The Challenge
A major wood products manufacturing facility purchased fabricated condensate tube bundles with mating expansion joints intended for installation during a limited outage window. The tube bundles were delivered to the plant site, while the expansion joints remained in storage at the fabricator’s yard two states away.
There was low confidence that the expansion joints would properly align with the installed tube bundles. A misfit during installation would have resulted in:
- Extended outage duration
- Additional shipping and fabrication delays
- Increased labor costs
- Production downtime and lost revenue
- Risk of the facility being inoperable until corrections were made
Given the tight installation window, confirming dimensional compatibility prior to shipment was critical.
The Solution
Onsite Laser Scanning of Tube Bundles
AsBuilt performed high-resolution 3D laser scanning (LiDAR) of the condensate tube bundles at the plant site. The scan data was processed into an accurate point cloud and converted into 3D models representing exact as-built conditions.
Remote Laser Scanning of Expansion Joints
AsBuilt then traveled to the fabricator’s yard and scanned the expansion joints using the same high-accuracy methodology. The expansion joints were modeled in 3D based on verified scan data.
Virtual Alignment & Fit Verification
Both datasets were brought into a coordinated Navisworks model, allowing the expansion joints to be virtually aligned and mated with the tube bundles.
This virtual fit-up process enabled:
- Exact dimensional comparison
- Flange alignment verification
- Bolt pattern validation
- Clash detection and interference analysis
- Precise gap and tolerance evaluation
The analysis revealed that the fit-up was not acceptable. As a result, the expansion joints were modified before shipment, preventing installation failure onsite.
Quick Facts
As-Builts Captured Across States
Even though the mating components were located in separate states, 3D scanning and modeling enabled accurate virtual alignment on a single coordinated platform.
Virtual Fabrication Inspection
Traditional tape-measure verification introduces measurement error and assumptions. Laser scanning provided exact geometry and eliminated dimensional uncertainty.
Shipping & Travel Savings
One technician and one scanner captured accurate data the first time, eliminating return trips. Thousands of dollars were saved by preventing shipment of incompatible parts.
Outage Risk Mitigation
The facility had a limited window for demolition and installation. Identifying the misfit prior to shipment avoided a scenario where the plant would be inoperable while awaiting corrections.
Deliverables
- Registered point cloud datasets
- Navisworks coordination model
- Clash detection analysis
- Fabrication inspection and fit-up verification documentation
Results & Impact
The project prevented a high-risk installation failure by identifying incompatibilities before shipment. Through 3D laser scanning, modeling, and virtual fabrication inspection, AsBuilt reduced outage risk, avoided costly shipping errors, and ensured the components were corrected prior to delivery—protecting both schedule and operational continuity.
