Crack inspection in railway sleepers is crucial for ensuring rail safety and avoiding deadly accidents. Traditional methods for detecting cracks on railway sleepers are very time-consuming and lack efficiency. Therefore nowadays, researchers are paying attention to the vision-based algorithm, especially Deep Learning algorithms. In this work, we adopted the U-net for the first time for detecting cracks on a railway sleeper and proposed a modified U-net architecture named Dense U-net for segmenting the cracks. In the Dense U-net structure, we established several short connections between the encoder and decoder blocks, which enabled the architecture to obtain better pixel information flow. Thus, the model extracted the necessary information in more detail to predict the cracks. We collected images from railway sleepers, processed them in a dataset, and finally trained the model with the images. The model achieved an overall F1-score, precision, Recall, and IoU of 86.5% 88.53%, 84.63%, and 76.31% respectively. We compared our suggested model with the original U-net, and the results demonstrate that our model outperformed the U-net in both quantitative and qualitative results. Moreover, we considered the necessity of crack severity analysis and measured a few parameters of the cracks (e.g., length, maximum width, area, density). The engineers must know the severity of the cracks to have an idea about the most severe locations and take the necessary steps to repair the badly affected sleepers.

Crack inspection is important to monitor the structural health of pavement structures and to facilitate an easier rehabilitation process. Currently, pavement crack inspection is conducted manually, which is inefficient and costly at the same time. For solving the problem, this work has developed a robotic system for automated data collection and analysis in real-time. The robotic system navigates on the pavement and collects visual images from the surface. A deep learning-based semantic segmentation framework named RCDNet was proposed and implemented on the onboard computer of the robot to identify cracks from the visual images. Simulation results show that the deep learning model obtained 96.29% accuracy for predicting the images. The proposed robotic system was tested on both indoor and outdoor environments and was observed that it can complete inspecting a 3m × 2m grid within 10 minutes and a 2.5m × 1m grid within 6 minutes. This outcome shows that the proposed robotic method can drastically reduce the time of manual inspection. Furthermore, a severity map based on the results from visual images was also generated to provide an idea of which locations should be paid more attention to repair in a test grid.