Enel Green Power, in partnership with the Federico II University in Naples, has successfully pioneered the use of 3D printing technology to construct permanent concrete structures in a seismic zone, a first for Italy. The project, carried out at the Montalto di Castro power plant in the Lazio region, represents a significant innovation in the construction and energy sectors. These structures are part of a Battery Energy Storage System (BESS) at the Alessandro Volta power plant, designed to store excess electricity generated by the plant. The structures include a small industrial building and the foundations for key electrical equipment, marking a new era in sustainable construction.
This milestone is the first non-temporary concrete construction in Italy to be built using 3D printing technology, and it is also one of the first of its kind worldwide in the energy sector. Importantly, the project has received seismic clearance, meaning it is safe for use in earthquake-prone areas, a vital consideration in Italy’s seismic zones. The ability to gain approval from the Civil Engineering Department for such an innovative construction method underscores the technical rigor and innovation behind the project. These developments signify a major step forward for Enel Green Power and the entire Enel Group, as they work towards more sustainable and efficient building practices.
The construction of the BESS facility at Montalto di Castro employs additive manufacturing, commonly known as 3D printing. This process involves creating objects layer by layer from a digital model designed on a computer. In this case, a robotic arm fabricated 11 walls and other components, using a cement material specifically designed for 3D printing by Heidelberg Materials. The walls, each approximately 3 meters high and 1.5 meters wide, were printed with about 2.5 kilometers of material in total. The foundations, which support the electrical equipment, were made in a similar fashion, with each piece resembling more of a natural formation like a tree root, as opposed to a traditional concrete structure.
After being fabricated in Volla, near Naples, the walls and foundations were transported to the Montalto di Castro plant for assembly. This process of printing the building’s components off-site and then assembling them at the final location is reminiscent of constructing large-scale Lego blocks. The construction is not only innovative but also highly efficient. The building at the Montalto di Castro plant is small, about 15 square meters, but its significance lies in the technology and methods used to create it. The project combines conventional prefabrication techniques, such as the separate creation of the roof, with cutting-edge 3D printing technology, demonstrating the compatibility of the two methods.
The use of 3D printing offers numerous advantages in the construction industry. First and foremost, it significantly reduces the time needed for building. The construction process at Montalto di Castro was completed in less than half the time it would have taken using traditional methods. This speed is crucial in the energy sector, particularly in the growing field of renewable energy, where quick installation can improve competitiveness. Additionally, 3D printing eliminates the need for formwork, the temporary molds traditionally used to hold poured concrete in place while it hardens. This reduces both the labor involved and the environmental impact, as less material is wasted.
Manufacturing on Demand
Sustainability is at the core of Enel Green Power’s mission, and 3D printing plays a key role in reducing the environmental footprint of construction. By optimizing the distribution of concrete, 3D printing minimizes material use—by as much as 50% in some cases—resulting in lower CO2 emissions. Given that concrete production is responsible for a significant portion of global carbon dioxide emissions, this reduction is a critical benefit. In addition, by using less material and cutting down on waste, 3D printing aligns with the goals of the renewable energy industry, which aims to minimize its environmental impact across the entire production and infrastructure lifecycle.
Beyond its environmental advantages, 3D printing also offers greater flexibility in design. Complex shapes and customized details that would be difficult or impossible to achieve with traditional construction techniques can be easily handled through digital design and additive manufacturing. This flexibility not only opens new possibilities for architectural creativity but also enhances the mechanical performance of the structures. The highly digitalized nature of 3D printing also improves on-site safety, as much of the labor is automated, reducing the risk to workers.
The Montalto di Castro project was not without challenges. According to the engineers involved, controlling the consistency of the printing process and ensuring the material’s structural integrity were key hurdles. Producing pieces as large as three meters high while maintaining stability in both their soft and hardened states required precise control of the extrusion speed and the geometry of the printed blocks. However, the successful completion of the project demonstrates the potential of 3D printing in overcoming these challenges and creating durable, reliable structures.
The partnership between Enel Green Power and the Federico II University in Naples began two years ago, with the goal of developing a revolutionary structural calculation theory for 3D printed elements. This theory was rigorously tested in laboratories and through numerical simulations before being implemented on-site. The result of these efforts was submitted to Italy’s Civil Engineering Department and the Superior Council of Public Works for approval. The project team’s dedication to research and innovation has resulted in what will likely become a textbook example in future engineering and architecture studies.
Looking ahead, Enel Green Power plans to further develop 3D printing technology in construction. The company has already secured a grant from the ARTES4.0 Competence Center through Italy’s National Recovery and Resilience Plan (NRRP) to industrialize the process of 3D printing structural elements for energy infrastructure. The upcoming OM3GA project will involve collaboration with several partners, including WASP, Italy’s leading manufacturer of 3D printing machines, and Materias, a company specializing in advanced materials. The goal is to create 3D-printed foundations for substation equipment using a mobile factory, allowing structures to be printed directly on-site, further reducing transportation and environmental costs.
The Montalto di Castro project marks a significant step forward for Enel and the energy industry as a whole. By demonstrating the viability of 3D printing for permanent, seismic-resistant concrete structures, Enel has opened the door to faster, more sustainable construction methods. As the technology continues to evolve, it is likely to play an increasingly important role in the energy sector, particularly in the development of renewable energy infrastructure. With its ability to reduce construction time, cut material use, and lower CO2 emissions, 3D printing offers a promising solution to some of the key challenges facing the industry today.
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Author: Davide Sher
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