What Is Smart Concrete Technology & How Does It Work?
14th July 2025 Smart concrete technology embeds sensing capability directly into the mix. The material uses conductive fibres or small sensors to detect stress, cracks, and temperature changes from the inside out. For contractors overseeing bridges, tunnels, or heavy-use slabs, it’s an easier win. One that results in faster interventions, tighter safety margins, and data-driven maintenance planning.
Although first demonstrated by Dr Deborah D.L. Chung in the late 1990s, recent UK research has pushed the concept forward. UK Research & Innovation is funding projects that test graphene-enhanced mixes. These mixes enhance conductivity and reduce cement use, thereby lowering embodied carbon.
In this article, you’ll see how it works, where it’s already being tested, and how it’s shaping the future of large-scale concrete builds.
How Smart Concrete Works
Smart concrete replaces bolt-on probes with in-mix sensing. Carbon nanofibres or embedded sensor nodes form a conductive network inside the slab. When vehicles load a bridge or ground settles under a tunnel, tiny shifts in the material change its electrical resistance. A handheld reader, or cloud gateway, converts the signal into stress, crack width, or temperature data. Engineers can see this data on a dashboard or get it as automated alerts.
Because the sensing layer is integral, there are no external components to degrade or detach. It ultimately reduces lifecycle inspection costs. For example, it keeps critical areas, such as overhead pours accessed via concrete pumps, free from surface wiring. With the right gateways, the same data can feed BIM models or asset-management software. This helps with predictive maintenance and reduces unplanned closures. The National Highways’ Digital Roads strategy now includes real-time digital twins that rely on sensor data.
5 Benefits of Smart Concrete in Infrastructure
Smart concrete isn’t science fiction. It’s already being trialled on major infrastructure projects. Here are five reasons it’s gaining attention across the sector.
1. Faster Fault Detection
Smart concrete monitors internal stress and microcracks in real time. This lets project teams spot structural issues early. As a result, they can reduce the risk of expensive, reactive maintenance, especially in slabs or concrete flooring exposed to vibration or thermal variation.
2. Data-Led Asset Planning
Live performance data enables asset managers to more accurately predict repair timelines. It also allows them to plan budgets with greater confidence. This insight is particularly valuable in challenging environments or those with time-sensitive requirements.
3. Fewer Manual Inspections
Because sensors are embedded, there’s less need for road closures, coring, or surface disruption. This is especially valuable in transport infrastructure or commercial sites with high foot traffic.
4. Better Safety Margins
Continuous monitoring enables engineers to check live loads and environmental stress in real-time. This helps them make better decisions about reinforcement or load limits.
5. Lower Environmental Impact
Smart concrete reduces rework and waste. In some tests, it also aids carbon reporting for public infrastructure tenders.
Many of these are well-known schemes, but the same technology could soon help local projects. This is especially true for those with essential load paths or ongoing monitoring needs.
Where Is Smart Concrete Being Used Today?
Across the UK and beyond, early-stage deployments are underway:
- National Highways is trialling embedded sensors to monitor stress on motorway slabs.
- Network Rail has trialled concrete with sensors. This concrete monitors temperature and shifts in bearing blocks on vital rail bridges.
- The University of Bath and the University of Manchester are testing graphene-reinforced mixes. These mixes strengthen concrete and transmit structural data.
- The I-35W bridge in Minnesota has gathered over 15 years of live stress and deflection data. This data comes from smart concrete layers installed during its rebuild in 2008.
These case studies demonstrate how the material helps with long-term visibility in both important and everyday projects.
What Makes Smart Concrete Different from Sensors?
Traditional concrete monitoring utilises sensors placed on the surface or embedded within the concrete. These sensors are usually added after the concrete has cured. These components can degrade, detach, or fail. This can happen on motorway hard shoulders, airport runways, or platform slabs. These areas are exposed to vibration and temperature changes.
Smart concrete removes that risk. Its sensing capability is built into the mix itself. Carbon nanofibres, conductive threads, and microelectronic circuits are spread out evenly. This way, the whole structure functions as a sensor. This means fewer failure points, broader coverage, and better long-term performance.
For sites with metal decking or T-beam flooring, smart concrete offers added control. Best of all, it does this without affecting any pour schedules. If you’re already using concrete pumps or custom precast elements, it’s good news. Adding embedded intelligence can safeguard your investment and simplify logistics.
Future-Ready Concrete, Without the Guesswork
Smart concrete is a relatively new material, but its concepts are revolutionising how we plan, build, and maintain infrastructure. It features sensing capabilities, embedded data, and integration potential with digital construction tools. This reflects a shift toward infrastructure that’s safer, more efficient, and built to last.
At The LGW Group, we’re paying attention while continuing to support contractors in the South with everything they need. From precast components to liquid screed and concrete blocks, we have the expertise to keep projects on track. If your project requires standard or specialist pours, our ready mix concrete is batched and delivered with speed and precision. And while smart concrete isn’t yet part of our product range, we’re actively exploring where it fits into the future of construction.
If you’re working on a civic, commercial or infrastructure project and want to plan for tomorrow’s requirements today, we’re ready when you are.
Call 0117 958 2090 or contact us online and let’s talk about your site.