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Drone Scan to BIM: the Elios 3 digitizes a cement plant
# Drone Scan to BIM: Digitizing a Cement Plant with Elios 3
At a cement plant in France, the Elios 3 drone played a pivotal role in a scan-to-BIM project, meticulously capturing the entire facility with its advanced LiDAR scanner. The Elios 3’s ability to navigate tight spaces and capture data from every angle proved invaluable for creating a comprehensive digital replica of the site. This project marked a significant leap forward in leveraging Industry 4.0 technologies in the cement sector.
## Key Benefits of Using Elios 3
The Elios 3 brought a range of benefits that transformed the conventional approach to data collection and modeling. For starters, the drone delivered full coverage of both internal and external assets without leaving any blind spots—something terrestrial scanners often struggle with. This level of precision and completeness is crucial for creating reliable BIM models. Additionally, the process was remarkably efficient, completing the scans in just one day instead of the usual ten days required by traditional methods.
Beyond speed, the Elios 3 minimized disruptions to the plant’s operations. Instead of requiring contractors to be on-site for an entire week, the drone completed its task in a single day, allowing the plant to maintain its workflow uninterrupted. Furthermore, the cost savings were substantial. By handling the scans in-house, the plant avoided outsourcing costs, which typically exceed €30,000. Post-processing took only two additional days, bringing the entire project lifecycle down to under a week—a stark contrast to the weeks or even months it might take with conventional techniques.
## BIM in the Cement Industry
Holcim, one of the largest cement producers globally, has embraced the "Plants of Tomorrow" initiative, integrating BIM into its operations to modernize plant management, reduce carbon footprints, and enhance efficiency. As part of this initiative, the French plant sought to create a digital twin of the entire facility. This virtual representation would serve as a blueprint for future projects, aiding in the integration of new technologies like carbon capture systems and optimizing workflows.
The digital twin would also play a key role in demonstrating the plant's commitment to sustainability. By documenting its efforts to reduce emissions, the plant could apply for grants from European commissions and showcase its achievements to regulatory bodies. Moreover, the BIM model would facilitate smoother communication between stakeholders, ensuring that everyone—from architects to maintenance teams—had access to the most accurate and up-to-date information.
## Leveraging the Elios 3 for Scan-to-BIM
The Elios 3 was chosen for this project due to its proven track record in asset inspection and stockpile monitoring at the same plant. Pilots familiar with the drone's capabilities were confident in its ability to deliver precise results safely. During the scan, the drone navigated through the labyrinthine network of pipes and ducts, capturing detailed data from angles inaccessible to terrestrial scanners. This meticulous attention to detail ensured that the final BIM model was free of gaps and inconsistencies.
The scanning process itself was swift and efficient. What would have taken weeks with traditional methods was accomplished in just one day of drone flight. Post-processing followed suit, with the data being refined into a complete 3D model within a week. The Elios 3’s Surveying Payload facilitated this by delivering high-resolution LiDAR data, which aligned seamlessly during post-processing. Any low-quality data, such as dust interference or distant captures, was carefully filtered out to produce a polished final product.
## The Value of Drone-Based BIM Models
The resulting BIM model has proven invaluable for the plant's ongoing initiatives. For instance, it enabled planners to visualize potential locations for carbon capture technology with unprecedented clarity. Engineers can now precisely determine the placement of new ducts, fans, filters, and heat exchangers, streamlining the construction process. The accuracy of the model has also simplified communication among contractors, ensuring that everyone works from the same blueprint.
In addition to practical applications, the BIM model serves as a testament to the plant's dedication to sustainability. By documenting its progress toward reducing emissions, the plant can seek funding opportunities and build trust with regulators. The model also ensures that the plant remains adaptable to future changes, as the same process can be repeated to update the digital twin whenever new installations are added.
## Long-Term Potential of Drone-Based Solutions
Looking ahead, the plant anticipates expanding its use of the Elios 3 beyond scan-to-BIM tasks. Its LiDAR and ultrasonic testing (UT) capabilities make it an ideal tool for continuous asset monitoring and remote inspections. These functions not only enhance safety but also reduce operational downtime by identifying issues before they become critical.
The Elios 3 is more than just a scanning device—it represents a shift toward smarter, safer, and more sustainable operations. As the plant continues to embrace these innovations, it stands as a beacon of progress in the cement industry, paving the way for others to follow.