Large-Scale Laser Scanning Projects
March 17, 2025
Large-Scale Laser Scanning Projects
Joydeep Chatterjee | Senior Engineer - PMI Corps
Comprehensive Laser Surveys for Large Industrial Sites
Managing large-scale laser scanning projects goes beyond simple data collection—it's about executing precise scans and accurate registration across expansive areas, all while ensuring facility operations continue uninterrupted. Manufacturing facilities, warehousing facilities, scientific labs, hospitals, and beyond are a specific category of project that requires the utmost care due to their complexity and size. This complexity increases when multiple structures are involved, requiring careful coordination to capture each one accurately.The larger the site, the more challenging it becomes to maintain consistent accuracy while meeting tight schedules.
Scan registration control merges multiple scans to create a cohesive 3D representation of a site. This process ensures that all data collected from different angles fits together accurately, allowing for a precise and comprehensive view of the entire facility. Proper registration control helps prevent errors and inconsistencies, ensuring that the final model reflects the true layout of the space.
Many laser scanning service providers struggle in this area due to inadequate control measures. Implementing well-defined processes is crucial for ensuring accurate data capture and scan alignment. Without these safeguards, the quality of results can be unusable due to consecutive improperly registered scans, leading to delays and bloated
In this article, we’ll break down why these failures occur, how to avoid them, and why having a skilled team like PMC is essential. Our experience in managing large teams, staying on top of tight deadlines, and running multiple scanners 24/7 ensures we consistently deliver precise results without sacrificing efficiency.
Technology Used:
- FARO Terrestrial Scanners
- Navis mobile scanners
- Drones for outside work only
- Lyca Total Stations for secondary control
Major Considerations for Large Facility Projects:
- Utilizing high-resolution laser scanners and sophisticated 3D modeling software
- Employing effective planning and logistics coordination to streamline operations and enhance project delivery
- Implementing comprehensive data management strategies to ensure data integrity and accessibility throughout the project lifecycle
- Addressing accuracy challenges by adopting rigorous quality control measures
Ensuring 3D Laser Scanning Accuracy
Achieving accuracy across vast spaces requires the latest 3D scanning technologies and advanced registration techniques to align data from various vantage points via scan plans, Total Stations, and Secondary Control. This process necessitates frequent data review and powerful computing resources to handle large complex datasets after the scans are captured. Teams must quickly access and assess data to verify accuracy as part of the ongoing scan process, requiring expedient global data transfer. The ability to quickly and efficiently transfer information from various locations via the internet or dedicated networks allows teams to quickly access and verify the data early in the project. This registration and review process is just one major aspect that ensures the success of large-scale projects.
The Importance of 3D Modeling Data:
Proper archiving and backup are essential in large-scale scanning projects to prevent wasting valuable time and data. Each scan produces about 1.5 gigabytes of data, so a single error can lead to days of lost work and thousands of missing scans. To prevent such issues, we implement strict backup protocols and securely transfer all data over network and via hard drives. This doubled-down approach ensures that all information is preserved and readily accessible, maintaining the integrity of our scanning efforts. Handling such immense data volumes requires high-performance computers and rigorous quality control measures. Early data registration errors can cause significant inaccuracies over time. However, our experienced team quickly identifies and corrects these issues in the field, ensuring the accuracy and integrity of every project deliverable.
Total Stations and Secondary Control
Total stations measure angles and distances, establishing a network of accurate reference points throughout the project. This network helps create a precise framework that ensures all measurements and layouts are consistent, leading to reliable results in every phase of the project.
Secondary control creates additional reference points after primary control is set, ensuring precision over larger spaces. These points serve as checkpoints, helping verify registration and prevent cumulative project errors.
We expertly use control points to maintain precision over large areas, preventing errors and delivering reliable, measurable results. By employing the highest-precision total stations, mounted on metrology-grade tripods, we ensure absolute accuracy in large-scale laser scanning projects.
Facility Access and Timing
Managing access to the facility is critical for capturing large volumes of data without interrupting ongoing operations. This requires careful scheduling and coordination with plant personnel to perform scanning sessions during off-peak hours to maintain seamless plant operations. Planning and execution become even more essential for projects over 500,000 or even millions of square feet. PMC oversees these processes ensuring operations run smoothly and efficiently, minimizing disruptions while maintaining the highest accuracy standards.
Personnel and Assets
Large-scale projects require experience navigating complex environments, knowing when to move equipment, and the knowledge to ensure safety compliance, especially on massive sites with union involvement. PMC is accustomed to working with union representatives and plant management to ensure scan projects run smoothly. Effective communication and careful planning with all parties are crucial—you can’t just show up and start work. Engaging with unions early on and building a positive relationship is vital, as they can halt your work if not properly consulted. Scanning equipment is challenging to get up and running in the field, particularly when coordinating with active manufacturing schedules. Knowing who to talk to and what to ask is essential.
Conclusion
Successfully managing large-scale laser scanning projects in complex industrial environments and large complex facilities requires more than just technical skills—it demands precise coordination, proactive problem-solving, and a deep understanding of both the scanning technology and the project’s operational needs. By leveraging PMC's 20 years of large-scale project expertise, our skilled team can overcome the unique challenges of any project site, ensuring accurate, reliable data. Count on us to deliver what others fail to even attempt: Accuracy down to the millimeter even on projects over +1M sqft.
Let our experts show you how our services can support your projects!
Joydeep Chatterjee
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