Kopterflug inspects cement plants with the Flyability ELIOS 3 – Drehrohröfen, cement silos, chimneys, conveyor systems – LiDAR, thermography and 4K documentation. No human entry into hazardous areas. Germany-wide, since 2017.
Cement plants operate with extreme temperatures, abrasive materials and confined spaces. We inspect all safety-critical assets – without scaffolding, without human entry:
The Flyability ELIOS 3 – our primary system for all interior inspections in cement plants.
Our services:
From cement plants in Hannover (HeidelbergCement), Duisburg, Nürnberg, Dortmund to Karlsruhe – we inspect cement plants throughout Germany.
Cement plants are among the most demanding industrial environments for inspections. Rotary kilns with refractory lining, cement silos with build-ups, chimneys with abrasion and conveyors under continuous load – wherever conventional inspection requires scaffolding, climbers or confined space entry, substantial costs and safety risks arise.
Production shutdowns in the cement industry are particularly costly. Every hour a rotary kiln stands still means production loss. At the same time, refractory linings wear at different rates – condition data is the basis for targeted maintenance planning instead of generic calendar intervals.
The Flyability ELIOS 3 enables inspections directly after cooling: 4K video, thermography and LiDAR-3D document rotary kilns, silos and chimneys – without scaffolding, without human entry. On steel components such as chimney steel shells, the UT payload additionally delivers geo-referenced wall thickness values – for refractory linings or concrete walls, other methods are used instead.
We fly the ELIOS 3 into silos, kilns, chimneys and conveyor shafts and systematically document wear, corrosion and structural damage. Technical evaluation is carried out by your maintenance engineers and inspectors – we deliver the data:
What we check: Wall corrosion, concrete shell breakouts, bridging, deposits and build-ups, condition of discharge equipment
Why it matters: Cement and clinker silos are subjected to extreme abrasive loads. Build-ups and concrete shell breakouts can lead to silo collapses – conventional inspection by entry is risky due to dust atmosphere and confinement.
How we do it: ELIOS 3 navigates through the manhole into the silo – 16,000-lumen lighting makes build-ups and wall damage visible even in dusty conditions; LiDAR documents wall geometry and breakouts metrically.
What we check: Condition of refractory lining (brick displacement, cracks, spalling), corrosion on steel shell, damage to internals
Why it matters: The refractory lining of the rotary kiln is the decisive cost factor – an early-detected local damage costs a fraction of an unplanned full repair. Every hour of kiln downtime costs significantly.
How we do it: ELIOS 3 flies after kiln cooling (<50°C) through the inlet opening – thermography detects hotspots and areas with damaged lining; LiDAR documents geometry deviations and lining thicknesses.
What we check: Wall corrosion, cracks and material damage inside, sooting, condition of liner and compensators
Why it matters: Cement plant chimneys carry aggressive, dust-laden flue gases and are therefore above-averagely at risk of corrosion. Interior inspections by scaffolding or rope access are expensive and risky.
How we do it: ELIOS 3 with tether power unit for chimneys up to 300 m – LiDAR documents wall geometry and plumb deviations; colorization visualizes corrosion zones in colour.
What we check: Wear on conveyor chutes and shaft inner walls, deposits, damage to walkways and internals
Why it matters: Conveyor shafts and transfer points are weak points with abrasive materials such as clinker and raw meal. Wear is often only noticed at breakdowns – early documentation enables plannable shutdowns.
How we do it: ELIOS 3 flies conveyor shafts top to bottom – even tight and convoluted geometries are fully captured; 4K documentation shows wear patterns on shaft inner walls.
What we check: Deposits, clinker build-ups, corrosion on tube bundles and internals, condition of cooler beds and grate plates
Why it matters: Clinker build-ups in coolers and heat exchangers reduce heat transfer and increase energy consumption. Damage to grate plates and cooler beds is conventionally only detectable at full dismantling.
How we do it: Thermography identifies hotspots and areas with reduced cooling; ELIOS 3 documents internal geometry and build-ups from close range.
What we check: Corrosion, cracks and deformations in steel structures, walkways, support frames and silo supporting structures
Why it matters: In dust-rich cement plant environments, steel components corrode significantly faster than in other industries. Elevated structural components are often only inspected during expensive rope access or aerial platform operations.
How we do it: DJI M30T (exterior areas) and ELIOS 3 (tight interior areas) – thermography for hotspots at bearings and joints; LiDAR for structural geometry and deformation analysis.
At the end, we hand over a detailed inspection report with 4K images, thermography evaluation and optionally LiDAR point clouds. Documentation according to BetrSichV and the relevant standards for pressure vessels and combustion systems. Technical evaluation and all maintenance decisions remain with your engineers and inspectors.
Rotary kilns, cement silos, chimneys – extreme heat, abrasion, dust exposure. Human entry requires DGUV measures, scaffolding and extensive preparation. ELIOS 3 inspects in hours – without human entry, with 4K + Thermography + LiDAR + UT.
With the Flyability ELIOS 3, we inspect safety-critical assets in cement plants – precisely, safely and with minimal downtime. Up to approx. 80% cost savings compared to conventional methods:
Visually document the condition of the refractory lining: 4K video for cracks and spalling, thermography for thermal anomalies, LiDAR-3D for geometry capture and wear profiles. Abrasion rates become measurable over repeat flights.
Document bridging, build-ups and liner damage. LiDAR volume measurement for stock assessment and capacity planning. Without entry, without cleaning.
Interior inspection of industrial chimneys – without scaffolding, without climbers. UT wall thickness measurement on the steel shell, visual inspection of masonry and liner pipes.
LiDAR scan of bulk material stockpiles in storage halls – volume measurement for stock assessment, digital twins for plant planning. Centimetre-accurate, reproducible, without manual survey.
Inspection of cyclones, risers and connection ducts in the preheater – extremely hot, tight, classically barely accessible. Thermography shows hotspots, LiDAR captures constrictions and build-up volumes.
Inspection of calciners and air ducts between kiln and preheater. Document lining wear, deposits and thermal anomalies without human entry.
Inspection of cooler channels, grate plates and air distribution zones. Thermography shows worn zones and thermal irregularities without scaffolding.
Inspection of large-diameter connection ducts between kiln, filter and chimney. LiDAR captures deposit volumes, thermography shows leaks.
Inspection of filter chambers, collection hoppers and housing structures – conventionally extremely laborious with scaffolding. Drone flies into the chamber and documents completely without extending downtime.
Inspection of mill housings and interiors after shutdown – document wear on impact surfaces, material build-ups and foreign objects without laborious dismantling.
Inspect cooling water basins, sedimentation basins and wastewater ponds without emptying and without divers – ROV inspection with 4K camera. Completely document base, wall surfaces and internals.
The ELIOS 3 inspects rotary kilns, mills and silo inner walls. The DJI Matrice 30T complements for chimneys, outer shells and silo exterior walls.
Rotary kiln outer shell, chimneys, silo exterior walls – thermographically and visually from the air, without scaffolding and without operational shutdown.
Inspect cooling water basins, sedimentation basins and wastewater ponds without emptying and without divers – ROV inspection with 4K camera.
We discuss the plant, access routes, cooling times and your inspection requirements. Free preliminary clarification.
You receive a transparent quotation including on-site time, sensors and report scope. Together we plan the deployment in the maintenance window.
We arrive with ELIOS 3 and inspect rotary kilns, silos, chimneys. Live feed for your maintenance planners. At least two people on site.
Detailed report with 4K recordings, 3D models, thermography analyses and UT measurement data. Audit-proof archiving.
Our inspections meet the highest safety and documentation standards:
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for cement plant inspection projects.
Active since 2017 – numerous inspections in heavy industry and the building materials sector. We know the requirements of cement plants: tight maintenance windows, extreme conditions, precise documentation for maintenance planning.
Yes, deployment is generally possible when carried out within the framework of the operational hazard assessment and applicable regulations. Drones are used in particular to avoid hazardous confined space entries and human entry. An overview of typical applications in cement plants is described by Flyability at flyability.com/cement-plant-drone-inspections. More on our confined spaces deployments: Confined Spaces Inspection.
Yes, especially after shutdown and sufficient cooling to below 50°C. Typical applications are visual detection of cracks and spalling, documentation of wear and optical assessment of lining conditions. Practical examples from cement plants (cyclones, calciner, clinker cooler) are shown by Flyability at casestudies/drone-digital-twin. More on our rotary kiln deployments: Confined Spaces Inspection.
Thermography can make temperature anomalies and potential weak points visible, for example with breakthrough risks, insulation problems or thermally stressed areas. The benefit is highly dependent on local conditions – the degree of cooling and residual heat influence the significance. Applications are described at casestudies/drone-digital-twin. More on thermographic inspections: Confined Spaces Inspection.
Yes – but with an important restriction: the UT payload of the ELIOS 3 operates with probes in the 2–7.5 MHz range and is optimised for homogeneous and metallic materials. On steel components such as the steel shell of chimneys or steel flue ducts, UT delivers reliable geo-referenced wall thickness values. For refractory linings or concrete walls of silos, the method is not standardly suitable – impact echo or through-transmission is used here instead. Application examples from the cement industry are shown by Flyability at casestudies/ut-drone-inspection-cement. Details on the ELIOS 3: ELIOS 3 at Kopterflug.
This depends strongly on the object – length, diameter, desired sensor technology and level of detail determine flight time. Practical examples show that drone inspections can in many cases be carried out significantly faster than conventional methods with scaffolding or climbing teams. Flyability describes the advantages at flyability.com/cement-plant-drone-inspections. More on inspection methodology: Confined Spaces Inspection.
For interior inspection of rotary kilns, silos and chimneys with the ELIOS 3, yes – the object must be cooled to below 50°C and emptied. The rotary kiln outer shell thermography via DJI Matrice 30T, however, is also possible during ongoing operation: hotspots are detected without shutting down the kiln. Details on deployment conditions: Confined Spaces Inspection.
In general yes – for visual inspection, LiDAR surveying and thermography in rotary kilns, silos and chimneys. Whether human entry is still required for supplementary measures (e.g. manual sampling) depends on the inspection objective. For pure condition assessment and damage diagnostics, the ELIOS 3 completely replaces entry. More at Confined Spaces Inspection.
You receive a complete inspection report with 4K video documentation, thermography analyses with temperature data and anomaly map, LiDAR-3D point cloud (geometry, volume measurement, wear profiles) and UT wall thickness values on steel components. All data is geo-referenced and archived – as a basis for maintenance planning and compliance documentation. More on our service scope: Drone Inspection Kopterflug.
In many cases, no. The ELIOS 3 can fly chimneys from the inside – without scaffolding, without a climbing team. Whether this is possible in an individual case depends on the inspection objective, geometry and accessibility. A practical example from a cement plant is shown by Flyability at casestudies/chimney-tower-inspection. More on chimney inspections: Chimney Inspection.
Practical examples exist even for tall installations. Important: feasibility always depends on geometry, signal connection and safety concept – blanket statements about maximum heights cannot be derived from this. Experience with chimney and stack inspections is shown by Flyability at casestudies/stack-inspection. All details: Chimney Inspection.
Typical findings are deposits, corrosion, cracks and spalling – both visually documented and (for steel components) quantified by UT wall thickness measurement. The steel shell of industrial chimneys is a typical application field for UT. Practical examples at casestudies/stack-inspection. More on chimney inspection: Chimney Inspection.
Yes, LiDAR enables 3D capture of geometries and build-ups. This makes bridging, wall deformations and unusual deposits visible – without entry. An example is shown by Flyability at casestudies/lidar-stockpile-measurement. More on silo inspection: Silo Inspection.
Yes, through LiDAR-3D data, volumes and fill levels can be estimated. Accuracy depends on material, surface properties and ambient conditions. Examples from stock assessment are shown by Flyability at casestudies/lidar-stockpile-measurement. Details on silo inspection: Silo Inspection.
Practical examples show clear advantages over conventional methods – particularly through elimination of scaffolding, fewer personnel in hazardous areas and faster execution. The actual effect is always project-dependent. Flyability shows relevant applications at casestudies/drone-digital-twin. More on our industrial inspections: Confined Spaces Inspection.
The ELIOS 3 is designed for tight environments and tolerates light contact thanks to its carbon protective cage. Nevertheless, every deployment is planned to avoid contact with sharp-edged or critical structures as far as possible. Our page on the ELIOS 3: ELIOS 3 at Kopterflug. Details on the design at flyability.com/elios-3.
Yes, through 3D point clouds and systematically documented inspection areas, changes can be quantitatively compared across multiple campaigns. This is particularly relevant for refractory wear, deposit development and structural changes. Examples at casestudies/drone-digital-twin. More on our inspection services: Drone Inspection Kopterflug.
Yes – especially for condition assessment, maintenance planning and documentation. 4K recordings, LiDAR point clouds and thermography data provide the basis for targeted maintenance decisions instead of calendar-schedule maintenance. Examples for scan-to-BIM and plant modelling are shown by Flyability at casestudies/drone-scan-to-bim. Details on our services: Drone Inspection Kopterflug.
Yes, especially for transfer points, hard-to-access areas and documentation of build-ups and wear patterns. Bucket elevators, belt conveyor transfers and elevator shafts are typical application fields. Typical applications in cement plants are described at flyability.com/cement-plant-drone-inspections. More on confined spaces deployments: Confined Spaces Inspection.
Yes. The ELIOS 3 has a maximum operating temperature of 50°C – plants must cool down sufficiently before inspection. Dust exposure influences both flight stability and data quality, especially for the camera. In potentially explosive dust atmospheres (e.g. cement or coal dust), the drone must not be deployed, as the ELIOS 3 is not ATEX-certified. Details on the ELIOS 3: ELIOS 3 at Kopterflug.
Decisive factors are experience with indoor drones in industrial environments, understanding of processes and hazards in cement plants, and a coordinated safety concept. A specific drone class licence is not the central factor for interior deployments without manned airspace – the industrial experience profile is more important. More about Kopterflug: Drone Inspection Kopterflug.
Yes, particularly from cement plants with cyclone inspections, digital twins of plants and chimney inspections. Flyability documents examples at casestudies/drone-digital-twin and a practical video at youtube.com (cement plant inspection). More on our deployments: Drone Inspection Kopterflug.
The advantage lies in overall effort: less downtime through eliminated scaffolding, fewer personnel in hazardous areas and faster execution without weeks of preparation. Concrete savings are project-dependent. Practical examples can be found at casestudies/chimney-tower-inspection. More on our offering: Drone Inspection Kopterflug.
This depends on plant, usage intensity and current condition. Typical are inspections before planned shutdowns for condition assessment, regular condition checks per BetrSichV and DGUV, and event-driven inspections after anomalies. A condition-based approach – instead of fixed calendar intervals – is often more economical for refractory-intensive plants. More on inspection intervals: Confined Spaces Inspection.
Yes – this is one of the most valuable deployments in cement plants. The DJI Matrice 30T scans the rotating steel shell of the rotary kiln with radiometric thermography during ongoing operation. Hotspots on the shell indicate refractory damage – detected early, before an emergency shutdown occurs. No downtime, no scaffolding, no production interruption. More on the DJI M30T: Drone Inspection Kopterflug.
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