In a remarkable feat of engineering and coordination, the A46 Bypass Bridge near Kenilworth was installed in just 18 days as part of the UK’s High Speed 2 (HS2) programme. The project, led by Balfour Beatty VINCI (BBV), demonstrates how innovation and collaboration can overcome complex construction challenges, especially when time, safety, and precision are critical.
Project Description
The A46 is a vital transport corridor linking Coventry, Kenilworth, and Leamington Spa to the M40. To minimise disruption to road users, the 14,500-tonne, 4,300-cubic-metre concrete box structure was built offline and then slid into place across a newly excavated section of the highway.
Challenge
Once positioned, the structure required approximately 400 cubic metres of concrete infill on either side to secure it. However, the design, featuring tall, enclosed voids and no direct line of sight, posed a significant challenge: how to ensure complete and accurate concrete placement without the ability to visually inspect the pour.
Solution
To address this, the project team turned to a real-time monitoring solution developed in collaboration with PERI UK and Vemaventuri. Using 24 PHONO sensors connected wirelessly to a central hub and cloud platform, the team was able to track the flow of self-compacting concrete live on site. This allowed them to confirm full coverage, switch pump lines as needed, and maintain the required rate of rise, approximately 0.9 metres per hour, across a three-day pour involving more than 800 cubic metres of material.
Results
The result was a flawless installation completed ahead of schedule, with minimal disruption to the public and a validated digital record of the concrete placement, supporting both structural integrity and long-term compliance.
This project not only marks a milestone in the HS2 programme but also sets a new benchmark for how smart construction technologies can enhance safety, efficiency, and quality in infrastructure delivery.
