In many cases 30 to 90 % cheaper than conventional methods. No rescue concept required. Findings report within 24 hours. Operating since 2017.
Most operators know the individual line items – but rarely the total:
What many underestimate: the biggest effort is not in the inspection itself – it is in the preparation.
The actual inspection is often the smallest part – the rest is organisation, risk and downtime.
A two-person team at the access hatch – inspection starts within minutes, not days.
The drone does not just replace the inspection itself – it eliminates the largest part of the preparation:
Typical order of magnitude for cost savings compared to conventional methods – depending on asset type and previous access requirements. Experience base: hundreds of industrial deployments since 2017.
In many projects the biggest saving does not come from the drone flight itself – it comes from these steps being eliminated entirely.
Wherever access, safety requirements and shutdown time create the greatest overhead.
Do not compare just quotation totals – compare the entire real-world effort.
| Cost Component | Conventional Inspection | Drone (Kopterflug) |
|---|---|---|
| Access equipment (Zugangstechnik) | Scaffolding or rope access: €5,000–190,000 depending on asset | Eliminated entirely |
| Personnel effort | 3–8 people, multiple days on site | 2 people, usually under 1 day |
| Safety overhead | Gas-free measurement, PPE, rescue concept (Rettungskonzept), permits | Technical assessment and flight planning – handled entirely by us |
| Shutdown duration (Stillstandsdauer) | 2–5 days, often full plant shutdown | 0.5–2 days, often possible in parallel with other work |
| Project complexity | Multiple trades, high coordination overhead, delay risk | One service provider, clear workflow, plannable |
| Documentation | Limited by accessibility | 4K video, images, optional thermography and 3D models |
| Total savings | – | Typically 30–90 % cheaper |
The greatest savings come not from the drone flight itself – but from the elimination of scaffolding (Gerüst), rescue chain (Rettungskette) and coordination overhead.
LiDAR 3D point cloud of a steel tank interior – centimetre-accurate geometry documentation without human entry.
We tell you clearly when a drone inspection offers no advantage – or is technically not possible:
In these cases we recommend conventional methods, or combine drone and conventional approaches – depending on what makes economic sense.
Direct contact – no detours.
This is all we need for a reliable initial assessment:
We give realistic effort assessments – and will tell you honestly if a conventional method makes more sense for your situation.
Christian Engelke
Managing Director & Chief Pilot
Karsten Lehrke
Dipl.-Ing., Senior Inspector
Philipp
Drone Pilot & Inspector
Juliana
Project Coordination
Stephan
Drone Pilot & Inspector
In most cases drone inspection is 30 to 90 % cheaper than conventional entry methods – the exact figure depends on asset type and previous access overhead. The greatest savings effect is not in the drone flight itself, but in the elimination of scaffolding (Gerüst), rope access (Seilzugang), confined-space entry process (Confined-Space-Entry) and multi-day shutdown. For a reliable estimate we need asset type, dimensions and access situation. Contact us for a free initial assessment.
Drone inspection regularly eliminates: scaffolding erection & dismantling (Gerüstbau und -abbau) (depending on asset, €5,000 to €190,000), industrial climbers or rope access, confined-space entry with gas-free measurement, PPE and rescue chain, and several days of production shutdown for coordination and infrastructure. Additionally, the internal coordination overhead for multiple trades is avoided. Experience base: hundreds of industrial deployments since 2017.
Conventional entry methods often require 2 to 5 days of shutdown – purely for scaffolding erection, coordination, entry process and dismantling. Drone inspection is in most cases completed within a few hours, maximum 1–2 days, including preparation and data backup. The findings report is available within 24 hours of the deployment.
For interior inspections (tanks, boilers, silos, shafts) a brief shutdown is required – but significantly shorter than with conventional methods, since no scaffolding is erected and no entry process is initiated. For exterior areas the DJI Matrice 30T can be deployed during live operation. Interior temperatures must be below 50 °C – boilers and furnaces must therefore have cooled to operating temperature.
Yes. The BetrSichV (German Industrial Safety Ordinance) prescribes the inspection obligation, not the method. The drone is a legitimate data-collection method. Since no human entry occurs, the requirements of DGUV Rule 113-004 for the inspection itself do not apply. Our documentation is regularly used by TÜV inspectors and authorised experts as an assessment basis. On request, we align scope and format with your inspector in advance.
The greatest economic lever comes wherever access equipment, safety overhead and shutdown are the biggest cost drivers: tanks and storage vessels, boilers and pressure vessels, confined spaces, chimneys, and pipelines of sufficient diameter. Particularly efficient: when multiple objects can be inspected in a single turnaround (Turnaround), sharing mobilisation time.
Drone inspection is not suitable when: access diameter is below DN 600 (minimum opening 50 × 50 cm required), ATEX zones without gas-free clearance (ELIOS 3 is not ATEX-certified), interior temperatures above 50 °C, or when contact-based NDT methods (kontaktgebundene ZfP-Verfahren) such as ultrasonic or magnetic particle testing are mandatory. In these cases we recommend conventional methods or a combination of both.
You receive a structured findings report (Befundbericht) containing: 4K video and photos of all captured areas, a position-referenced findings list (Befundliste) with type and severity of each anomaly, recommended actions, and optionally thermography evaluation and a LiDAR 3D point cloud for geometry and deformation evidence. The data package is audit-proof and directly usable by TÜV inspectors and authorised experts. More: Condition Documentation.
In urgent cases – e.g. unplanned shutdown or imminent revision – we are often on site within a few working days. This is a significant advantage over conventional methods that require scaffolding logistics, diver teams or multi-day lead times. For planned inspections we recommend a little lead time for coordination with your inspector.
Yes. Our documentation is regularly used by TÜV, DEKRA and authorised experts as an assessment basis. Kopterflug provides the data – assessment and acceptance rest with the respective inspector, oriented to BetrSichV, API 653 or the applicable standard. On request, we align report format and scope with your inspector in advance.
We operate as a standard two-person team: pilot and assistant (Pilot und Assistent). The assistant handles safety check, communication and data backup – this significantly improves quality and reliability compared to solo operation. For complex assets or multiple objects in a single deployment, the team can be expanded to three people.
The price consists of deployment fee, flight time and documentation effort. The deployment fee covers travel, equipment and preparation. Flight time depends on asset size and complexity. Documentation – findings report with 4K imagery, findings list and recommended actions – is included in the standard scope. Additional services such as LiDAR 3D models or thermography are quoted separately.
Yes. When multiple objects are inspected in a single deployment (e.g. during a turnaround), travel and mobilisation costs are shared – significantly reducing the unit price per asset. For framework agreements with regular inspection intervals we offer special conditions. Contact us directly – we calculate transparently based on your specific requirements.
Our base is in Bremen, and we operate throughout Germany. Travel costs are transparently listed in the quote and depend on the distance to the deployment site. For projects with multiple assets or multi-day deployments, travel costs are significantly reduced in proportion. For the greater Northern Germany area, only a small travel surcharge typically applies.
ROI is derived from the comparison of total costs: conventional inspection vs. drone. Do not just compare quotation prices – also factor in scaffolding costs, shutdown days (production loss per day), personnel effort for coordination and safety measures. In practice, the drone deployment often pays for itself through a single saved shutdown day alone. On request, we provide a comparative calculation for your specific asset.
No. Our quote covers deployment planning, execution, data backup and findings report – with no additional charges. Special services such as thermography, LiDAR 3D modelling or extended report formats are clearly communicated in advance and quoted separately. There are no costs for scaffolding, rescue concepts or additional safety measures – these items are eliminated entirely with drone inspection.
Thermography and LiDAR are optional additional services quoted separately per project. The ELIOS 3 features an integrated thermal camera and a LiDAR sensor – the additional effort therefore lies mainly in data evaluation and report preparation. Thermography is particularly suitable for detecting insulation damage and leaks; the LiDAR point cloud provides precise geometry capture and deformation evidence.
For large assets such as tanks exceeding 10,000 m³ or complex geometries (e.g. reactors with numerous internals), the effort for flight time and documentation increases – but proportionally far less than with conventional methods. Scaffolding costs for such assets would increase disproportionately, whereas the drone excels through agility and access efficiency. For large assets the relative savings are particularly high.
For operators with regular inspection intervals – such as annual tank inspections or scheduled boiler revisions – a framework agreement is economically sensible. You benefit from predictable costs, priority scheduling and reduced unit prices. We also document the development of findings over time, enabling better maintenance planning.
Production shutdowns cost between €5,000 and over €100,000 per day depending on industry and asset. Drone inspection typically reduces shutdown time from 2–5 days to a few hours or at most 1–2 days. The reduction by 1–3 shutdown days alone often exceeds the entire cost of the drone deployment. This lever is particularly significant in the process industry and energy sector.
Drone inspection is a regular operating expense for maintenance and inspection and is fully deductible – analogous to conventional inspection services. You receive a proper invoice with VAT stated. Whether the cost is allocated to maintenance, inspection costs or operational safety depends on your internal cost structure – consult your accounting department.
If a deployment cannot be carried out as planned – for example due to insufficient cooling or missing gas-free clearance – we clarify the conditions transparently in advance. Typically only travel and proportional mobilisation costs are incurred. To avoid such situations, we coordinate the technical prerequisites in detail with you beforehand.
Individual cost estimate within 24 hours – without an on-site visit. Operating since 2017.