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World-first digital twin of site concreting

Gammon Construction Limited (“Gammon”) in collaboration with Converge has created the world’s first digital twin of site concreting, thanks to the launch of the latest version of a pioneering concrete maturity platform, ConcreteDNA.

Gammon is the first to use Converge’s advanced concrete construction data platform, called ConcreteDNA Pro, which is now equipped with capabilities to integrate with building information modelling and provide in-depth material performance analytics to form the first iteration of a real-time digital twin.

The enabling hardware behind the ConcreteDNA platform is a powerful embedded sensor, called Converge Signal, which measures the compressive strength of concrete as it cures. The new cellular gateway, Signal Live automatically transmits sensor data to the cloud in real time. Previously, concrete data had to be collected manually via the Converge app.

ConcreteDNA Pro introduces in-depth analytics to the platform, which means project teams can track and ensure concrete is meeting expected standards. With this added certainty, cube testing procedures can be reduced, resulting in lower carbon emissions. Thanks to ConcreteDNA Pro, Gammon saved over 110 tonnes of concrete waste by reducing testing by approximately 14,000 cubes on its Hong Kong Science & Technology Parks Corporation’s Advanced Manufacturing Centre (AMC) project in Hong Kong. Insights from performance analytics facilitates optimisation of materials by selecting the right mix to suit programme requirements meaning less cement is used and the project has a smaller carbon footprint.

Sammy Lai, Director - Building at Gammon, said: “The AMC project team no longer needs to collect data from each pour, saving considerable manpower and avoiding potential human error. The curing predictions and notifications that a pour has reached the required strength also mean the right people get to the right place at the right time. The contextual information to the curing predictions has allowed our team to coordinate better, allocate resources more efficiently, and mitigate project risks by planning ahead with better 4D oversight.”

Gammon’s digital business, Digital G, and Converge have been working together since 2017 and have deployed the ConcreteDNA technology on over 30 projects. It is the only digital maturity system approved by the Hong Kong authorities and consultants, including Airport Authority Hong Kong, and the solution is available through the Construction Innovation and Technology Fund of the Hong Kong Construction Industry Council.