Three-dimensional, fast and precise laser scanning is the most modern measurement method for buildings. Dürr is using the method worldwide in its paint shop modernization and expansion projects. When the scan data is combined with the plant plans in 3D, virtual models reveal possible collisions upfront. This means shorter installation times, reduced conversion costs and smooth processes.
Laser scanning has revolutionized property surveying. The laser beam records all relevant building features like parapet heights, doors or cable ducts as well as the existing production facilities. This will be done even in hard-to- access areas, in a non-contact measurement and from distances of up to 130 m. A software program then generates real, detailed images from the data.
“When working on brownfield projects, we are frequently confronted with the situation where there is either no documentation any more for factories and the sections they contain, or just analog original plans that have never been updated,” says Marc Altmann from the Engineering Department at Dürr Systems AG, while explaining the problem.
Virtual visit to the future
Laser scans bring the real world to the screen digitally, and thus provide the perfect basis for planning. For large industrial buildings, the data consist of hundreds of individual scans that are precisely matched using reference points. They provide a way of reviewing whether a customer’s vision is compatible with the structural conditions and the engineering of a painting line or final assembly line, namely, at a very early stage.
Dürr uses the method as early as during the tendering phase. Special computer technology processes the large volume of the scanning data and transfers it as photorealistic images or videos to the so-called Powerwall at the Dürr Campus in Bietigheim-Bissingen.
“We can take a virtual tour of any building, no matter where it is in the world, together with our customers here in the Powerwall room. This is much more visual than a plan on paper and makes it possible to identify and discuss complications in advance and find a good solution. This means that a paint shop can be executed as planned with a high degree of certainty when it comes to quality, schedule and costs,” explains Marc Altmann.
Laser scans identify all eventualities
In the next step of the process, the laser scans bring reality into the engineering department. Regardless of where a site is located, a design engineer can view the realistic image at his or her desk in Bietigheim-Bissingen. The exact scans have an accuracy of +/- 2 mm. A conventional measurement using a ruler or manual laser measurement could not reach this level of precision. Forgotten measurements can also be easily added on the screen.
“We create 3D CAD models for a project’s entire scope of delivery, and merge them with the laser scans. We therefore integrate our plant virtually on the PC into the reality of the building situation. This lets us see whether collisions might occur, for example due to an air duct in the way of the planned constructional steelwork,” says Marc Altmann.
This method visualizes the entire layout of the plant construction like dimensions and interfering edges, as well as areas where space for door openings needs to be included. Each individual part of the plant such as the conveying technology or the plant in its entirety with all components like spray booths and painting robots can be visualized.
The highly precise laser scans also show things that cannot be seen with the naked eye, like small tolerances in the floor. This knowledge enables the design engineer to react in good time and plan filler plates on the machines or specific minimum distances from the outset. It is not always possible to adapt the plant engineering to the building situation. “The laser scans let us see very clearly whether demolition will be necessary, which saves our customers time. This makes conversion work much easier than doing them while installation is underway,” says Marc Altmann.
Dürr is now using laser scanning almost as standard in modifications and expansions. In view of the growing requirements and the increasing complexity involved in the construction of paint shops, the innovative measurement method makes a valuable contribution to projects going smoothly on site.