SYNCHRO 4D Powering the World’s First Iron Ore Briquette PlantāÆ
Organization: Deloitte and Vale
Project Name: SYNCHRO 4D Powering the World’s First Iron Ore Briquette PlantāÆ
Location: VitĆ³ria, Brazil
Project Phase: Construction
Expected Completion Date: December 2023
Estimated Project Cost: USD 340 million
Bentley Software: SYNCHRO 4D, iTwin Capture, Cesium
Project
Valeās iron ore briquette plant in VitĆ³ria, Brazil is the worldās first facility of its kind, designed to deliver a product that can help reduce COā emissions in steelmaking by up to 10%. As part of Valeās global decarbonization strategy, the project transforms a former pellet plant into a high-tech, sustainable production site. Deloitte led the digital execution, integrating AWP, BIM, and lean methodologies with Bentleyās SYNCHRO 4D as the central software.Ā
The team coordinated over 1,500 work packages through visual planning, improving schedule accuracy by 41% and cutting engineering approval cycles byĀ 10 days. Advanced 4D simulations enabled safer field operations and the identification and removal in advance of more than 2,000 constraints. AI-powered transcription of technical videos streamlined communication and reduced reporting time by more than 50%.Ā
This project sets a new benchmark for digital transformation in industrial construction and now serves as the reference model for future iron ore briquette plants across Valeās global portfolio.Ā
Ā Facts
- Valeās plant is the worldās first to produce iron ore briquettes, an innovative product can help reduce greenhouse gas emissions in steel production by up to 10%, supporting global industrial decarbonization efforts.
- Visual planning with SYNCHRO 4D construction software improved schedule accuracy by 41% and cut engineering approval cycles by 10 days.Ā
- 4D simulations enabled the identification and removal of more than 2,000 constraints, enhancing safety and reducing on-site conflicts.Ā
āBentleyās SYNCHRO 4D served as the digital backbone for coordinating over 1,500 activities in the construction of Valeās first iron ore briquette plant. By consolidating CWPs, schedules, and 4D models in a uniform environment, the tool enabled connected and collaborative site management, supporting strategic decisions with traceable, shareable, and visual data. Its implementation marked a turning point in the digital transformation of industrial capital projects.ā
Solution
SYNCHRO 4D served as the core planning software for planning, execution, and monitoring in the construction of Valeās first briquette plant. Led by Deloitte, the project team implemented AWP, BIM, and lean methodologies, integrating over 40 construction work areas (CWAs) and 1,500 construction work packages (CWPs) into SYNCHRO to enable dynamic, collaborative planning. Despite limited model detail and digital maturity, SYNCHRO 4D provided a unified environment for constructability analysis, risk simulations, and schedule integration.
During engineering, SYNCHRO supported logistics planning and constructability reviews. In execution, it enabled detailed tracking of service fronts and material deliveries. For commissioning, the software visualized progress and flagged outstanding issues, improving predictability. The Appearance Profile feature allowed granular monitoring across engineering, procurement, and construction phases. SYNCHRO also facilitated realistic lifting simulations via Unreal Engine, enhancing safety in high-risk operations.
Phased tracking, like ring-by-ring tank assembly, was supported through custom subdivisions and Excel-based updates. Integration with Power BI dashboards enabled real-time visual progress tracking and early deviation detection. AI-powered transcription of SYNCHRO-generated videos added traceability and reduced reporting time by over 50%.
In total, SYNCHRO 4D coordinated over 1,500 activities, improved schedule accuracy by 41%, and helped reduce the supply total lead time by 15%. Its implementation marks a turning point in digital project delivery and establishes a scalable model for future iron ore briquette plants worldwide.
Outcome
The project achieved a 41% increase in schedule accuracy and cut engineering approval cycles byĀ 10 days through SYNCHRO 4Dās visual planning. AI-powered transcription reduced reporting time by over 50%. 4D simulations enabled the identification and removal of more than 2,000 constraints, enhancing safety and minimizing conflicts. Despite a six-month delay in engineering completion, proactive use of AWP and 4D replanning prevented rework and stoppages, ensuring the project was delivered on schedule. The success of this pilot plant has established a scalable model for future iron ore briquette plants worldwide.Ā
Software
SYNCHRO 4D ProĀ was key for planning, execution, and monitoring. It was used for 4D simulations, sequencing, risk analysis, and visual tracking of over 1,500 activities.Ā
iTwin CaptureĀ was used to integrate reality data (e.g., drone imagery and point clouds) into the 4D model for immersive reporting and progress validation.Ā
CesiumĀ supported geospatial modeling and visualization, enhancing spatial context for planning and execution.Ā
Ready to reduce emissions through smarter construction? See how SYNCHRO 4D supports low-carbon project delivery.
Bentley Year in Infrastructure (YII) and the Going Digital Awards is an annual event where global industry leaders come together to showcase infrastructure delivery and performance excellence and exchange visionary ideas for the future. Find out more on the YII site.
