Costs, duration, safety, data quality – an honest comparison from practice. We have been conducting drone inspections since 2017. In this comparison we are honest: the drone is superior in many scenarios, but not in all.
Every inspection faces the same question: How do I reach the damage spot? Scaffolding, rope access, aerial work platform or drone – each method has strengths and limits.
We have been conducting drone inspections since 2017 – initially with the ELIOS 1 and 2, today with the Flyability ELIOS 3. In this comparison we are honest: the drone is superior in many scenarios, but not in all. Whoever needs to perform manual repairs on-site still needs physical access.
This article helps you choose the right method for your application – or the optimal combination (hybrid inspection).
For pure condition assessment (VT, thermography, surveying) the drone is the most economical option in many cases. For repair needs: hybrid inspection.
Evaluation and report creation takes additional time for all methods. The drone advantage: data is digital and already georeferenced, which accelerates evaluation.
Rope access (Seilzugang) at a chimney inspection – skilled, but limited in documentation depth and repeatability.
Here lies the greatest advantage of the drone: No human needs to enter the confined space.
Zero Human Entry: the greatest safety advantage of drone inspection. Less exposure = less risk = less liability.
Scaffolding / Rope Access:
Drone (ELIOS 3):
The drone delivers more objective, measurable and reproducible data. Particularly for damage progression monitoring over years this is a decisive advantage.
LiDAR 3D scan of power station pipelines – the data quality difference compared to manual scaffold inspection is fundamental.
| Criterion | Scaffolding | Rope Access | Drone (ELIOS 3) |
|---|---|---|---|
| Costs | High (5–6 figures) | Medium | Low–Medium |
| Duration | Weeks | Days | Hours–Days |
| Safety (personnel) | Highly exposed | Exposed | Zero Entry |
| Data quality | Subjective/manual | Subjective/manual | 4K + LiDAR + Thermography |
| Reproducibility | Low | Low | High (saved paths) |
| Repair possible | Yes | Yes | No (inspection only) |
| Confined space suitable | Limited | Limited | Optimal |
| Operational interruption | Long | Medium | Minimal |
Honesty creates trust. We do not recommend drone inspection when:
For pure condition assessment in confined spaces the drone is superior in most cases: faster, cheaper, safer, better data.
The hybrid inspection (drone + targeted human intervention) is the future model: the drone identifies where and what, the human intervenes only where truly necessary.
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for honest method comparison.
We advise honestly – and only recommend the drone when it really is the best solution. Speak with us.
For pure inspection and documentation: in many cases yes. For repairs (welding, coating, mounting): no – physical access is still needed for that. The optimal solution is often hybrid inspection: drone for screening, human only where action is needed.
Depends on the comparison scenario. Compared to full scaffolding for large plants, savings of 60–90% are not uncommon. Compared to rope access the cost advantage is smaller, but data quality (LiDAR, thermography) is significantly higher. We don’t quote blanket figures – we’re happy to calculate your specific case.
Acceptance is steadily growing. Many certification bodies (TÜV, DEKRA, DNV and others) already work with drone-assisted inspection data. Important: each certification body decides independently whether and to what extent it accepts drone inspection data as an inspection basis. We clarify this in advance with the relevant bodies.
Hybrid inspection combines drone initial inspection with targeted human intervention. The drone identifies and localises damage points (4K, LiDAR, thermography) – the human intervenes only where repair or tactile testing is required. Result: up to 80% less human deployment in hazardous areas.
For inspection only: the drone is typically faster, cheaper and delivers better data (4K + LiDAR vs. photos and notes). For repairs on the chimney (pointing, lining, equipment mounting): rope access is still necessary. For a combined approach – drone identifies where repair is needed, rope access team works only there – the hybrid model gives the best result.
Zero Human Entry means: no confined space entry, no fall risk, no rescue chain obligation. Fewer people in hazardous areas = fewer incidents = lower liability. Additionally: drone documentation (4K, LiDAR, georeferenced finding list) is significantly more objective and traceable than manual inspection reports – relevant for insurance documentation and legal disputes.
The DJI M30T can document the external shell of chimneys at any height – limited only by signal range (typically 5–7 km) and legal regulations (in Germany >120 m flight altitude requires a special permit). For the chimney interior the ELIOS 3 flies vertically from the base – the flight range inside the chimney is sufficient for most industrial chimneys (typically up to 150–200 m depending on geometry).
Not sure which inspection method fits your plant? Fill out the form below and we’ll get back to you within 24 hours with an honest assessment.