A novel net shape continuous casting process was used to apply a thick metallic protective jacket over optical fibres for the purpose of producing embeddable fibre optic sensors in civil structures. For the first time, optical fibres were confined in 1–3mm diameter aluminium alloy jackets. Special measures were taken in order to prevent fibre cracking during casting. It was found that a buffer layer composed of graphite powder and a binder can effectively eliminate fibre cracking. This allowed the optical fibres to be embedded within the wires.
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