BAM Nuttall used Converge’s ConcreteDNA sensors to monitor real-time strength development during the construction of five gravity-based offshore wind foundations. The data enabled a 25% faster formwork cycle time.
As part of the pioneering Blyth Offshore Windfarm project, BAM Nuttall undertook the construction of five gravity-based foundations—the first of their kind used in the UK for offshore wind. Each foundation required 1,800 cubic metres of concrete and was assembled onshore in a precast yard before being floated out to sea and submerged into position.
The scale and complexity of the works presented unique challenges. With limited custom formwork available, productivity relied on striking and cycling formwork as quickly as possible without compromising safety or quality.
To meet these demands, BAM deployed Converge’s ConcreteDNA sensor technology, embedding sensors within the large modular precast components to track temperature and strength development in real time.
Armed with accurate, in-situ data, the team could confidently strike and reuse formwork earlier—achieving a 25% faster formwork cycle time. This optimisation not only accelerated the onshore programme but also reduced the overall period required to work offshore, limiting disruption to marine life and improving sustainability outcomes.
With only a handful of large, custom formwork units available, faster cycling directly increased throughput. This efficiency gain translated into more foundations built in less time, keeping the project on track.
By shortening the construction programme in open water, BAM minimised both noise pollution and disturbance to marine mammals—a key environmental consideration for offshore wind projects.
Traditional lab-cured cube tests often lag behind or fail to reflect actual site conditions. With ConcreteDNA, BAM could act based on live, site-specific data, making decisions with confidence and accelerating progress without compromising safety.
The use of real-time monitoring marked a step-change in how large-scale offshore wind foundations could be built. The data-driven approach gave engineers actionable insights that simplified planning, reduced risk, and maximised the value of limited formwork resources.
Blyth Offshore Windfarm showcased how digital innovation and real-time data can unlock new efficiencies in major infrastructure projects. By combining pioneering foundation design with Converge’s sensor technology, BAM successfully delivered a faster, safer, and more environmentally sensitive construction programme—helping set the standard for future offshore wind developments.