Surface cracks in infrastructure can lead to significant deterioration and costly maintenance if not efficiently repaired. Manual repair methods are labor-intensive, time-consuming, and imprecise and thus difficult to scale to large areas. Breakthroughs in robotic perception and manipulation have advanced autonomous crack repair, but proposed methods lack end-to-end testing and adaptability to changing crack size. This paper presents an adaptive, autonomous system for surface crack detection and repair using robotics with advanced sensing technologies. The system uses an RGB-D camera for crack detection, a laser scanner for precise measurement, and an extruder and pump for material deposition. A novel validation procedure with 3D-printed crack specimens simulates real-world cracks and ensures testing repeatability. Our study shows that an adaptive system for crack filling is more efficient and effective than a fixed-speed approach, with experimental results confirming precision and consistency. This research paves the way for versatile, reliable robotic infrastructure maintenance.

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