To ensure success in these demanding conditions, VolkerStevin deployed Converge’s sensor technology and Data Hub platform—gaining valuable insights into on-site concrete behaviour and significantly enhancing project planning and quality control.
As part of the UK Environment Agency’s broader flood risk mitigation programme, VolkerStevin undertook the Littleborough Flood Defence scheme, a critical infrastructure initiative aimed at minimising future flood risks in the Greater Manchester area. The project, led by the Environment Agency in partnership with Rochdale Borough Council, Network Rail, the North West RFCC, TfGM, and the Departments for Education and Transport, is designed to bolster flood resilience for the region.Concreting in Challenging Winter Conditions.
Phase 1B involved extensive concrete works during winter. Cold temperatures pose a significant challenge, particularly for low-cement concrete mixes where extended curing times can impact scheduling and safety.
VolkerStevin deployed 12 Converge signal sensors attached to rebar and embedded in the walls of the outlet structure. With real-time, in-situ data from the sensors, the team could confidently strike formwork upon reaching a minimum of 5MPa—a threshold often difficult to assess through traditional lab cube testing alone.
“The cubes crushed in the lab cannot always reflect what’s happening on-site. Converge’s sensors gave us the confidence we needed to act decisively and save time.”
Bartosz Chwalewski, Senior Engineer, VolkerStevin
Using Converge’s data insights, VolkerStevin improved planning and scheduling, especially in periods where delays could be costly.
"Our two main priorities were having reliable data to inform planning and saving time on-site. Real-time insights helped us achieve both—giving us a clearer picture of actual curing conditions and saving around a day per pour by helping avoid unnecessary delays. Traditional lab-cured cube tests don’t always reflect real-world conditions, especially in winter, so having accurate, site-specific data made all the difference.”
Bartosz Chwalewski, Senior Engineer, VolkerStevin
A 7-metre wall monitored with Converge sensors allowed the contractor to confidently strike formwork several days earlier than conventional methods. The system was also used on covered roof structures, providing continuous monitoring even in hard-to-access or confined environments.
The VolkerStevin team made extensive use of the Converge app, finding it both intuitive and efficient. Despite occasional connectivity challenges, +90% of sensors performed flawlessly —an impressive result given industry standards and past experiences with sensors from other suppliers.
The app’s user-friendly design made it easy to use both in the field and back at the office, streamlining data access and decision-making.
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VolkerStevin also implemented Converge’s Data Hub platform to centralise project data. Engineers could easily access key information such as material testing results, concrete volumes, and embodied carbon metrics.
“Having everything in one place has been a game changer. It makes quality control easier and supports quantity surveyors in cross-checking against supplier data.”
Bartosz Chwalewski, Senior Engineer, VolkerStevin
The automation and organisation provided by Data Hub are now integral to the team’s workflow, and the platform will continue to play a role throughout the remainder of the project.
VolkerStevin’s use of Converge’s sensor technology and Data Hub during the Littleborough Flood Defence project is a great example of how digital innovation can make complex infrastructure projects more manageable. By bringing together accurate data, easy-to-use tools, and smarter decision-making, the team was able to tackle challenges, reduce risk, and keep the project on track—even when conditions were tough. It’s a clear demonstration of how technology can make a real difference in delivering successful outcomes.