A cement plant in France recently used the Elios 3 drone for a scan-to-BIM project, capturing detailed LiDAR data of the entire site. This innovative approach allowed the team to create a comprehensive digital model of their facility, streamlining future planning and maintenance efforts. Full Data Coverage The Elios 3 provided complete scans of both the interior and exterior of all assets, ensuring no gaps in the data. This level of detail is often difficult to achieve with traditional terrestrial laser scanning methods. Plus, the process can be easily repeated to keep the model up to date with minimal effort. Speed and Efficiency Using the Elios 3 instead of a terrestrial scanner reduced the scanning time from at least 10 days to just one day. This dramatic improvement in speed not only saved time but also minimized operational disruption. Minimal Site Disruption Instead of having contractors on-site for an extended period, the drone completed the task in a single day. This significantly reduced the impact on daily operations and improved workflow efficiency. Cost-Effective Solution The faster data collection and simplified post-processing made the entire process more cost-effective. By using in-house teams, the plant avoided the need for external contractors, further reducing expenses. Scan-to-BIM has become a powerful tool for infrastructure managers who are creating digital replicas of real-world environments. Building Information Modeling (BIM) is now a standard in many industries, including construction and industrial facilities. With Scan-to-BIM, real-world sites are transformed into accurate BIM models, enabling better planning, early problem detection, and precise comparisons between as-built and as-designed projects. This technology not only improves communication but also reduces errors, rework, and overall costs. Holcim, one of the world’s largest cement producers, is leading the way with its "Plants of Tomorrow" initiative. This project aims to integrate Industry 4.0 technologies into the building materials sector, including BIM. The goal is to modernize plant management, reduce carbon emissions, and enhance performance across all operations. Part of this initiative involves digitizing plant assets and production areas. In a French facility, a project was launched to create a digital twin of the entire cement plant. This model would support the broader goals of the Plants of Tomorrow program by enabling efficient planning, better communication with contractors, and improved collaboration. It also helps track actions taken to reduce the plant's carbon footprint, potentially opening doors to funding opportunities from European authorities. The Elios 3 drone is already widely used at this plant for asset inspections and stockpile monitoring. The trained pilots appreciate its safety and accuracy, which is why they chose it for the Scan-to-BIM project. The challenge was to capture data from hard-to-reach spaces, such as the areas between pipes and ducts that stretch from ground level up to tens of meters high. Traditional methods would have required 10 days of scanning and could cost over €30,000. Plus, if initial scans missed data, additional trips to the site were needed, slowing down the whole process. Using the Elios 3, the team was able to collect all necessary data in just one day, with in-house pilots handling the work efficiently. A laser scan with the Elios 3 captures detailed data between pipes and ducts before post-processing. The final BIM model was created in just two days of post-processing, with the team merging scans from multiple flights and filtering out any poor-quality data. They used FARO Connect, Flyability’s partner software, to handle the data efficiently. Creating a BIM model requires a full survey of the site. Industrial environments often have complex structures that make it difficult to capture all data using traditional methods. The Elios 3, however, can navigate tight spaces and provide a complete dataset, making it ideal for this kind of project. Pilots were able to gather all the necessary scans in just one day, compared to the weeks it might take with a terrestrial laser scanner. After flying, the team processed the data quickly, resulting in a fully detailed model within a week. The Elios 3 allows safe inspection of complex industrial assets from the ground. This project was crucial for the plant, as it cut costs, ensured full coverage, and eliminated the need for multiple attempts. The in-house team’s familiarity with the site made the process faster and more accurate, avoiding the need to explain layout details to subcontractors. The BIM model produced from the Elios 3 scan proved invaluable for the plant. It enabled the team to plan the integration of carbon capture technology and provide precise engineering details for new installations. The model also helped demonstrate the plant’s sustainability efforts, which could support funding applications from the EU. The success of this project has already led to its use in other initiatives, showing the value of drone-based BIM models in improving project management and decision-making. This project marks a significant step toward bringing Industry 4.0 technologies to cement plants. The Elios 3’s ability to quickly and accurately collect data makes it an essential tool for future digitalization efforts. Its LiDAR and UT capabilities allow for ongoing asset digitization and remote inspections, keeping workers safe while maintaining operational efficiency. As the plant continues to innovate, the BIM model will serve as a foundation for future upgrades and improvements. The combination of drone technology and BIM is not just transforming how the plant operates—it’s setting a new standard for the industry. Coating Material Changzhou Dahua-Luckypower , https://www.czluckypowertech.comDrone Scan to BIM: The Elios 3 Digitizes a Cement Plant
Key Benefits at a Glance
BIM in the Cement Industry
Using the Elios 3 for Scan-to-BIM
Flying the Elios 3 for BIM Data Collection
Applying the Drone Scan-to-BIM Model
The Advantages of Drone Scan-to-BIM Models