€350,000 Savings in the Everton Stadium Project with 3DEXPERIENCE Solutions!
In the construction of Premier League club Everton FC’s new stadium, the installation processes for nearly 900 complex facade panels were simulated virtually using Dassault Systèmes solutions before site work began. The result: zero accident risk, optimum workplace safety, and €350,000 in cost savings. With traditional methods, the cost of errors in mega projects where over a thousand unique parts must be installed in tight spaces under high risk can be extremely severe.
To eliminate this risk, main contractor Laing O’Rourke and facade specialist Lindner Prater partnered with digital manufacturing expert Prodtex to fully transition the facade installation process of Everton Stadium into a digital environment powered by the 3DEXPERIENCE Platform.
Complex Crane Op. & Occupational Safety Risks
- Access and Crane Challenges: Due to the curved roof structure, crane approach angles and the safety of installation tooling had not been tested in advance.
- Ergonomics and Worker Health: Physical strain and fall risks that workers might experience while bolting and securing panels at height were uncertain.
Solution: Digital Rehearsal with CATIA, DELMIA, and Virtual Reality (VR)
Months before any on-site work began, the Prodtex team built a full - 3D Digital Twin on the Dassault Systèmes 3DEXPERIENCE Platform: Detailed 3D modeling was performed using CATIA by importing third-party architectural and BIM data into the CATIA environment, producing a high-precision 3D model integrated into the digital twin.
- Process and Ergonomics Simulation with DELMIA: Crane lifting angles, installation sequences, and equipment access were simulated using DELMIA. Virtual human mannequins were utilized to conduct RULA (Rapid Upper Limb Assessment) ergonomic analyses. Worker Insights via VR (Virtual Reality): On-site workers wore VR headsets to experience the installation process firsthand. While bolting in the virtual environment, workers provided critical feedback such as “I can’t reach here” or “I can’t hold this plate alone in this basket” directly to management during the design phase.
Tangible Results and Key Benefits
€350,000 Direct Savings: Thanks to these virtual rehearsals, numerous design and process errors were identified and corrected before installation began. By preventing faulty installations, downtime, and tooling revisions, €350,000 in installation costs was saved.
Complete Success in Workplace Safety and Ergonomics: The installation angle initially flagged as high-risk (RULA score of 4) was reduced to the safest level (RULA score of 1) by redesigning the tooling and switching to a larger 2-person basket.
Right-First-Time Installation: Thanks to the process rehearsed multiple times in the digital environment, field teams installed all 872 panels with zero errors and zero workplace accidents within the planned schedule.
Watch the Prodtex Customer Story Now
“This industry has long relied on working things out on site. But when you start rehearsing the work before it happens, you realize just how many problems you can solve before anyone picks up a tool. Dassault Systèmes’ construction technology solutions act as a catalyst for change, giving architects, engineers, and contractors the ability to build virtually first and leave nothing to chance.” — James Wilkinson-Brown / Head of Digital Manufacturing, Prodtex
Your Job Site is Safe with the 3DEXPERIENCE Platform!
Dassault Systèmes 3DEXPERIENCE, CATIA, and DELMIA solutions protect your projects in the architecture, eng. & construction industry from budget overruns, delays, and workplace safety risks. Contact the ArGe PLM expert team to leverage the power of digital twins and process simulation in your projects, reduce installation costs & elevate job site safety to the highest level.
