From concept to a deployable sensing system
Monitoring infrastructure in real time is no longer theoretical. Compact, solar-powered sensors are already being used to track strain continuously, operating unattended for years in harsh environments.
Priority One Infrastructure, a South-West start-up, developed the concept - a sensing unit that bonds directly to a structure and continuously tracks strain, temperature and vibration. No wiring. No mains power. Just a device that listens to the structure and flags when something changes.
NCC’s job was to make that concept robust enough to survive in the real world, and validate the accuracy of the sensors.
What NCC did
We started with the requirements.
Roadside infrastructure is a hostile environment - vibration, temperature swings, moisture, dust, electromagnetic interference. The sensor has to handle all of it, unattended, for years.
We worked through these with Priority One, separating what was needed now from what could come later and built a technical roadmap to guide both development and future certification.
Then we focused on the enclosure design.
The housing must do two things at once - protect the electronics from environmental exposure, while accurately transferring strain from the structure into the sensing element. It also needs to allow reliable wireless communication and GPS timing.
Glass-fibre-reinforced ASA gave us what we needed - stiff enough for consistent strain transfer, stable across thermal cycling, transparent to the wireless signal.
The final design consists of a reinforced backplate and a sealed front cover, incorporating the sensing elements, electronics, power and communications into a single integrated unit.
We used rapid prototyping to iterate the design - refining sealing surfaces and build orientation. Small details, but critical to long-term performance.
Proving the data
A sensing system is only valuable if the data can be trusted.
We carried out a structured validation programme to assess performance. The sensor tracked the load profile accurately. Results aligned closely with the optical reference across the full test range.
Further testing of the integrated unit demonstrated that it could reliably detect changes in structural behaviour, with consistent response patterns across different loading conditions.
For structural health monitoring, that’s what matters. Establishing a baseline and detecting meaningful change.
Where it stands
Priority One now has a sensing system in an engineered housing, designed for real-world infrastructure environments.
The focus now moves to formal certification, extended validation across different materials and structures, and integration into live monitoring systems. The design is already set up to transition from prototyping to scalable manufacturing as volumes increase.
Why it matters
For infrastructure owners, this kind of technology changes how assets can be managed.
Instead of relying solely on periodic inspections, continuous data provides earlier visibility of change - supporting more informed decisions about maintenance and intervention.
It doesn’t replace inspection. It makes it smarter.
How this project happened
This work was funded through an Innovate UK Business Growth Grant and delivered by NCC.
It reflects how we support early-stage companies - helping to refine concepts, address engineering challenges, and build confidence through testing and validation.
If you're developing sensing, monitoring or smart infrastructure technologies and need independent engineering support, NCC can help.