From cracking to carbonation (Karbonatisierung) – modern inspection methods for safe structures. Drone inspections detect all 7 damage types early and without scaffolding. Since 2017, Kopterflug has been inspecting concrete structures throughout Germany.
LiDAR 3D scan of a retention basin (Regenrückhaltebecken) – concrete condition documented with centimetre accuracy.
Concrete forms the foundation of many industrial structures – from support pillars and foundations to chimneys and silos. In heavy industry and power generation in particular, concrete structures are exposed to high loads.
The challenge: Many damage types remain invisible for a long time and impair load-bearing capacity and service life. Modern drones with 4K cameras, thermography and LiDAR detect this damage early – without scaffolding and with up to 80% cost savings.
Our expertise since 2017: With modern drone technology, we inspect concrete structures throughout Germany.
| Damage Type | Detection Method | Key Indicator |
|---|---|---|
| Cracking | ELIOS 3 / DJI M30T (4K Zoom) | Cracks from 0.2 mm detectable; large-area capture |
| Spalling | ELIOS 3 / DJI M30T (4K + Thermography) | Exposed rebar immediately visible; thermography shows moisture |
| Carbonation | ELIOS 3 / DJI M30T (Thermography) | Thermography detects moisture as indicator; phenolphthalein test as supplement |
| Chloride Attack | 4K Camera + Thermography | Corrosion products and staining visible; thermography for moisture accumulation |
| Frost & Thaw Damage | 4K Camera + Thermography | Scaling, spalling; thermography for moisture accumulation |
| Sulfate Attack | 4K Camera (4K + Zoom) | Surface degradation, discolouration, crystal formation |
| Biological Growth | 4K Camera (Visual) | Algae, moss, lichens visible; root penetration damage |
Bending, shear and torsion cracks arise when strength limits are exceeded. Concrete has only approximately 10% of its compressive strength as tensile strength. Cracks allow moisture and pollutants to penetrate and promote rebar corrosion (Bewehrungskorrosion).
Surface damage from frost-thaw cycles, mechanical impact or rebar corrosion. Exposed rebar dramatically accelerates corrosion. Distinction between shallow (<5 mm), medium (5–20 mm) and deep (>20 mm) spalling.
CO₂ reacts with concrete and lowers the pH value from approximately 13 to below 9 – the passive layer of the rebar is destroyed. The carbonation front advances with √t (time). The process is visually invisible, but thermography detects increased moisture as an indicator.
Chlorides from de-icing salt, seawater or industrial processes penetrate the concrete and destroy the rebar passive layer locally – leading to pitting corrosion (Lochfraß). Particularly critical for reinforced concrete in coastal areas, bridge structures and parking garages.
Water in the concrete pores expands upon freezing and creates internal pressure that leads to cracking and spalling. Repeated frost-thaw cycles produce cumulative damage. Particularly critical: concrete with high water-cement ratio and inadequate air void content.
Sulfates from soil, groundwater or industrial wastewater react with concrete components. Ettringite formation (Ettringitbildung) causes expansion and concrete disintegration. Visible indicators: surface degradation, whitish deposits, crystal formation.
Algae, moss, lichens and roots on concrete surfaces are not merely aesthetic problems. Root penetration forces cracks open further; biological metabolic products (organic acids) attack the cement matrix. Particularly common on shaded, humid concrete structures.
Which concrete structures are particularly suitable? Especially structures with hard-to-reach areas: bridges (piers, superstructures, bearings), chimneys (exterior), cooling towers (interior and exterior), silos (exterior), industrial buildings (facades, roofs), retention basins and sewage treatment plants.
What drone inspections deliver for concrete structures:
Drones enable rapid capture of hard-to-reach concrete surfaces such as elevated bridge areas or concrete facades: no scaffolding required (60–80% cost savings), 60–80% faster than scaffolding methods, no height work with personnel risk, and regular inspections become economically viable for early damage detection.
Drones eliminate personnel risks during concrete inspection: no height work risk (bridges, chimneys often 20–50m height), no scaffolding with fall hazard, no dangerous access to structures, no exposure to environmental influences (cold, heat, wind). The inspection team stays on the ground.
Yes – modern drones often surpass the human eye: 4K–6K cameras with up to 200x zoom (DJI M30T) detect cracks from approximately 0.2–0.5 mm, radiometric thermography detects moisture and delamination, LiDAR creates precise 3D models for deformation measurement. For safety-relevant decisions, drone findings serve as the basis for targeted follow-up NDT testing.
Especially suitable: bridges (piers, superstructures, bearings), chimneys (exterior), cooling towers (interior and exterior), silos (exterior), industrial buildings (facades, roofs, fire protection), retention basins and sewage treatment plants, tunnels with GPS-independent navigation.
Drones enable more frequent inspections (more cost-effective): regular inspections (annually instead of every 5 years) enable early detection, thermography detects moisture before visible damage appears, 4K cameras document crack progression for trend analysis, and LiDAR enables measurable deformation monitoring over years.
Yes, indirectly through visual indicators: crack patterns (bending, shear, torsion cracks) provide indications of load type, spalling indicates rebar corrosion, thermography shows moisture infiltration paths. Note: drone inspection is visual pre-detection; structural engineering assessment and NDT testing are required for safety-relevant statements.
Comprehensive digital documentation: 4K videos of the entire inspection archived, high-resolution photos with GPS coordinates, thermography images show development over years, 3D models enable precise deformation measurement, and all findings are traceable for comparison inspections.
Yes, with some conditions: tunnels require GPS-independent navigation (ELIOS 3 with LiDAR-SLAM), good illumination (16,000 lumen LED), and systematic flight planning. Parking garages: ideal for ceiling inspections (rebar corrosion), column condition assessment, and crack monitoring. Generally: indoor structures require ELIOS 3; outdoor structures use DJI M30T.
Yes, through visual and thermographic capture: visual inspection detects scaling, spalling, surface cracks, exposed aggregate. Thermography detects moisture (precursor to frost damage), delaminations and zones of increased water saturation. Regular thermography inspections after winter are particularly valuable for bridges and exposed concrete structures.
Yes – significant cost savings: 60–80% cheaper than conventional methods with scaffolding, no scaffolding (often €20,000–100,000 saved), minimal downtime, low personnel requirements (2 inspectors vs. 8–15 persons), and early damage detection prevents expensive emergency repairs.
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