Kopterflug inspects high-bay warehouses with the Flyability ELIOS 3: 4K footage with 0.2 mm/pixel resolution and LiDAR 3D model – without dangerous RBG traversal, without height workers, supporting DIN EN 15635. Logistics, industry, cold storage – nationwide.
The ELIOS 3 flies through the rack aisles – both sides, full height, without any personnel at risk.
At Kopterflug we are specialists in drone inspections with the Flyability ELIOS 3. We support logistics companies, industry, warehouse operators and inspection associations in inspecting high-bay warehouses per DIN EN 15635 – without RBG traversal, without risk to personnel, during ongoing operations.
High-bay warehouses are often 20–40 m high, with narrow rack aisles and hard-to-access areas. Our ELIOS 3 inspections help you identify damage such as deformations to uprights, cracks, bolt damage, corrosion and impact damage early – avoiding unplanned failures. We deliver high-resolution 4K footage and LiDAR 3D models – your inspectors and experts assess the findings per DIN EN 15635.
| Area | What we document | Why it matters |
|---|---|---|
| Rack uprights & posts | 4K footage of deformations, cracks, corrosion, impact damage, deformations at load-bearing uprights | Damaged uprights can cause collapse of the entire racking system. DIN 15635 requires regular inspection. |
| Beams & cross-members | Detailed footage of deformations, cracks, overload damage, corrosion, weld problems | Overloaded or damaged beams can break and drop pallets. We deliver data for your technical assessment per FEM 10.2.02. |
| Bolts, hooks & locking mechanisms | Condition of safety bolts, beam hooks, locking pins, missing parts, age-related damage | Missing or damaged bolts/hooks are a frequent cause of racking damage. DIN 15635 requires inspection of these safety-critical parts. |
| Impact protection & floor fixings | Damage to impact protection systems, floor fixing damage, settlement, floor cracks | Damaged impact protection and loose floor fixings can endanger stability of the entire racking. |
| Diagonal braces & frame stabilisation | Condition of diagonal struts, cross-braces, screw connections and frame connections over the entire rack height | Loose or missing diagonal braces reduce frame stiffness significantly. DIN EN 15635 explicitly requires inspection of these connections. |
The ELIOS 3 with its collision-safe carbon cage – designed for narrow rack aisles and full rack heights.
| Aspect | Classical (RBG traversal / elevated platform / height workers) | Drone (ELIOS 3) |
|---|---|---|
| Safety risk | Fall hazard at 20–40 m, crush risk from RBG | Zero risk – no personnel at height |
| Operations shutdown | Partial or full – aisles must be closed | Only inspected aisle temporarily cordoned |
| Time | Days to weeks for large installations | Multiple aisles per day |
| Resolution | Handheld camera, limited angles | 4K with 0.2 mm/pixel from close range |
| 3D model | Not possible | LiDAR 3D model of complete racking |
| Documentation | Handwritten notes, few photos | Position-referenced 4K + LiDAR data |
We assess your warehouse: rack height, aisle widths, number of aisles, specific inspection requirements per DIN EN 15635. We advise you at no charge on which areas are priority.
You receive a transparent fixed-price quote. We plan the deployment – coordinated with your warehouse operations and, if needed, your rack inspector.
Our pilot flies systematically through your rack aisles – both sides, full height, from base plate to top beam. 4K footage for visual documentation, LiDAR for 3D model and deformation measurement.
You receive a detailed report with 4K footage, LiDAR 3D model, systematic damage overview with rack position assignments. Documentation per DIN EN 15635, DGUV Rule 108-007 and FEM 10.2.02.
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for high-bay warehouse inspection projects.
Christian
Founder & Drone Pilot
Karsten
Founder & Managing Director
Philipp
Founder, Mission Planning & Logistics
Juliana
Drone Pilot
Stephan
Mission Planning & Logistics
Since 2017, we have been inspecting industrial installations with drones. We support logistics companies, industry and warehouse operators with ELIOS 3 inspections – supporting DIN EN 15635 documentation.
Yes – with one prerequisite: the drone delivers the required image and measurement data; the assessment and damage classification (green/yellow/red) is still performed by a qualified inspector. We deliver the data, your inspector makes the assessment.
Yes. The ELIOS 3 is specifically designed for confined environments with its protective cage. It navigates safely through rack aisles from approx. 1.2 m width – even at great heights. The cage protects the drone and prevents damage to the racking.
No. The ELIOS 3 has its own 16,000 lumen lighting – even dark rack areas, upper levels and poorly lit aisles are fully captured. This is a clear advantage over handheld cameras.
The ELIOS 3 is collision-protected – its carbon protective cage is specifically designed for confined spaces with obstacles. Light contact with rack struts or uprights typically does not affect the flight. No racking damage is expected from brief contact – the drone's mass and energy are too low for significant impact.
Yes – that is the decisive advantage. Upper cross-beams, diagonal braces, rear column areas and base plates are fully documentable – areas that are often inaccessible or unsafe to reach in classical inspections.
Typical findings: deformations and impact damage to uprights and beams, cracks and weld defects, missing or loose bolts and hooks, corrosion, deflection and damage to floor fixings.
The ELIOS 3 delivers 4K footage with 0.2 mm/pixel resolution at close range. Deformations, cracks, corrosion, impact damage and missing bolts are clearly detectable. Additionally, LiDAR measures deformations with centimetre accuracy.
Yes, on request. The LiDAR-based 3D model enables precise location of damage, reproducible deformation measurements and traceable documentation across multiple inspection cycles.
You receive structured image and video data with clear assignment of each finding to the rack position, optionally supplemented by LiDAR 3D data. All results are traceably documented and prepared so that your inspector can assess them directly.
Generally not completely. The inspected rack aisle must be cordoned off during the flight – adjacent aisles can continue operating. In automated warehouses (AKL) we coordinate individually with your operations team.
Typically we inspect several rack aisles per day – both sides, full height. This is significantly faster than classical RBG traversals, which in large installations can take weeks.
Typically up to 35–40 m height. For larger installations the inspection is carried out in sections with battery changes – the GPS-independent SLAM navigation of the ELIOS 3 functions throughout.
Yes with limitations. At temperatures close to 0°C the ELIOS 3 can be used without restriction. At deep-freeze temperatures below −10°C flight time is greatly reduced – deployments are possible but only in sections or with individual coordination.
No. The drone does not replace the inspector but supports them. We deliver the high-resolution data (4K footage, LiDAR 3D model), which your rack inspector or expert uses as assessment basis. The formal inspection responsibility remains with the qualified inspector.
Yes – this is actually our recommended procedure. We coordinate in advance with your inspector or expert so that the documentation precisely meets their requirements. On request the inspector can be present during the flight.
Not under aviation law – drone flights in buildings are not subject to aviation law and require no official permits. Internally we naturally coordinate the deployment with your safety officer and relevant departments in advance.
Optionally yes. Thermography can be useful for specific questions – for example structural anomalies or temperature differences in temperature-controlled areas. We clarify in advance whether it makes sense for your specific installation.
At least annually to support the expert inspection per DIN EN 15635. For warehouses with high throughput, heavy loads or frequent forklift movements we recommend more frequent intervals.
Costs depend on warehouse size, number of aisles and rack height. Compared to the classical method (RBG traversal, elevated platforms, height workers) you save considerably with drone inspection. We prepare a transparent fixed-price quote on the basis of your information.
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