C-Bird used the Elios 3 to inspect the hull of a cargo ship, achieving results that were safer, faster, and more efficient than ever before.

Key Benefits at a Glance

SAFETY: By using the Elios 3 for hull inspections, C-Bird eliminated the need for scaffolding in cargo tanks, saving approximately 10,000 hours of work at height in confined spaces.

COST SAVINGS: Replacing scaffolding with the Elios 3 during the vessel survey led to a direct cash saving of around $1 million, along with significant time and logistics savings.

ENVIRONMENTAL IMPACT: Using a drone instead of rafting avoids creating large volumes of oil-contaminated water that require treatment before disposal.

DATA QUALITY: The onboard LiDAR on the Elios 3 enabled accurate data localization, making it easier to share findings with all stakeholders during the survey.

Over 90% of the world's cargo vessels are subject to the IACS Common Structural Rules (CSR), which set standards for design, construction, and operation of ships.

The CSR ensures that vessels meet specific structural criteria based on their classification. Once in service, a vessel must renew its class certification every five years, and a major part of this process is the hull survey, which assesses the ship’s structural integrity.

Crude oil tankers face particularly challenging inspection requirements because much of the structure inside the Cargo Oil Tanks (COT) is out of reach. Traditionally, this required either building scaffolding or filling the tanks with water—a process known as rafting.

The scale of a cargo tank is immense—scaffolding here can rise tens of meters high, making detailed inspections difficult.

As a vessel ages, the complexity of hull surveys increases. For ships over 15–20 years old, the cost of erecting scaffolding alone can exceed $1 million, which represents a significant portion of the total project cost for class renewal.

Erecting scaffolding poses safety risks, including working at height in confined spaces and the potential for foreign objects like scaffold tubes or tools to be left behind, causing damage later. Rafting also presents environmental and safety challenges, such as managing large volumes of contaminated water.

Seeking an Alternative for Efficient Hull Inspections

A U.S.-based oil tanker fleet operator needed to conduct a No. 4 Special (20-year-old) periodical survey on one of its vessels. The 250-meter ship, classified by the American Bureau of Shipping (ABS), was undergoing dry docking in Southeast Asia for class renewal and other maintenance tasks.

The company had been using C-Bird’s services for several years and had already seen significant reductions in scaffolding needs thanks to the Elios 2. This collaboration helped them improve efficiency and safety across their fleet.

The goal was to perform the hull survey using the Elios 3 without any personnel entering the hull, minimizing risk while collecting all necessary data. Initially, an underwater ROV was considered, but C-Bird’s experience with the Elios drones made it clear that the drone was the better option in this case.

Inspecting the Ship’s Hull with the Elios 3 Drone

C-Bird pilot Malcolm Connolly had previously used the Elios 2 for similar projects but opted for the new Elios 3 for this particular mission. He wanted to take advantage of the LiDAR live map feature to navigate areas where he couldn’t see the drone directly. He also tested the new UT payload for ultrasonic thickness measurements.

Malcolm guides the drone through the empty space during the hull inspection.

The Elios 3 was flown into the cargo tanks without anyone entering the space. Malcolm flew the drone around the entire hull, capturing 4K video footage and a simultaneous 3D LiDAR scan of the structures. The data was then imported into Inspector 4 for processing.

After processing, the comprehensive results provided a full 3D reconstruction of the area, ensuring no uncertainty about what was surveyed or where anomalies were found. This level of detail significantly improved the accuracy and reliability of the inspection.

The Elios 3 combines LiDAR data with a visual feed for enhanced inspection accuracy.

How the Elios 3 Transforms Hull Inspections in Maritime

The Elios 3’s 3D Live Map allowed the C-Bird team to ensure complete coverage of the inspection areas from the safety of the ship’s deck, eliminating the need for human entry into the COTs. This not only improved safety but also reduced the risk of dropped objects and minimized manual handling, vessel crew support, and setup time for each tank.

Malcolm Connolly, CEO and founder of C-Bird, emphasized the benefits of the Elios 3: “The 3D laser scan produced by the Elios 3 allows for precise data localization. This brings us closer to true risk-based asset management and automation. Being able to repeat surveys accurately and measure changes over time opens the door to predictive maintenance using machine learning.”

He highlighted several key advantages of the Elios 3, including:

• Full data coverage via the 3D live map, ensuring all required areas are inspected despite the size and uniformity of the tanks.

• Enhanced safety by reducing human entry into confined and high-risk environments.

• Cost savings from eliminating scaffolding and downtime.

• Performance in extreme conditions, such as high temperatures up to 45°C.

Transforming Hull Inspections with Drone Technology

Thanks to the Elios 3, C-Bird completed a safer, faster, and more efficient hull inspection. By avoiding scaffolding, they saved over 10,000 hours of working at height.

C-Bird and their client both appreciated the simplified logistics and reduced environmental impact, as there was no need to fill the tanks with water for rafting. They also recognized the drone as a viable alternative to underwater ROVs for hull inspections.

The Elios 3’s 3D mapping provided inspectors with enough accurate data to successfully renew the ship’s class certification. This case study highlights how advancements in drone technology are reshaping the maritime industry, offering safer, more efficient, and more sustainable inspection solutions.

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