Using state-of-the-art 3D laser scanners, complex factories and workshops can be precisely measured. This is an advantage both when relocating completely and when replacing individual complex machines and systems.

SCHOLPP gained its first experience with 3D laser scanning on the mammoth project for Novalis Sheet Ingot GmbH. Between November 2013 and March 2015, Europe’s largest aluminum recycling plant was built in Nachterstedt, Saxony-Anhalt. Using the latest planning tools, a professional plan was created for the complex construction of the factory. SCHOLPP then monitored the entire construction site logistics for the global market leader for aluminum rolled products and aluminum recycling, carried out the new mechanical and electrical installations and supervised the commissioning.

In the past, most factory planning was usually carried out without 3D models. Companies therefore often only know the size and structure of their buildings thanks to CAD (computer-aided design) data. However, after a few years, these no longer correspond to reality. “Whether it is conversion or modernization measures, the replacement of machines and systems or the re-laying of cables and connections – every structural change creates a new current state,” says Benjamin Bielefeld, Managing Director of HÖRMANN Rawema Engineering & Consulting GmbH. The factory planner from Chemnitz has been working with 3D laser scanning since 2014 and supports companies in updating their data. His team has now completed 80 orders of various sizes, including one for Novalis with SCHOLPP as a competent partner for industrial assembly.

The topic of 3D layout was treated rather poorly by industry in the past. In the meantime, however, building data modeling has become significantly more important. With 3D laser scanning, images of the layout, structure and length of a factory or workshop can be taken with an accuracy of just a few millimeters within a very short time. These form the basis for subsequent topics such as “BIM – Building Information Modeling”. The result is ultimately a complete digital image with a large amount of visualized information. This forms the basis for optimized planning, execution and management. “Some companies have recognized the advantages and are using them for themselves, for example when building a new hall, relocating or replacing individual machines and systems,” explains Benjamin Bielefeld, whose employees have already carried out measurements in Sweden and Mallorca, among other places.

Many individual points and a complete picture

A 3D laser scanner – attached to a tripod – is always placed at neuralgic points in the hall. Using a laser beam and 360-degree rotations, it then records all the geometric data of its surroundings. Depending on the resolution level selected, several hundred million individual points can be generated. These then form the three-dimensional overall point cloud. Since a 3D laser scanner cannot see around corners or through massive systems and machines, recordings are made from several locations. If you have the 3D scanning process repeated regularly, you keep your existing and facade plans as well as floor plans, views and sections up to date and are always prepared for any new construction, conversion or expansion measures.

The effort required for a 3D laser scan depends on the scope of the task. “It starts with scanning individual machines and systems and can end with a large factory with several floors,” says Benjamin Bielefeld, describing the range and immediately giving an example. “For a company area of ​​10,000 square meters, three employees with three 3D scanners needed a whole day.” A single 3D laser scan takes a few minutes and can be carried out regardless of the time of day or light. In order to be able to work effectively, 3D laser scanning is often deliberately scheduled for a weekend. There are two reasons for this: firstly, production is usually at a standstill, and secondly, there are no employees there to walk through the image.

The time of the folding rule is over

Comprehensive 3D laser scanning is a good idea, for example, before a relocation. This gives assembly specialists like SCHOLPP access to relevant coordinates and can use them to create schedules for transport and assembly and discuss detailed coordination with the customer. Regardless of this, SCHOLPP always carries out at least one on-site inspection to ensure tailor-made planning, even if the folding rule is no longer used. Instead, the experienced eyes of the company’s planners and designers pay attention to details that may remain hidden from the 3D scan. This applies to the structure and interior of machines and systems that must be dismantled into their individual components as part of a relocation. Here, the know-how and expertise of specialists like SCHOLPP are still crucial to the success of the project.