Drone Scan to BIM: the Elios 3 digitizes a cement plant
June 04 05:03:54, 2025
# Drone Scan to BIM: Digitizing a Cement Plant with Elios 3
In France, a cement plant embarked on a groundbreaking project to digitize its entire facility using the Elios 3 drone. The plant utilized the drone’s LiDAR scanner to capture comprehensive scans of both the interior and exterior of the site. This approach marked a leap forward in efficiency compared to traditional terrestrial laser scanning methods, which often leave gaps in data coverage and require significantly more time.
## Key Benefits at a Glance
### Data Coverage
The Elios 3 provided full scans of the site, reaching areas that are notoriously hard to access—like spaces between pipes and ducts—ensuring no blind spots. Unlike conventional methods, this drone allows for seamless repetition, enabling updates to the digital model whenever necessary.
### Speed
Switching to the Elios 3 drastically cut down the time required for data collection. What would have taken at least 10 days with traditional tools was completed in just one day of drone flight. This accelerated timeline minimized downtime and kept operations running smoothly.
### Site Management
Minimizing disruption was another critical advantage. Instead of requiring contractors to be onsite for an entire week, the Elios 3 only needed a single day to gather all necessary data. This reduced interference with daily workflows and ensured continuity in operations.
### Cost Efficiency
The reduced time spent on-site translated directly into cost savings. By handling the process in-house, the plant avoided outsourcing expenses, which typically run upwards of €30,000 for similar projects. Additionally, the streamlined post-processing phase further lowered overheads.
## BIM in the Cement Industry
Holcim, one of the world’s leading cement producers, is spearheading the **Plants of Tomorrow** initiative—a project focused on integrating Industry 4.0 technologies into the building materials sector. As part of this effort, Holcim aims to digitize its assets and production sites to enhance efficiency, sustainability, and collaboration.
At a specific location in France, a project was launched to create a digital twin of an entire cement plant. This virtual replica serves as a foundation for optimizing processes, streamlining communication, and improving cooperation with contractors. Beyond internal benefits, this digital model can also support grant applications with European commissions and showcase the plant’s commitment to reducing its carbon footprint.
## Leveraging Elios 3 for Scan to BIM
The Elios 3 drone was already in use at this plant for asset inspections and stockpile monitoring. Pilots familiar with the drone appreciated its safety features and trusted its precision, making it the ideal choice for this BIM project.
Traditional methods for capturing such detailed scans often struggle to navigate tight spaces like those found between pipes and ducts. These areas pose challenges due to their height and complexity, making it nearly impossible to achieve full coverage without extensive effort. However, the Elios 3 excels in these environments, offering complete data sets in a fraction of the time.
Post-processing the data collected from the Elios 3 took only two days. Within a week, the final model was refined into a comprehensive .las file, ready for integration into the BIM system. Filters were applied during processing to remove low-quality data caused by dust or distant captures.
## Flying the Elios 3 for BIM Data Collection
Creating a BIM model demands meticulous documentation of every aspect of a site. Industrial settings present unique challenges, as obstructive structures like pipes and ducts can create blind spots in scans. The Elios 3 overcame these hurdles by navigating through tight spaces and capturing every detail.
Pilots managed to collect all required scans in just one day. In contrast, traditional terrestrial scanners might require several weeks to achieve comparable results. After completing the flights, the data was processed using FARO Connect, the software included with the Elios 3’s Surveying Payload.
## Utilizing the Drone Scan-to-BIM Model
The resulting BIM model proved invaluable for the plant. By using the Elios 3, the plant achieved full data coverage without the need for multiple attempts or extended sessions. Having in-house pilots familiar with the site expedited the process and ensured high-quality results.
For this project, the goal was to produce a “schematic design†(Level of Development 200), a standard for BIM models. The Elios 3’s LiDAR data met this requirement perfectly, delivering the precise level of detail needed.
The BIM model now enables planners to identify optimal locations for carbon capture technology and related infrastructure, such as ducts, fans, filters, and heat exchangers. Architects and engineers can rely on the model to accurately determine dimensions, positions, and placements for these additions.
Moreover, the plant can use the BIM model to document its sustainability efforts, providing evidence for EU grants and demonstrating progress to regulatory bodies.
## Long-Term Value of Drone Scan-to-BIM
This project represents a substantial advancement toward integrating Industry 4.0 technologies in the cement industry. The BIM model has already proven its worth by simplifying project management and facilitating collaboration among subcontractors.
The benefits of adopting the Elios 3 for scan-to-BIM are immense. Not only did the drone reduce data collection time significantly, but it also ensured 100% coverage both indoors and outdoors. Financially, the plant saved money by cutting down on external contractors and expediting post-processing.
Looking ahead, the plant anticipates continued innovation through the Elios 3. Future applications may include remote inspections using LiDAR and ultrasonic testing (UT) to maintain asset integrity safely. The BIM model complements ongoing drone initiatives, positioning the plant at the forefront of technological progress.
By embracing these advancements, the cement plant not only enhances its operational efficiency but also aligns itself with the broader goals of Holcim’s **Plants of Tomorrow** initiative.
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eliminate the entrained droplets in steam or gas and liquid foam, and car
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mesh(It has the characteristics of large flow and high filtration efficiency)
