The Challenge
AsBuilt was contracted to provide laser scanning and 3D modeling services to support the installation of a new overhead monorail system at a power generation facility. The monorail was designed to be installed above a 3D conveyor system to facilitate the safe removal, installation, and maintenance of critical components, including:
- Conveyor motor
- Gearbox
- Head pulley
- Transfer chute
The installation area was structurally complex and densely populated with steel framing, platforms, mechanical equipment, and utilities. Accurate field verification was essential to:
- Confirm structural capacity and clearances
- Avoid clashes with existing utilities
- Ensure proper monorail alignment over serviceable equipment
- Support safe lifting and maintenance operations
- Reduce risk during fabrication and installation
Outdated drawings and undocumented modifications increased uncertainty, making high-accuracy reality capture necessary for design validation.
The Solution
High-Resolution 3D Laser Scanning
Acensium performed a comprehensive terrestrial laser scan (LiDAR) of the structure, equipment, and surrounding utilities above and around the 3D conveyor head assembly. The scan captured:
- Structural steel members and supports
- Conveyor components and head assembly
- Platforms and access structures
- Adjacent piping and utilities
- Overhead spatial constraints
The data was processed into a registered, colorized point cloud, creating a precise digital representation of existing site conditions.
3D Modeling & Structural Drawing Development
Using the processed scan data, a detailed 3D as-built model (DWG format) was developed to represent structural framing, equipment, and surrounding infrastructure. The model was used to:
- Develop and evaluate monorail design concepts
- Confirm structural clearances and load paths
- Accurately position overhead rails
- Ensure alignment with equipment maintenance points
- Perform clash detection prior to fabrication
In addition, 2D structural drawings were generated to support engineering review, fabrication planning, and installation sequencing.
Deliverables
- Raw laser scan data
- Post-processed, registered point cloud
- Photorealistic 3D visualization
- 3D as-built model (DWG)
- 2D structural drawings
Results & Impact
The integration of laser scanning and model-based design enabled precise positioning of the new monorail system while minimizing installation risk. The project improved maintenance accessibility for critical conveyor components, enhanced operational safety, and reduced the potential for field rework within an active power plant environment.
