Sensors in concrete: New technology to improve efficiency and minimise material waste

The Cactus Towers, Copenhagen, Denmark.

(Source: BIG)

SENSORS IN CONCRETE:

New technology to improve efficiency and minimise material waste

Control of concrete strength and maturity in largescale projects has traditionally been recorded and measured manually. Nowadays, there are new technologies that allow builders to melt sensors directly into the concrete whereby when connected to a transmitter show continuous data on the material’s temperatures, sending the data wirelessly to the cloud platform. The software then automatically calculates maturity and strength based on historical data, so the concrete mix and strength development process can be followed from any device and in real-time.

These sensors, based on 0G technology from Sigfox – one of the main IoT (Internet of Things) operators in the world – have facilitated the construction of one of the most innovative architectural projects in Europe, the Cactus Towers (Kaktustårnene) in Copenhagen, helping calculate the exact moment to remove the formwork that shapes its characteristic façade.

Expected to be completed by spring 2022, the Cactus Towers have been designed as a hotel and a residence for youths in central Copenhagen, Denmark. The towers stand at a height of 60m and 80m respectively, and are shaped by hexagonal cores.

The 21,000sqm hotel consists of 1,250 rooms spread over the two towers, which also house 500 ‘youth rooms’ averaging 30sqm in size with modern aesthetics.

The project has a technical complexity that few buildings have as each floor is rotated in a different axis and their complicated forms create displaced balconies and cornered façades. In terms of materials, special attention is paid to the concrete formwork to achieve a solid foundation, which is an additional challenge since large structures with many floors normally require cooling to guarantee product quality. Therefore, the monitoring of the condition of the concrete plays a fundamental role as it is essential to give the towers their twisted and very particular shape.

In the case of the Cactus Towers, the builders used a solution by Maturix that consists of a comprehensive tool to control the strength of the concrete in a much more efficient way. With thermocouples fused into the structure, the concrete temperature can be accessed in near real-time and the data collected are sent wirelessly to the cloud. Maturix has a software to calculate maturity and resistance based on historical data, which is an advantage when making adjustments in project management. Given the complexity of the project and with many subcontractors involved, it is a plus in terms of organization and time measurement.

The second part that has made the project possible, together

(Source: kaktus-towers.dk)

(Source: Cortesía de Sigfox España)

with Maturix’s sensors and technology, is Sigfox’s 0G network. It is a simple, lowconsumption, long-range alternative for IoT connectivity widely used in the world of industry, logistics, or asset monitoring. As it is based on radio technology, it overcomes some of the traditional limitations of other alternatives based on cellular networks or SIM cards, such as scalability or being able to provide service in interiors, rural areas, or, in this case, monitor the temperature of concrete in real-time.

The 0G network is the first connectivity option exclusively designed for the IoT.

(Source: BIG)

Since most industrial IoT requirements only need a small data package, Sigfox decided to focus on a low-power network, to achieve a much greater reach in these applications. This technology is designed to streamline decision-making and improve efficiency in the use of materials. Having updated information in real-time, it is much easier to avoid material waste while improving the final quality of the project.

Concrete is one of the most used materials in the construction sector and any novelty that represents an advantage from the first to the last phase is sure to be welcomed in a sector as essential as construction.

This sector, on the other hand, is increasingly committed to efficiency, like so many others. Sustainability has ceased to be a commercial slogan and has become a pillar of business and the large-scale digitization of construction in many of its areas. It is already more common than just a few years ago, and this is just one of many examples.

Thanks to the IoT, data on the resistance of this material can be obtained, which is a key factor when it comes to saving resources but also ensuring that buildings are in good condition. In the case of construction, the IoT can be applied at different stages of the work process, helping in the design and subsequent maintenance of buildings. The use of connected sensors, as in the case of the Cactus Towers, provides architects with upto-date information on the development of the project, something that is useful for any building, but especially in bridges and tunnels that tend to suffer regular damage.

Undoubtedly, construction is undergoing a revolution with the arrival of the IoT and it is a path that should be used to transform the businesses of the sector, to continue innovating, and above all to improve the efficiency of the processes.