Structures Moonshot
The project aims to transform how we manage our ageing structures through effective use of existing and emerging technologies.
National Highways manages more than 5000 Priority Risk structures. These are structures with hidden critical components or features, the condition of which cannot be readily assessed from a visual inspection alone. Uncertainty around the condition of the hidden components can lead to costly precautionary renewals and unplanned closures. The project sought to reduce this uncertainty and improve safety, efficiency, and confidence in asset condition.
The project aims to transform how National Highways manages its ageing structures assets, and in particular, its ‘Priority Risk’ structures, through effective use of existing and emerging technologies. A key element of the work involves developing and deploying innovative non-destructive testing and quantum technologies.
These methods have the potential to provide reliable insight into hidden critical components that cannot be assessed visually. Work progressed from trials on recovered structural sections of a disused viaduct to deployment on in service structures across the Strategic Road Network and on Transport Scotland assets. The aim is for business as usual use by 2026 to 2027.
Objectives
Provide guidance on non-destructive testing techniques and technologies for practicing engineers.
Understand the condition of hidden critical components in Priority Risk structures.
Reduce the risk of structural failure and unplanned closures.
Avoid unnecessary major renewals by improving the evidence base.
Improve worker safety by reducing intrusive investigations.
Enable more proactive and intelligence led asset management.
Deliver capability in time to support increased renewals activity in RIS3.
Success criteria
Technologies provide reliable internal condition data for hidden critical components, giving engineers greater confidence in assessing the condition of Priority Risk structures.
Technologies provide reliable details of internal construction, when as-built records are incomplete.
A clearer understanding of condition reduces the risk of structural failure and lowers the likelihood of unplanned closures.
Condition (and internal configuration) insight enables potentially unnecessary reconstruction or extensive renewals to be avoided or deferred, delivering financial and carbon savings.
Reduced reliance on intrusive investigations lowers exposure to safety risks for National Highways and supply chain teams.
Effective deployment on in service structures, supported by improved data processing, enables more predictive and proactive asset management.
Technologies are ready for business as usual deployment early in RIS3, supporting renewal decisions at the speed required.
How the project supports National Highways KPIs
Network availability improves because better condition insight reduces unplanned closures and avoids disruptive intrusive investigations.
Safety (KSIs) improves because reduced failure risk and fewer intrusive activities lower the likelihood of harm.
Efficiency improves because accurate evidence allows National Highways to avoid major renewals that may not be required and to target resources effectively.
Carbon emissions reduce because avoiding unnecessary reconstruction minimises material use and embodied carbon.
Road user satisfaction increases as fewer closures and more reliable journeys improve customer experience.
The approach
The project progressed through Feasibility, Detailed Design and into Implementation, using a structured programme of trials, validation, and deployment. It tested a wide range of both established and innovative technologies, including muon tomography guided wave methods, on recovered structural specimens and live in service assets. Recovered sections from the Huntingdon Railway Viaduct and purpose built mock up beams enabled validation under controlled conditions, supported by hydro demolition to confirm the accuracy of test results.
During Implementation, technologies were deployed on real structures across the Strategic Road Network and on Transport Scotland assets, including Priority Risk structures and those with incomplete record drawings. This required close collaboration with Operations regions to identify suitable sites, plan access, and manage logistics. Improved data processing enhanced the interpretation of muon tomography, and new methods were developed to combine outputs from multiple test types to produce a more complete picture of internal condition.
The work was delivered through collaboration between specialist suppliers, Transport Scotland, and regional engineering teams. Engagement activities, including a dedicated project conference and ongoing knowledge sharing, ensured that findings were widely disseminated and helped prepare the business for wider deployment during RIS3.
Project obstacles and how they were addressed
The project encountered several technical and operational obstacles during delivery. These arose as the work transitioned from controlled trials to deployment on live structures. Each obstacle was addressed as the team refined methods, validated results and coordinated with operational partners.
Securing long term deployment of specialist equipment on live structures, addressed through early in service trials that demonstrated equipment could be installed securely without disruption.
Validating the accuracy of new technologies, resolved through direct comparison with recovered viaduct sections and confirmation via hydro demolition.
Combining outputs from different testing methods, addressed by developing improved post processing techniques and methods to integrate data from multiple technologies.
Managing anticipated international demand for the technologies, mitigated through early engagement with Operations regions, Transport Scotland, and suppliers to plan deployment capacity and prioritisation.
Outcomes and impact
The project has proven the potential to deliver a step change in understanding the condition of structures with hidden critical components. Technologies such as muon tomography provided internal imaging that had not previously been possible and is already playing a part in major renewal decisions. Validation through hydro demolition, comparison with other data sources, and extensive trials on recovered viaduct sections has confirmed the accuracy of the results obtained, reducing uncertainty and enabling more confident decisions about structural safety, renewal needs, and asset life.
Key outcomes include
Potential avoidance of a £15m reconstruction at M18 Greenland Lane.
Up to £50m in potential savings at Broughton Circle.
Reduced risk of structural failure due to improved condition insight facilitating intervention at the optimum time.
Potential fewer unplanned closures and lower disruption to road users.
Safer working conditions through reduced need for intrusive investigations.
Potential for lower carbon and material use from avoided large scale renewals.
Potential for an accelerated shift toward predictive, data led asset management.
User and stakeholder outcomes
Operational teams will now have greater confidence in assessing structural condition and can make decisions with reduced reliance on intrusive investigations. This reflects the experience of regional engineering teams involved in early deployments, who identified suitable structures and saw how the technologies provided clearer insight than conventional methods.
Decision makers benefit from stronger, evidence based renewal planning, illustrated by examples such as the M18 Greenland Lane where early findings are helping re-evaluate major renewal schemes. Supply chain and regional teams will also experience safer and more efficient inspection processes as the need for intrusive, on network investigations reduces.
The project has attracted significant international interest, with specialists, government departments and academics engaging with findings shared at the June 2025 project conference and through ongoing technical publications. Engagement with organisations such as Transport Scotland, the UK Bridges Board and overseas delegations demonstrate the wider relevance of the work and the growing appetite for these technologies across the sector.
Key insights and learning
A combination of technologies provided the most reliable insight into hidden critical components, and early trials showed that practical deployment on in service structures is achievable. Several important lessons emerged.
Testing on realistic structural specimens, e.g. recovered viaduct sections, is essential to validate accuracy and build confidence.
Multi technology approaches outperform single methods, particularly for complex deterioration mechanisms.
Direct validation through hydro demolition significantly strengthens confidence in non-destructive testing results.
Operational involvement early in the process helps identify suitable structures and reduce deployment risks.
Reliable condition data supports better renewal planning, enabling financial, operational and carbon savings.
Future value and next steps
The next phase will expand the use of these technologies across additional in service structures. Much of the technical risk was addressed during the Detailed Design stage, meaning the Implementation phase can proceed with greater confidence.
Opportunities for collaboration with Transport Scotland, Network Rail and Innovate UK will support broader deployment and knowledge sharing. Continued validation on samples recovered from the Huntingdon Railway Viaduct will further strengthen confidence in long term monitoring techniques and help embed these technologies into routine asset management during RIS3.
- Deploying technologies across additional in service structures, prioritising those with the greatest need.
- Completing further validation on the Huntingdon Railway Viaduct samples to confirm long term monitoring accuracy.
- Trials of emerging quantum sensing technologies.
- Developing enhanced data processing and multi technology integration methods.
- Working with partners such as Transport Scotland, Network Rail, and Innovate UK to broaden deployment and share learning.
- Embedding improved condition insight into routine asset assessment workflows.
- Preparing for business as usual adoption early in RIS3, enabling decisions that could avoid or defer major renewal schemes.
