BAM Nuttall saved £218,000 on the construction of a landmark three-span bridge by using Converge's Signal System for smart concrete monitoring.
The Cross Tay Link Road project involves the construction of a 6km route from the A9 to the A94 north of Scone, alongside a 2km realignment of the A9 north of Inveralmond Roundabout. This ambitious infrastructure project encompasses roadworks, earthworks, structures, active travel infrastructure, landscaping, and forestry planting.
A critical component of this project is the Destiny Bridge (ST02), a balanced cantilever bridge with 60 segments. Designed to ease traffic congestion and improve air quality in Perth’s city centre, the bridge provides an alternative route connecting the A9 to the A93 and A94. Beyond its role in transportation, Destiny Bridge marks a major milestone in infrastructure development, supporting environmental sustainability and economic growth in Perth and its surrounding regions.
Traditional curing methods posed several challenges in the construction of Destiny Bridge, particularly due to the non-uniform structure and the reliance on temperature match curing (TMC) and cube testing, as per BS 1881-130:2013. While TMC provided a more accurate estimation of in-situ concrete strength by replicating actual curing conditions, it required multiple test cubes and continuous monitoring, resulting in delays.
Additionally, each newly cast concrete segment needed to reach 40MPa before stressing tendons and launching the form traveller system, making real-time strength monitoring critical to maintaining the construction schedule. The reliance on manual cube testing further complicated the process, as the nearest laboratory was 50 miles away, causing delays in obtaining results. With engineers based remotely in a site cabin, manual monitoring was inefficient, creating a need for an automated, real-time solution.
The process was inherently complex, requiring a detailed understanding of BAM Nuttall’s requirements. To establish baseline performance data, BAM Nuttall carried out hot box trials using Converge sensors, placing them at the centre of large concrete samples to monitor curing behaviour over 1–2 weeks. This provided a more accurate representation of how the concrete would perform on-site than test cubes, offering critical insights into maximum temperatures, curing rates, and compliance with quality standards. By integrating real-time data into the concrete selection process, the team identified the best-fit mix for the project. This not only optimised performance but also strengthened confidence in ConcreteDNA’s capabilities.
The Converge system was implemented to provide accurate, real-time concrete strength and temperature gradient data via the ConcreteDNA app, ensuring efficient progress and reducing project delays. The ConcreteDNA platform provided the BAM Nuttall team with immediate access to comprehensive real-time data, presented in a user-friendly format that makes complex insights easy to understand and act on. To accurately monitor internal concrete temperature, the thermal tail was positioned at the centre of the concrete, while two Signal sensors were installed in each segment—one at the thinnest section (0.25m) for strength monitoring and one at the thickest section (1.2m) for temperature tracking. This strategic placement ensured optimal curing conditions and comprehensive real-time data collection.
The Signal Sensors continuously transmitted data to the Live Hub, positioned within a 15 metre radius, providing engineers with instant access to temperature and strength progression via the ConcreteDNA app. This allowed the team to optimise concrete mix designs, and ensure the 40MPa strength requirement was met efficiently while preventing temperatures from exceeding the 70°C threshold.
Additionally, the system’s ability to predict strength gain enabled better scheduling of tendon stressing and form traveller launches, significantly reducing downtime and saving at least half a day per 7-day cycle. By leveraging Converge’s real-time, data-driven monitoring system, the project team minimised costly delays, reduced reliance on manual testing, and optimised labour efficiency. These improvements also cut unnecessary equipment hire costs, resulting in £218,000 in savings—delivering more than three times the return on investment while keeping the bridge construction on schedule and to specification.
“The Converge system provided critical insights into concrete curing, allowing us to optimise striking times safely and efficiently. This technology played a key role in supporting the timely delivery of a complex infrastructure project while maintaining high safety and quality standards.
The successful use of Converge’s smart sensor technology on this project highlights the value of innovative digital solutions in modern construction, demonstrating their potential to drive efficiency, reduce timelines, and enhance project outcomes."
Cameron Swan, Site Engineer, BAM Nuttall
With accurate, real-time decision-making, the Converge system saved BAM Nuttall at least half a day per 7-day cycle, significantly reducing downtime, labour costs, and equipment hire. Over the course of the project, this translated into £150,000 in net savings from using the Converge system. Faster progress, lower costs, and greater efficiency proves the value of intelligent concrete monitoring.
Converge’s thermal monitoring system provided real-time data on internal concrete temperature, ensuring it stayed within the required limits for quality control and compliance. By automating temperature monitoring, the system mitigated risks and prevented exceedance of maximum thresholds. Additionally, it reduced reliance on manual cube testing, minimising human error and enhancing the accuracy and efficiency of the construction process.
