Image-Assisted Residual Load-Bearing Capacity Assessment of Plain Concrete Beams Using U-Net Crack Segmentation and Phase-Field Simulation

Concrete cracks are ubiquitous in practical engineering structures and continuously affect structural safety and durability. Crack images provide important visual evidence of damage evolution; however, crack images alone are insufficient to determine the residual load-bearing capacity of concrete members. Although the development of deep learning algorithms has significantly improved the automatic detection of concrete surface cracks, most existing methods remain limited to the extraction of crack geometric features and lack a direct connection with mechanical performance. To explore the relationship between image-based crack geometry and mechanical response, this study combines U-Net-based crack segmentation, OpenCV-based crack geometry extraction, and phase-field fracture simulation to establish a preliminary visual–mechanical framework for plain concrete beams. In this framework, surface crack images are first segmented using a U-Net model, and crack length, average width, and propagation path are extracted from the predicted binary masks. The extracted crack length is then used as the primary variable to match the observed crack state with the phase-field crack evolution sequence. Once the corresponding simulation stage is identified, the associated load level and residual load-bearing capacity can be obtained from the simulated load–crack mouth opening displacement (Load–CMOD) response. Through a mixed-mode I–II fracture test, the crack geometric features extracted by deep learning are compared with the phase-field simulation results. The results show that the error in crack length is within 2.5%. Meanwhile, the relative error between the simulated peak load and the experimental value was 1.57%, which preliminarily verified the correlation between image-based crack information and the load-bearing capacity of plain concrete beams. The method is further applied to a Mode I fracture test without recorded load-bearing capacity data. By mapping the crack length identified from the image, namely 36.89 mm, to the phase-field evolution sequence, the load-bearing capacity of the member at this stage is estimated to be 74.4% of the peak load. The results indicate that the crack geometry extracted from images can be correlated with phase-field crack evolution, thereby supporting preliminary residual load-bearing capacity assessment of plain concrete beams. However, the proposed framework should be regarded as a case-level feasibility study rather than a general structural assessment method. Before broader engineering application, further validation using synchronized crack image sequences, crack mouth opening displacement (CMOD) measurements, and load records is required.