# Drone Scan to BIM: Digitizing a Cement Plant with Elios 3
In France, a cement plant embarked on a pioneering Scan to BIM project, leveraging the advanced capabilities of the Elios 3 drone. By employing its LiDAR scanner, the entire facility—both inside and out—was meticulously digitized. This effort marked a significant leap toward integrating Industry 4.0 technologies into the cement production sector, aligning with Holcim’s ambitious "Plants of Tomorrow" initiative.
## Key Benefits in a Nutshell
The Elios 3 brought several advantages to the table:
- **Full Coverage**: Unlike terrestrial laser scanners, the Elios 3 achieved comprehensive scans without leaving blind spots. This ensures no data gaps, whether in tight spaces or expansive areas.
- **Speed**: The Elios 3 drastically reduced the time required for scanning—from at least 10 days with traditional methods to just 1 day.
- **Minimal Disruption**: The plant could operate almost uninterrupted during the scanning process, minimizing downtime and maintaining productivity.
- **Cost Efficiency**: By eliminating the need for external contractors and expediting the workflow, the plant saved significantly on both time and resources.
Infrastructure managers worldwide are embracing digital twins to replicate physical environments. For industries like construction and manufacturing, BIM (Building Information Modeling) offers unprecedented precision in planning, execution, and maintenance. Whether designing skyscrapers or managing industrial facilities, BIM streamlines processes, reduces errors, and enhances collaboration across teams.
## BIM in the Cement Industry
Holcim, a global leader in cement production, has prioritized the "Plants of Tomorrow" initiative, aiming to infuse cutting-edge technologies into the building materials sector. This involves modernizing plant operations, fostering sustainable practices, and optimizing efficiency. One crucial component of this vision is creating digital twins of existing plants.
At this French facility, the goal was to generate a precise digital replica of the entire plant. This virtual model would serve as a blueprint for future developments, particularly in incorporating carbon capture solutions. It would also facilitate smoother communication with contractors and stakeholders, ensuring alignment with Holcim’s broader sustainability goals.
## Leveraging the Elios 3 for Scan to BIM
This plant already relied on the Elios 3 for asset inspections and stockpile monitoring. Its pilots trusted the drone’s accuracy and safety features, making it the logical choice for this BIM project. The challenge lay in capturing every detail, including hard-to-reach spaces between pipes and ducts extending high above the ground. Traditional methods would have required weeks of work and substantial costs, while the Elios 3 achieved the same result in a single day.
Post-processing the scans took an additional two days, culminating in a fully refined model within a week. The team aligned multiple flight datasets into one cohesive file, filtering out low-quality data caused by dust or excessive distance. Software like FARO Connect facilitated seamless integration of the Elios 3’s LiDAR data into the final BIM model.
## Transforming Plant Operations
The resulting BIM model exceeded expectations, offering unparalleled insights into the plant’s layout. This schematic design, categorized under Level 200 BIM standards, provided the precision needed for future engineering tasks. Architects and engineers now possess accurate blueprints to integrate carbon capture technology, including ducts, fans, filters, and heat exchangers.
Beyond aiding internal planning, this model strengthens the plant’s case for securing EU funding aimed at reducing carbon footprints. It also serves as tangible proof of the plant’s commitment to sustainable practices.
## Long-Term Value and Future Potential
The success of this Scan to BIM project underscores the Elios 3’s versatility. Future expansions or renovations can rely on this existing model, saving time and resources. Additionally, the drone’s LiDAR and ultrasonic capabilities will enable remote inspections, keeping personnel safe while maintaining operational excellence.
By adopting these technologies, the plant is not only meeting today’s demands but also preparing for tomorrow’s innovations. The Elios 3 continues to redefine how cement facilities approach digitization and sustainability.
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This real-time account captures the transformative journey of a traditional cement plant embracing modern technology. From initial skepticism to groundbreaking outcomes, the story reflects the convergence of innovation and practicality in industrial settings.
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