AI-Powered Digital Twin Revolutionizes Tunnel Maintenance in Italy

5 January 2026
Construction Focus
965 Views

Italferr S.p.A. has set a new benchmark in railway safety by implementing an AI-powered digital twin for the Serravalle Tunnel, part of the strategic Tezo Valico dei Giovi line connecting Genoa and Milan.

By moving away from manual, time-consuming inspections, the project has successfully automated defect detection, dramatically reducing operational risks.

The primary challenge for Italferr was the inefficiency of traditional inspection methods. To modernize this process, the team utilized a suite of Bentley Systems software to create a high-precision digital environment:

Precise Modeling: Using OpenRail and OpenTunnel, Italferr developed dual 3D models representing both the original design and the current “as-built” conditions.
Data Capture: iTwin Capture processed laser-scanned data to create a comprehensive point cloud, which served as the foundation for the tunnel’s digital replica.
AI Integration: The iTwin Platform served as the host for advanced AI algorithms. These algorithms automatically scan the digital twin to identify structural defects, replacing the need for exhaustive manual visual checks.
Streamlined Collaboration: ProjectWise managed the massive data workflows, ensuring all stakeholders could access real-time information in a unified environment.

The transition to remote surveys and predictive maintenance has not only extended the life of the asset but also significantly improved worker safety by reducing the time spent in hazardous tunnel environments.

“The integration of Bentley software… represented a paradigm shift,” said Rossella de Robertis, BIM Coordinator at Italferr. “We have achieved finer control, reduced uptime, and an overall improvement in project quality.”

This digital modernization ensures that one of Italy’s most vital rail corridors remains resilient, sustainable, and less prone to sudden service disruptions.

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