Kopterflug inspects tanks, boilers, silos, chimneys, reactors and channels using the Flyability ELIOS 3 – without personnel entry, without scaffolding, without a DGUV-Befahrung (German confined space entry permit). The drone flies in, your team stays outside.
A confined space (German: enger Raum or umschlossener Raum) is defined under DGUV Regel 113-004 (German statutory accident insurance rules for working in vessels, silos and confined spaces) as any area that:
Typical industrial examples: tanks, boilers, silos, chimneys, columns, reactors, sewers and industrial furnaces.
Working in confined spaces is among the most hazardous activities in industry. Tanks, silos, boilers and shafts are often difficult to access, poorly lit, and carry significant risks.
The ELIOS 3 with its collision-safe carbon cage – designed for confined, dark and hazardous industrial environments.
At Kopterflug, we offer confined space inspection by drone to document hazardous interiors safely and efficiently. Our drone services set new standards: no human entry, no DGUV-Befahrung (confined space entry permit), no scaffolding, no rescue chain. The ELIOS 3 navigates GPS-independently using SLAM technology and LiDAR through confined spaces – collision-safe thanks to its fully enclosed protective cage. This allows us to precisely document corrosion, cracks, coating damage and structural anomalies.
A major advantage: drastically reduced downtime and costs compared to conventional entry. No gas measurement preparation, no ventilation, no safety guards – in many cases up to 80% cheaper. Our high-resolution 4K images, thermography recordings and LiDAR point clouds provide a reliable basis for assessment by your maintenance teams.
The ELIOS 3 in action inside an industrial power plant boiler – zero human entry required.
We inspect with the ELIOS 3 and systematically document all safety-relevant areas in confined spaces. The technical assessment is carried out by your maintenance teams – we deliver the data:
What we capture: 4K recordings of corrosion, wall thinning, pitting, weld seam damage, coating failures and cracks.
Why it matters: Corrosion in confined spaces is often invisible until failure occurs. Early detection prevents leakage, contamination and structural failure. Your experts assess findings based on our data.
How we do it: 4K camera from close proximity (ELIOS 3), thermography for hidden hotspots and moisture damage.
What we capture: Product residues and deposits from the previous medium, corrosion traces, coating damage, pitting and area-wide material loss at the vessel floor.
Why it matters: The floor of a vessel often gives the clearest indication of the overall asset condition. Media residues may have accelerated corrosion – visible through discolouration, pitting or exposed base material.
How we do it: 4K camera documents floor and wall transitions at close range; LiDAR captures geometry and unevenness precisely.
What we capture: Condition of agitators, pipelines, ladders, connections, internals and support structures.
Why it matters: Loose or damaged internals are safety hazards. We document the condition of all accessible components – without anyone needing to enter.
How we do it: 360° documentation with the ELIOS 3, 16,000-lumen LED lighting for the darkest environments.
What we capture: Deformations, settlements, wall thickness changes, volume changes and comparison measurements.
Why it matters: LiDAR point clouds deliver centimetre-accurate 3D models. Digital twins enable comparison inspections over years – damage progression becomes measurable.
How we do it: The ELIOS 3 LiDAR sensor generates real-time 3D point clouds (SLAM-based).
At the end, we hand over a detailed inspection report with 4K images, thermography evaluation (on request), LiDAR point clouds (optional) and a systematic findings overview. Your maintenance teams assess the findings and make the decisions.
Safe, precise, without human entry – and without complex DGUV confined space procedures or scaffolding: the ELIOS 3 handles all types of narrow, dark, hazardous or inaccessible spaces.
Crude oil tanks, fuel tanks, chemical tanks, water/wastewater tanks, ballast tanks (ships), pressure vessels – inspection without human entry and without DGUV-Befahrung.
Steam boilers, waste heat boilers, industrial furnaces, firing systems, reactor boilers, FCC units – documentation of wear and damage without DGUV-Befahrung. Findings list for certified inspectors (TÜV/DEKRA) in accordance with BetrSichV (German Industrial Safety Regulation).
Distillation columns, reactors, separators, scrubbers, process vessels in chemical/petrochemical plants – inspection in toxic or explosive atmospheres without risk (after gas-free measurement).
Chimneys, flares, flue gas lines, smoke ducts, industrial stacks – vertical and horizontal inspection without scaffolding or industrial climbers.
Cement silos, grain/feed silos, coal bunkers, raw material/ore silos, bulk material storage – condition survey without human entry.
Walkable profiles (from DN 1200), main collectors, sewers, special structures, penstocks, pressure pipelines, mining shafts – inspection without entry.
Ballast tanks, cargo tanks, double bottoms on ships and offshore platforms – inspection without scaffolding, without confined space entry.
Old adits, access drifts, ventilation tunnels in mining and infrastructure – mapping and condition capture without personnel risk.
Note: The ELIOS 3 is not ATEX-certified. Deployments in potentially explosive zones (Ex zones) are carried out only after gas-free measurement and operator clearance. Minimum access opening: approx. DN 600 (50–60 cm). Internal clearance of approx. 1.5 m recommended for full sensor use.
The ELIOS 3 is our primary system for confined spaces – tanks, boilers, shafts and pipes. Two complementary systems extend coverage:
| Aspect | DGUV-Befahrung (conventional entry) | Drone Inspection (ELIOS 3) |
|---|---|---|
| Human entry | Required – respiratory protection and safety guard (Sicherungsposten) mandatory | No entry – drone flies in, team stays outside |
| DGUV entry permit | Mandatory under DGUV Regel 113-004 | Does not apply to the inspection team |
| Rescue readiness | At least one person permanently standing by outside | Not required |
| Preparation | Gas measurement, ventilation, safety guards, permits – days | Gas-free measurement, access point – deployment in hours |
| Downtime | 2–5 days including pre- and post-processing | A few hours |
| Documentation | Photos by technician, spot-check and incomplete | 4K full coverage, thermography, LiDAR 3D model |
LiDAR 3D point cloud generated by the ELIOS 3 inside an industrial boiler – centimetre-accurate geometry data for documentation and digital twins.
The use of drones in confined spaces follows the relevant German regulations. The decisive advantage: no human entry means that DGUV Regel 113-004 (entry into vessels, silos and confined spaces) does not apply to the inspection personnel.
| Standard / Regulation | Relevance to Drone Inspection |
|---|---|
| DGUV Regel 113-004 | Governs entry into vessels, silos and confined spaces (German statutory accident insurance rules). With drone deployment: no human entry – DGUV 113-004 does not apply to the inspection team. |
| BetrSichV (German Industrial Safety Regulation) | Basis for inspection obligations on safety-critical plant. Kopterflug delivers findings data as a basis for certified inspectors (TÜV/DEKRA). |
| EN 12952 / EN 12953 | Standards for water-tube and shell boilers – basis for recurring inspections. Drone data as documentation foundation. |
| API 653 | Standard for tank inspections – drone data as basis for assessment by accredited inspectors. |
We analyse your confined space: which asset? which hazards? We select the optimal inspection method and assess technical feasibility based on your drawings. Free of charge and without obligation.
You receive a transparent quotation. Together we plan the timing, access and safety concept – coordinated with your teams and revision planner.
We carry out the inspection – always with at least two people (pilot + assistant) for maximum safety. Significantly faster than conventional entry. No human entry into the confined space.
You receive a detailed report with 4K images, thermography analysis (on request), LiDAR point clouds (optional) and a systematic findings overview. Typically delivered within a few working days.
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for confined space inspection projects.
Since 2017, Kopterflug has been inspecting confined spaces throughout Germany – from small boilers to large industrial tanks. As ELIOS 3 specialists, we document corrosion, thermography findings and 3D point clouds wherever human entry is hazardous or impossible. Our certified drone pilots have carried out hundreds of deployments in tanks, boilers, silos and shafts.
We work as a standard two-person team – pilot and assistant – with our own safety concept and gas-free measurement capability. We advise openly and without sales pressure.
24 questions on confined space drone inspection – from technical basics to practical deployment planning.
A confined space (German: enger Raum / umschlossener Raum) is defined under DGUV Regel 113-004 as any area not intended for continuous human occupation, with restricted entry and exit options, that may present hazards such as oxygen deficiency, toxic gases, explosion risk or structural collapse. Typical examples are tanks, boilers, silos, chimneys, columns, reactors and sewers.
The ELIOS 3 inspects virtually all types of confined spaces: tanks and storage vessels, boilers and combustion chambers, silos and bunkers, chimneys and shafts, columns and reactors, channels and large-diameter pipelines (from DN 1200), and industrial furnaces. The key requirements are an opening for drone entry and sufficient space inside.
The ELIOS 3 navigates GPS-independently using SLAM technology (Simultaneous Localization and Mapping). The integrated LiDAR sensor captures the surroundings in real time and creates a 3D map, from which the drone determines its position. Additionally, the fully enclosed protective cage ensures collision safety – the drone can touch walls and internals without crashing.
Before every deployment, we carry out a gas-free measurement (Gasfreimessung) with our multi-gas sensor, measuring O&sub2;, LEL (explosion limit), H&sub2;S and CO. The ELIOS 3 is not ATEX-certified – a gas-free atmosphere must be confirmed before the drone enters. We work as a standard two-person team (pilot and assistant) with our own safety concept; for some assignments also as three.
The ELIOS 3 can enter through a DN 600 manhole as the access point to the confined space. Inside, the drone requires approx. 1.5 m clear diameter to fly in a controlled manner and use all sensors. During the free initial consultation, we assess feasibility based on your plant drawings.
In many cases, the drone inspection fully replaces human entry – especially for visual condition surveys, thermography and LiDAR measurement. For certain checks (e.g. contact ultrasonic wall thickness measurement or repairs), a human entry may still be necessary. Our data allows your inspectors to decide precisely whether and where an entry is truly required – significantly reducing risk and effort.
You receive a detailed inspection report with 4K images of all documented areas, LiDAR 3D point clouds for geometry measurement and digital twins, and on request thermography recordings for hotspots, leaks and insulation damage. All findings are systematically documented with positional reference.
Our inspections follow DGUV Regel 113-004 (working in vessels, silos and confined spaces) and BetrSichV (German Industrial Safety Regulation). Since no human entry occurs, the confined space entry requirements of the DGUV do not apply to the actual inspection. The documentation is structured so that your inspectors and experts can assess findings on this basis.
The decisive advantage: nobody has to enter the vessel. This eliminates the greatest confined space risks: no exposure in hazardous atmospheres, no respiratory protection inside the vessel, no rescue chain required. Gases, oxygen deficiency, falls, narrow escape routes – all these affect only persons, not the drone. We have carried out hundreds of deployments in tanks, boilers and silos – more on our pages for Tank Inspection, Boiler Inspection and Silo Inspection.
Savings arise primarily from three factors: no scaffolding, no complex DGUV confined space preparation, and significantly shorter deployment duration. What classically takes days is often completed in a few hours with the drone. In many cases, up to 80% cost savings are achievable. We have inspected hundreds of vessels, boilers and silos ourselves – more on our Tank Inspection and Boiler Inspection pages.
Yes – and this is one of the primary application areas. The 4K camera of the ELIOS 3 enables close-up imaging of weld seams, wall areas and internals that are often difficult to reach in conventional entry. Corrosion, cracking, coating breakdown and erosion become clearly visible and documentable. We have confirmed this in numerous own deployments – more on our Tank Inspection and Condition Documentation pages.
Yes. The ELIOS 3 is equipped as standard with an integrated thermography camera (Thermografiekamera). This makes temperature differences visible – indicating moisture, insulation defects or thermal anomalies in vessel walls. Thermography is an indication method, not a substitute for further testing procedures. We deploy thermography in many of our confined space assignments – more at Confined Spaces Inspection and Condition Documentation.
Depending on vessel size and sensor package, typically just a few hours – compared to the multi-day preparation and execution time of conventional entry. In many cases, multiple assets can be processed in a single deployment day. We plan the deployment in advance with your revision planner. More on the process: Confined Spaces Inspection.
The ELIOS 3 is built precisely for these situations: the carbon protective cage absorbs light collisions, and the drone stabilises autonomously. In the event of a flip, it independently returns to normal orientation. Reverse motors enable active manoeuvring when caught. In our own deployments in tanks, boilers and silos we have experienced this repeatedly – no crash, no damage. More on the technology: ELIOS 3 at Kopterflug.
The risk is very low by design, but cannot be fully excluded. Therefore, all deployments are planned with a clear retrieval and safety concept. In our long-standing experience with hundreds of vessels, boilers and shafts, this is not an obstacle – but a calculable risk with appropriate planning. We discuss our safety concept openly during the initial consultation.
Yes – with the optional Cygnus Ultrasonic Payload (Ultraschall-Payload), the ELIOS 3 enables georeferenced wall thickness measurements in flight. This allows corrosion mapping without human entry. We offer this service in our deployments for Tanks and Boilers. The UT payload makes physical contact with the inner wall to measure wall thickness; LiDAR alone only measures geometry.
Yes – this is one of the strategic advantages. Georeferenced LiDAR data and structured 4K image series enable direct comparison between inspection cycles. Corrosion progression, new damage and geometry changes become measurable and documentable. This forms the basis for condition-based maintenance (zustandsbasierte Instandhaltung) and RBI decisions. More: LiDAR Survey, Condition Documentation.
Yes. Vertical structures such as shafts, industrial chimneys and flue gas ducts are among the classic applications of the ELIOS 3. The drone flies vertically, documenting inner walls along their full height without scaffolding or industrial climbers. We offer this as a standalone service: Chimney Inspection.
Yes, within its technical limits. The ELIOS 3 has IP44 protection rating (dust and splash water); the LiDAR payload is even IP68 rated. It operates reliably in humid, dusty and dimly lit environments. In cases of extreme dust concentration or aggressive media, we discuss suitability with you in advance. We have confirmed this in many own deployments – e.g. in Silos, Sewer Systems and Tanks.
Our certified drone pilots have been specialised in confined space deployments since 2017. We work as a standard two-person team – pilot and assistant – with our own safety concept and gas-free measurement equipment; for some assignments also as three. We know the specific characteristics of tanks, boilers, silos and shafts from practical experience with hundreds of deployments. More on our team and approach: Confined Spaces Inspection.
Yes – since 2017 we have personally inspected hundreds of vessels, boilers, silos and shafts. On our sector-specific pages you will find deployment descriptions: Tank Inspection, Boiler Inspection, Silo Inspection, Chimney Inspection, Sewer Inspection. External references from Flyability: Tank and Boiler case studies.
The ELIOS 3 is the only drone that makes real confined spaces reliably flyable: collision-safe carbon cage, GPS-independent SLAM navigation, 16,000-lumen lighting for completely dark spaces, LiDAR and optional thermography. Other drones are either too fragile, too large or not designed for narrow, dark interiors. We have deployed the ELIOS 3 in our own operations since 2017 and know its strengths and limits from practice. More on the technology: Flyability ELIOS 3 at Kopterflug.
Drone inspection reaches its limits with: openings below approx. DN 600 (too narrow for the ELIOS 3), active ATEX zones without gas-free measurement (the ELIOS 3 is not ATEX-certified), temperatures above approx. 50–55°C inside the vessel (plant must be fully cooled), contact-based testing procedures such as direct manual ultrasonic wall thickness measurement, and legally prescribed inspections by licensed inspection personnel – here the drone can do preparatory work, but cannot replace the certified inspector. When in doubt, we assess feasibility in advance during a free initial consultation.
As a rule, the effort on your side is minimal: access to the plant (manhole, inspection opening), information on atmospheric conditions in advance (we carry out our own gas-free measurement), a brief safety briefing by your on-site safety officer, and – for vessel inspections – a cooled-down, depressurised plant. We draw up the safety concept, coordinate permits and align the process with your revision planner in advance.
Questions about confined space drone inspection? Need a quote or want to assess feasibility for your plant? Fill out the form below – we respond within 24 hours.