Hypertherm plasma cutting technology helps to transform Madrid’s Santiago Bernabéu Stadium

Renovation project has significantly increased the stadium's capacity

The Santiago Bernabéu stadium, home to Real Madrid Club de Fútbol, has undergone a major €575 million renovation, turning the iconic venue into a state-of-the-art football cathedral. The stadium now has a retractable roof, a stunning steel facade, and a terrace surrounding the stadium on top of the stands.

The renovation project has significantly increased the stadium's capacity from approximately 81.000 to an impressive 85.000. Furthermore, the addition of a new pitch removal and storage system ensures adaptability for hosting various large-scale events beyond football matches.

Santiago Bernabéu now features a retractable pitch housed on six underground levels. This innovative design incorporates an underground irrigation system and ultraviolet lighting, ensuring the maintenance of high-quality grass. The stadium's capacity is expected to further rise to 89.000, making it one of the largest and most advanced football arenas globally.

The Spanish construction company FCC was entrusted with the steel structure for the new roof system, which was fabricated by Horta Coslada using cutting-edge plasma technology. Horta Coslada utilized Tecoi and FICEP machines with Hypertherm^® HyDefinition^® technology,

including HPR260^®, HPR260XD^®, and HPR400XD^®. The equipment played a crucial role in the realization of this structural masterpiece, which weighs an impressive 13,000 tons and was completed in 2023.

Hypertherm plasma cutting technology: an industry workhorse

Hypertherm plasma cutting technology played a supportive but critical role in the renovation of the Santiago Bernabéu Stadium, particularly in the fabrication and installation of structural steel components used in the stadium’s transformation. Specifically, the 13,000-ton steel roof structure required high-volume, high-precision cutting, which was achieved using Tecoi and FICEP machines powered by Hypertherm plasma systems. This enabled the fabrication of components for the retractable roof, terrace structures, and facade, all of which demanded architectural precision and structural integrity.

Key roles of plasma cutting in large structural steel projects

Plasma cutting technology plays a critical role in large structural steel projects like the Santiago Bernabéu Stadium renovation by enabling precision, speed, and efficiency in the fabrication of complex steel components.

Here's how plasma cutting contributes:

1. Precision cutting of complex shapes

Stadiums often require custom-shaped beams, flanges, and joints to support dynamic architectural features like retractable roofs or curved facades. Plasma systems like Hypertherm HyDefinition^® technology (e.g., HPR260^®, HPR400XD^®) deliver tight tolerances and clean edges, reducing the need for secondary finishing.

2. Speed and efficiency

Plasma cutting is significantly faster than traditional methods like sawing or drilling, especially for thick steel. This speed is crucial in multi-phase construction projects with tight deadlines, like stadium renovations.

3. Automation and robotics integration

Systems like Robotmaster^® software allow for offline programming of robotic plasma cutters, which:

• Reduces setup time

• Enables consistent, repeatable cuts

• Improves safety and productivity in hard-to-reach or complex geometries

4. Reduced manual labor

Plasma cutting minimizes the need for grinding, punching, or manual shaping, saving labor hours and reducing fatigue. This also improves worker safety and lowers overall project costs.

5. Adaptability to harsh environments

Stadium construction often involves high-heat or outdoor conditions. Hypertherm heat-resistant torches and lead sets are designed to withstand these environments without compromising performance.

Hypertherm SureCut Technology powers large-scale structural steel projects

In large-scale construction projects — from stadiums and bridges to industrial complexes — precision and efficiency in steel fabrication are non-negotiable. That’s where Hypertherm SureCut^® technology comes in. Designed to optimize plasma cutting performance, SureCut integrates advanced cutting intelligence directly into the system, helping fabricators tackle complex steel components with speed and accuracy.

SureCut automates key processes like hole and bevel cutting, dramatically reducing setup time and manual intervention. Features like True Hole^® and True Bevel™ ensure bolt-ready holes and weld-prepped edges, while PlateSaver™ improves material utilization by minimizing waste. These capabilities are especially valuable in high-volume environments where thousands of parts must be cut to exact specifications.

By replacing traditional methods like drilling and grinding, SureCut not only accelerates production but also lowers labor costs and improves safety. Its seamless integration with CNC software and robotic systems makes it ideal for multi-phase projects with tight deadlines — like the recent renovation of the Santiago Bernabéu Stadium, where Hypertherm plasma systems helped fabricate a 13,000-ton steel roof with architectural precision.

Key plasma benefits for project managers

If you’re a project manager for large-scale projects that include fabrication and installation of structural steel components, plasma cutting is your solution of choice.

Here's why:

1.Time efficiency

Plasma cutting significantly reduces fabrication time by replacing slower methods like sawing and drilling—helping meet tight project deadlines.

2.Cost savings

Lower labor costs and reduced material waste contribute to substantial budget efficiency, especially when cutting thick or imperfect steel.

3.Precision and quality

• Delivers clean, accurate cuts with minimal rework, ensuring high-quality results for complex structural components.

4.Flexibility in material conditions

• Cuts through rusted, painted, or uneven surfaces without the need for extensive prep—ideal for renovation environments.

5.Robotic integration

• Compatible with robotic systems and offline programming (e.g., Robotmaster), streamlining automation and reducing setup time.

6.Durability in harsh conditions

• Torch systems are built to withstand high heat and molten splash, ensuring safe and reliable operation on-site.

7.Global Support Network

• Hypertherm offers extensive service and training support, minimizing downtime and ensuring smooth implementation.

Hypertherm: High-definition cutting for high-impact structures

The Santiago Bernabéu Stadium renovation stands as a testament to what’s possible when advanced fabrication technologies meet ambitious architectural vision. From complex geometries to high-heat environments, Hypertherm plasma solutions enable contractors to meet demanding timelines while maintaining exceptional quality. As large-scale infrastructure projects continue to push the boundaries of design and engineering, plasma cutting remains an indispensable tool for building the future.