PER GENOVA BREAKWATER: SIMEM AS A STRATEGIC PARTNER FOR THE CONSTRUCTION OF EUROPE’S DEEPEST BREAKWATER
Sea depths reaching up to 50 meters, a total length of 6 kilometers, and 34,000 gravel columns. These are just some of the incredible figures of the megaproject that has been taking shape for several months in Italy, specifically at the construction sites of the Port of Genoa.
The new breakwater of Genoa represents an ambitious and innovative engineering project that will transform the historic port city into a reference hub for trade across the Mediterranean and all of Europe. Once completed, the breakwater will allow access to the port for the largest container ships—over 400 meters long and up to 60 meters wide—as well as “World Class” cruise ships. This is a qualitative leap forward not only for Liguria, but for the entire Italian commercial system.
More than 100 caissons required: a giant puzzle suspended over the Ligurian Sea
Awarded to the PerGenova Breakwater consortium (40% WeBuild, 25% Fincantieri, 25% Fincosit, 10% SIDRA), the project involves the offshore prefabrication of breakwater components, allowing normal port activities to continue during construction.
The breakwater is made up of so-called caissons: massive structures as tall as a 10-story building, built using precast concrete molds. Once completed, the caissons are transported offshore and sunk to depths of more than 50 meters. They are then filled with rubble (partly recovered from the demolition of the old breakwater) and finished directly on site with a closure “plug” on top, where a concrete wave barrier is installed.
This megaproject involves more than 250 workers: each caisson requires up to 20 days to be completed, and the entire breakwater calls for the construction of over 100 caissons.
SIMEM’s winning combination: super-mobile plants and tailor-made solutions
MMX super-mobile plants to optimize installation time and space constraints
Simem was selected as the supplier of concrete production plants by Heidelberg Materials, which is managing construction activities at the sites of Vado Ligure and Porto San Giorgio.
At Vado Ligure, three MMX super-mobile plants have already been installed, with a production capacity of up to 130 m³/h of concrete, feeding the construction of prefabricated caissons. MMX plants are characterized by high mobility, designed for rapid installation to minimize assembly and commissioning times.
Concrete production for the caissons will last about four years: once completed, the client will be able to easily relocate the MMX plants to other projects worldwide, optimizing the initial investment.
The three plants are equipped with MSO 5000 twin-shaft mixers, delivering 3.3 m³ per batch, and feature an integrated lubrication system allowing continuous, frictionless operation. Durability of components is a key strength: the mixing tank is lined with stainless steel side plates. Mixing arms are made of cast iron and bolted directly to the shaft, while the blades—also cast iron—ensure consistent wear resistance and homogeneous mixing at all times.
The mixers are equipped with a safety system compliant with the latest CE regulations: inspection doors can only be opened after motors have been shut down, ensuring maximum operational safety.
Finally, the three MMX plants include a NEXSUS MASTER aggregate group with 4 compartments and a storage capacity of 160 m³. Here too, strength and precision are the key features that Simem continues to invest in: double galvanized dosing gates, a weighing hopper protected by bolted wear plates, and stainless steel load cells.
Custom Simem solutions: blending know-how and adaptability
At the San Giorgio del Porto site, two tailor-made plants are being installed, complete with a system for recycling mixer wash water. A distinctive feature of these plants is their location: they are positioned directly on barges. The plants will move along with the breakwater, producing concrete on site as the caissons are being completed. In this way, both the superstructure and the wave barrier will be built directly atop the caissons.
The plants are equipped with RHYNO 4000 twin-shaft mixers, producing 100 m³/h of concrete, featuring an integrated automatic lubrication system and anti-wear linings.
These two plants are also fed by a Nexus MASTER aggregate group, the largest in the range, with an expandable bolted frame.
Durable, high-quality concrete for projects that will shape tomorrow’s world
Simem plants are designed to facilitate both installation/assembly operations and maintenance activities. In practice, this means easy access to components thanks to scaffolding and dedicated levels, an integrated automation system, and sensitive elements protected against weather, salinity, and dust.
For more than 60 years, the mission has remained the same: to provide producers and builders with durable plants capable of lasting decades, producing high-quality concrete from the first to the very last cubic meter.
Thanks to its ongoing commitment to research—both in advanced construction technologies and in dedicated applications—Simem continues to deliver excellence in this sector, helping its clients complete projects that will shape the world of tomorrow. With this project, Genoa is set to become a symbol of European maritime engineering, strengthened by Simem’s technological contribution.