measurements to the 3D model. Laboratory validation confirms the system’s robustness, with controlled tests highlighting the importance of near-orthogonal camera angles and ground sample distance (GSD) thresholds to ensure crack detectability. By synthesizing photogrammetry and a convolutional neural network (CNN), the framework eliminates subjectivity in inspections, enhances safety by reducing manual intervention, and provides engineers with dimensionally accurate data for maintenance decisions.