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Italferr Uses Digital Twins to Streamline Workflows and Improve Accuracy on EUR 200 Million Bridge Redesign

Italferr Uses Digital Twins to Streamline Workflows and Improve Accuracy on EUR 200 Million Bridge Redesign
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Italferr Uses Digital Twins to Streamline Workflows and Improve Accuracy on EUR 200 Million Bridge Redesign - 1

CASE STUDY Bentley Advancing Infrastructure Project Summary Organization Italferr S.p.A. Italferr Uses Digital Twins to Build Pergenova Viaduct in Genoa, ItalyBridges Bentley Applications Help Automate Processes and Streamline CollaborationLocation to Meet Tight Schedule on Major EUR 200 Million Roadway Genoa, Italy Project Objectives • To quickly restore a vital transportation link in Genoa, Italy. • To incorporate new safety standards and technologies for bridge design in the region. Products Used Descartes, gINT®, iModel.js, LumenRT, MicroStation®, Navigator, OpenBuildings™ Designer, OpenRoads™, ProjectWise®, SYNCHRO™ Fast Facts • A 210-meter section of the 1,182-meter Morandi Bridge collapsed in 2018, resulting in a number of lost lives and disrupted transportation. • The large, complex redesign grew to include 34 different models that had to combine seamlessly into a federated model. • Italferr needed to complete the design in only three months, which caused the project team to implement a BIM methodology. ROI • The BIM methodology improved clash detection, accelerated design work, and created a seamless workflow. • The team used Bentley applications to create 3D models, meeting the tight schedule while maximizing durability, increasing energy efficiency, and ensuring road traffic safety. • SYNCHRO Pro's 4D construction visualization allowed designers to pinpoint critical issues in advance, creating a faster, more efficient construction schedule. Rebuilding a Critical Transportation Artery Italferr S.p.A., part of the Italian State Railways Group - Ferrovie dello Stato Italiane, designs and builds (work supervision activities) large-scale infrastructure projects around the world. Based on the organization's more than 30 years of experience in the industry, Pergenova Consortium Company chose Italferr to design an emergency replacement for the 1,182-meter Morandi Bridge over the Polcevera River in Genoa. The bridge is part of a key roadway that links Italy and France and is a main access point to a nearby airport. In August 2018, a 210-meter section of the Morandi Bridge suddenly collapsed. Cars and concrete slabs fell onto apartments, factories, roads, and railways. Though the cause of the collapse was never officially determined, corrosion had affected the bridge's structure and repairs were scheduled to begin only weeks after the collapse. The remainder of the bridge was demolished months later. The collapse closed three rail lines and added 120 kilometers to road travel. Consequently, rebuilding it as quickly as possible was critical for the city's long-term economic and cultural health—and construction would need to begin as the design progressed. Complicated Planning on a Tight Schedule Italferr faced the challenge of completing the design of the EUR 202 million project in only three months—extraordinarily fast for a project of this size and complexity. It also had to create a simple design while incorporating new Italian safety standards for the cross-section of the deck and the curvature radii of the junctions and entrances. Lastly, the project team needed to design and build the bridge on the same footprint as the previous one, with reinforced concrete piers positioned 50 to 100 meters apart. Each of these piers will have a continuous cross-section for their entire height. A consortium of local officials determined that the main deck should feature a continuous 1,067-meter girder with 14 50-meter and three 100-meter steel-concrete spans. The bridge will also include one 41-meter steel-concrete span approaching the west shoulder, one 26-meter steel-concrete span approaching the east shoulder, and a 110-meter steel-concrete ramp with three spans connected structurally to the deck. Various important technological features will be incorporated throughout the structure, including dehumidifiers and a solar generation plant, to enhance the bridges aesthetics, ensure road traffic safety, improve energy efficiency, and maximize durability. To visualize steel and concrete structures, the team created a 3D model that was continually updated with design changes. Optimizing Processes in a Digital Twin Environment To ensure the accuracy of the design while staying on schedule, Italferr used Bentley's BIM methodology and created a digital twin of the viaduct to streamline workflows throughout the design phase. "While we were completing our [design, the construction team was] starting to demolish and build piles and foundations," said Stefano Casula, structural engineer and BIM expert with Italferr. "We had to catch any mistakes and interferences as soon as possible." To achie

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Italferr Uses Digital Twins to Streamline Workflows and Improve Accuracy on EUR 200 Million Bridge Redesign - 2

"The BIM methodology used in this project follows the digital twin approach. The visibility and insight it enabled allowed us to significantly change the way in which we deal with the design and managementof infrastructure work.." - Daniela Aprea, BIM Manager, Italferr S.pA. Find out about Bentley at: www.bentley.com Contact Bentley 1-800-BENTLEY (1-800-236-8539) Outside the US +1 610-458-5000 Global Office Listings www.bentley.com/contact this goal, Italferr incorporated detailed information for construction and operation into the model, as there was little time to significantly alter the...

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