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    D’Appolonia S.p.A.

    1960 – Rezzato Cement Plant

    Rezzato, Brescia, Italy

Project Summary

Project

As part of the EUR 150 million renovation of Italy’s historic Brescia Rezzato plant, Italcementi retained D’Appolonia to design the 107-meter-tall, metal, cement-powder preheating tower. To facilitate coordination among multiple engineering disciplines, adhere to strict emissions, noise and other environmental requirements, and optimize production and economic sustainability, the team needed a collaborative, interoperable modeling and analysis environment.

Solution

D’Appolonia used Bentley’s STAAD.Pro for accurate, integrated 3D modeling and verification and resolution of detected clashes. Bentley’s flexible, interoperable software facilitated data sharing among disciplines and enhanced design quality to ensure eco-friendly, state-of-the art cement processes and optimize production efficiency.

Outcome

Bentley’s integrated modeling approach minimized errors and reduced costs during design and construction. The newly revamped plant will deliver a 23 percent reduction in production costs as well as a 75 percent reduction in emissions. STAAD.Pro proved invaluable to the renovation project, which has led to a significant improvement in the environmental and economic sustainability of the plant.

 Software

D’Appolonia used Bentley STAAD.Pro to design the 107-meter-tall preheating tower for the renovation of the historic Rezzato Cement Plant. Bentley’s integrated modeling and analysis software enhanced collaboration among the mechanical, electrical, and civil disciplines, allowing extractions of the respective fields within the 3D model. The interoperability among the STAAD.Pro models and the identification and resolution of detected clashes minimized errors and proved invaluable to the project. Using Limcon, the team was able to test steel connections and perform design calculations, optimizing structural analysis.

Outcome/Facts
  • Italcementi invested EUR 150 million to renovate Italy’s historic Rezzato Cement Plant making it Europe’s most efficient, eco-friendly plant, reducing production costs by 23 percent and emissions by 75 percent.
  • D’Appolonia used STAAD.Pro for integrated 3D modeling, and for identifying and resolving clashes during the design of the 107-meter-tall, metal, cement-powder preheating tower for the cement plant.
  • Bentley’s interoperable software enhanced collaboration among the multiple disciplines and proved invaluable to the project, minimizing design errors and reducing costs.
  • The revamping has led to a significant improvement in the environmental and economic sustainability of the plant.
Quote:
  • “The software programs used to design the integration and sharing of data with the management model have led to a substantial benefit with a reduction of costs in the design, sharing of data, and the quality itself of the project, reducing errors both in the design phase in in the construction phase.”

    Pietro Rocca Unit Manager D’Appolonia