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Smart sensors support rapid HS2 bridge installation on A46

By Richard High, 07 October, 2025
An aerial view of The 14,500-tonne concrete box structure for HS2’s A46 Kenilworth bypass bridge was built offline and slid into place in just 18 days. (Image courtesy HS2 Ltd) The 14,500-tonne concrete box structure for HS2’s A46 Kenilworth bypass bridge was built offline and slid into place in just 18 days.

A46 Kenilworth’s new bypass bridge, part of the HS2 programme, was installed in just 18 days using advanced concrete monitoring technology developed with PERI UK and Vemaventuri.

The 14,500-tonne, 4,300-cubic-metre concrete box structure was constructed offline and then slid into place across the A46 – a key corridor linking Coventry, Kenilworth and Leamington Spa to the M40. The bypass itself is being upgraded in a £500m scheme to ease congestion and support regional growth, with Skanska leading construction of a wider 6.5km dual carriageway upgrade between the Farndon and Winthorpe roundabouts.

Engineering challenge

Once the box was moved into position, around 400m³ of concrete infill was required on each side to lock it in place. The design included tall enclosed voids with no line of sight, raising a key question: how to ensure the concrete was placed correctly and safely.

The answer came from 24 PHONO wireless sensors linked to a central hub and cloud platform. Installed inside the structure, these sensors allowed Balfour Beatty VINCI (BBV) to monitor the live flow of self-compacting concrete, check full coverage, and adjust pump lines as required.

Over three days, more than 800m³ of material was placed at a controlled rate of rise of about 0.9m per hour. The system created a complete digital record of the operation, supporting compliance and long-term asset assurance.

Vemaventuri’s PHONO concrete monitoring sensors and cabling, used during the HS2 A46 bypass bridge slide to track self-compacting concrete placement in real time. (Image courtesy Vemaventuri) Vemaventuri’s PHONO concrete monitoring sensors and cabling, used during the HS2 A46 bypass bridge slide to track self-compacting concrete placement in real time. (Image courtesy Vemaventuri)

On time and on record

The result was a “flawless, ahead-of-schedule installation”, minimising disruption on one of the Midlands’ busiest roads, which carries around 60,000 vehicles a day.

Maurice Dowling, works manager at BBV, said: “The PERI/Vemaventuri void sensors proved invaluable during the A46 bridge slide. They gave us the confidence, control and traceability needed for a critical and complex operation.”

Sector significance

The project demonstrates how digital construction methods are becoming integral to UK infrastructure delivery. The smart monitoring system is a model for future HS2 works, helping contractors manage concrete placement in confined structures where safety and accuracy are paramount.

Self-compacting concrete being placed and monitored within the enclosed voids of the HS2 A46 bypass bridge structure, supported by Vemaventuri’s real-time sensor technology. (Image courtesy Vemaventuri) Self-compacting concrete being placed and monitored within the enclosed voids of the HS2 A46 bypass bridge structure, supported by Vemaventuri’s real-time sensor technology. (Image courtesy Vemaventuri)
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