In this study, an unmanned aerial vehicle (UAV) with a camera and laser ranging module was developed to inspect bridge cracks. Four laser ranging units were installed adjacent to the camera to measure the distance from the camera to the object to calculate the object’s projection plane and overcome the limitation of vertical photography. The image processing method was adopted to extract crack information and calculate crack sizes. The developed UAV was used in outdoor bridge crack inspection tests; for images taken at a distance of 2.5 m, we measured the crack length, and the error between the result and the real length was less than 0.8%. The developed UAV has a dual-lens design, where one lens is used for bridge inspections and the other lens is used for flight control. The camera of the developed UAV can be rotated from the horizontal level to the zenith according to user requirements; thus, this UAV achieves high safety and efficiency in bridge inspections.

While crack detection is crucial for maintaining concrete structures, existing methods often overlook the analysis of large cracks that span multiple images. Such analyses typically rely on image stitching to create a complete image of a crack. Current stitching methods are not only computationally demanding but also require manual adjustments; thus, a fast and reliable solution is still lacking. To address these challenges, we introduce a stitching method that leverages the advantages of crack image-segmentation models. This method first utilizes the Mask R-CNN model for the identification of crack regions as regions of interest (ROIs) within images. These regions are then used to calculate keypoints of the scale-invariant feature transform (SIFT), and descriptors for these keypoints are computed with the original images for image matching and stitching. Compared with traditional methods, our approach significantly reduces the computational time; by 98.6% in comparison to the Brute Force (BF) matcher, and by 58.7% with respect to the Fast Library for Approximate Nearest Neighbors (FLANN) matcher. Our stitching results on images with different degrees of overlap or changes in shooting posture show superior structural similarity index (SSIM) values, demonstrating excellent detail-matching performance. Moreover, the ability to measure complete crack images is indicated by the relative error of 7%, which is significantly better than that of traditional methods.