Durable Bonded Stress Gauges for High-Precision Strain Analysis
Measure mechanical strain with bonded stress gauges designed for high accuracy,
long-term durability, and full system integration.
Bonded Stress Gauges: Accurate, Long-Term Strain Monitoring for Critical Applications
Bonded stress gauges are essential tools used for measuring strain in materials subjected to mechanical loads. These gauges consist of a fine wire or foil grid bonded directly to the surface of a structure or component using high-performance adhesives. When the surface deforms due to stress, the gauge stretches with it, causing a measurable change in electrical resistance. This allows for highly accurate monitoring of material behavior under various load conditions. Widely used in aerospace, automotive, civil engineering, and energy industries, bonded stress gauges enable real-time, precise monitoring for testing, quality assurance, and structural health assessments. These devices are valued for their stability, sensitivity, and compatibility with complex geometries and harsh environments. Pressure Stress Measure proudly supports businesses across North America with advanced bonded stress gauge solutions. As a trusted B2B provider, we deliver scalable, reliable systems that meet industry standards and support both R&D and long-term field deployment.
Technologies & Systems We Offer
In addition to offering products and systems developed by our team and trusted partners for Bonded Stress Gauges, we are proud to carry top-tier technologies from Global Advanced Operations Tek Inc. (GAO Tek Inc.) and Global Advanced Operations RFID Inc. (GAO RFID Inc.). These reliable, high-quality products and systems enhance our ability to deliver comprehensive technologies, integrations, and services you can trust. Where relevant, we have provided direct links to select products and systems from GAO Tek Inc. and GAO RFID Inc.
Core Components of a Bonded Stress Gauge System
Hardware
- Foil and Wire Strain Gauges (Advanced) – BLE Gateways, Beacons & Accessories enable wireless broadcasting of stress data in insured real estate structures.
- Mounting and Bonding Kits – LF RFID Readers, Tags & Accessories tag sensor mounts for post-installation tracking and service in financial infrastructure.
- Signal Conditioning Equipment – Data Centre Edge processes high-volume structural test data from large-scale insurance underwriting facilities.
- Measurement Systems – UHF RFID Readers, Tags & Accessories track the calibration and movement of portable strain gauge DAQs in mobile audits.
Software
- Calibration and Setup Tools – Zeroing, linearization, and gauge factor adjustment
- Real-Time Visualization – Multi-gauge dashboards, stress/strain mapping, and comparative data overlays
- Historical Data Logging – Track performance trends, identify fatigue progression, and validate compliance
Cloud Services
- Remote Monitoring Interfaces – Cloud dashboards for multi-site load tracking and predictive alerts
- Secure Data Storage – Long-term archiving for compliance, inspection, and forensic analysis
- Integration APIs – Enable plug-in functionality for enterprise analytics platforms and IoT environments
Key Features & Functionalities
- Micro strain resolution as low as ±1 με
- Excellent linearity, repeatability, and long-term stability
- Compact and lightweight, perfect for embedded installations
- Resistant to vibration, temperature fluctuations, and environmental exposure
- Configurable for static or dynamic strain applications
- Compatible with quarter-, half-, and full-bridge configurations
Integrations & Compatibility
PLCs and SCADA systems for process automation
Custom LabVIEW-based control systems
Pressure Stress Measure bonded stress gauge systems integrate with a wide range of commercial and industrial tools:
NI DAQ boards and modular hardware
Third-party simulation and finite element analysis platforms
Our systems are compatible with a wide variety of software environments including MATLAB, Python, and proprietary testing platforms.
Benefits of Choosing Our Bonded Stress Gauge Solutions
Long-Term Monitoring
Ideal for embedded use in permanent infrastructure or mobile equipment
Flexible Deployment
Small footprint makes them easy to integrate into new or existing setups
Expert Technical Support
Our team helps customize, install, and interpret your strain gauge system
Accurate and Reliable Measurements
Trusted for critical stress evaluations and material testing
Enhanced Safety and Predictive Maintenance
Detect fatigue or overload conditions before failure occurs
Common Applications
- Structural integrity testing of bridges, dams, and towers
- Aerospace component fatigue monitoring
- Automotive crash simulation and load distribution
- Research and development in materials science
- Heavy equipment stress tracking in mining and construction
- Turbine blade and rotor stress profiling
Industries We Serve
- Aerospace & Defense
- Automotive & Transportation
- Civil Engineering & Infrastructure
- Renewable Energy
- Oil & Gas
- Industrial Equipment Manufacturing
- Universities & Research Institutions
Relevant U.S. & Canadian Standards
- ASTM E251 – Standard Test Methods for Performance of Bonded Resistance Strain Gages
- IEEE 1451 – Smart Sensor Interface Protocols
- ISO 9513 – Strain Gauge Calibration and Accuracy Standards
- CSA B354.8 – Structural Monitoring Systems (Canada)
- ANSI/ASME B1.20 – Mechanical Stress Instrumentation
Case Studies
U.S. Bridge Retrofit Project – Pittsburgh, PA
Challenge: A municipal engineering team needed to assess stress changes on aging bridge joints during reinforcement.
Solution: Our bonded stress gauges were installed directly on load-bearing beams, providing real-time data during staged repairs. The data helped confirm structural performance and pass DOT inspections with 100% accuracy.
U.S. Aerospace Research Facility – Huntsville, AL
Challenge: An aerospace R&D lab required micro strain-level precision during turbine testing.
Solution: We supplied foil-type bonded gauges calibrated for high-frequency vibration environments. Integrated with a multi-channel NI DAQ, the system achieved ±0.2% accuracy in dynamic conditions, contributing to next-generation turbine design validation.
Canadian Mining Equipment Manufacturer – Sudbury, ON
Challenge: Heavy-duty haul trucks were showing signs of fatigue under extreme loading conditions.
Solution: Our rugged bonded stress gauges were installed across the truck frame and suspension components. Combined with GAO RFID’s wireless transmitters, data was transmitted in real-time to maintenance teams, reducing unexpected failures by over 35%.
Looking to Implement Bonded Stress Gauge Solutions in your Systems?
Contact Pressure Stress Measure for personalized guidance, innovative products, and expert service across North America.