LiDAR & 3D Scanning in Industrial Inspection – Point Clouds from Confined Spaces

The ELIOS 3 carries an Ouster OS0-128 LiDAR sensor directly through the manhole into tanks, boilers and silos. While it flies, it generates a centimetre-accurate 3D point cloud in real time – without scaffolding, without human entry, without GPS.

• Centimetre-range precision – Ouster OS0-128, 1.31 million points/second
• Works in total darkness – LiDAR is active, needs no light
• CAD/BIM-compatible output – .las and .e57 formats
• Colourised point clouds since 2025 – automatic RGB texturing in Flyability Cloud

LiDAR Scanning in Confined Spaces: The Problem – and the Solution

Classic 3D scanning (terrestrial laser scanner) works excellently – when you can bring the scanner into the space. In a tank through a DN 600 manhole, in an 80-metre-high chimney, in a dusty silo? Barely possible without enormous effort.

The Flyability ELIOS 3 carries an Ouster OS0-128 Rev 6 LiDAR sensor directly through the manhole into the vessel. While it flies, it generates a 3D point cloud in real time – without scaffolding, without human entry, without GPS.

The result: A centimetre-accurate 3D model of your plant that serves as the basis for surveying, deformation analysis and digital twins.

ELIOS 3 LiDAR: Technical Core Data

LiDAR sensor: Ouster OS0-128 Rev 6

• Precision: centimetre range (1σ)
• Range: up to 100 m
• Points per second: 1.31 million
• Channels: 128
• Protection class: IP68 (waterproof, dustproof)

SLAM algorithm: FlyAware™ Engine

• GPS-independent navigation and mapping
• Real-time 3D live map during flight
• Computer Vision + LiDAR + NVIDIA processor

Output formats:

• .las / .e57 (CAD/BIM-compatible)
• .ply (mesh)
• Colorised Point Cloud (since 2025: automatic RGB texturing)

Post-processing: Flyability Cloud (Inspector 5) – measurement, annotation, reporting, export.

What Can You Do with LiDAR Point Clouds?

The LiDAR point cloud from the ELIOS 3 is far more than a 3D image – it is a versatile data foundation for a wide range of analyses.

SurveyingDistances, angles, diameters, wall thicknesses, volumes – all measurable directly in the 3D point cloud. Without physical access and without a tape measure.

Deformation AnalysisComparison of LiDAR scans at different points in time: how much has the tank floor subsided? Has the boiler wall deformed? Quantifiable statements instead of subjective estimates.

Digital TwinThe point cloud is the basis for a complete digital twin of the plant. Importable into CAD systems (AutoCAD, Revit, BIM 360) for planning and maintenance.

Damage Progression MonitoringRepeatable flight paths + LiDAR enable repeat inspections over years. How quickly is corrosion progressing? Where is the geometry changing?

As-Built DocumentationFor plants without current as-built drawings: the LiDAR point cloud delivers a complete as-built scan – even of areas that are otherwise inaccessible.

Colorization: Coloured 3D Models since 2025

Since the 2025 update, Flyability Cloud offers the Colorization function: the LiDAR point cloud is automatically overlaid with the 4K camera images, creating a photo-realistic 3D model.

Intuitive FindingsCorrosion, discolouration, deposits are directly visible in the coloured point cloud – no switching between data sources required.

Better CommunicationColoured 3D models are more understandable for non-technical stakeholders than plain grey point clouds. Ideal for decision presentations and training.

Geometry + Optics CombinedGeometry data (LiDAR) and visual data (4K) in one model – for damage documentation, reporting and maintenance planning.

LiDAR vs. Photogrammetry: Which Is Better for Confined Spaces?

Photogrammetry (3D from photos) works well with good lighting and textured surfaces. In confined spaces it is problematic: darkness (even with lighting: shadows, reflections), uniform surfaces (bare tank walls), narrow passages (insufficient image overlap).

LiDAR is superior for: darkness (LiDAR is active, needs no light), uniform surfaces (measures distance, not texture), large volumes (100 m range), precise surveying (centimetre range), real-time navigation (SLAM).

For confined spaces, LiDAR is the superior technology. Photogrammetry can be used as a supplement – but the foundation is LiDAR.

Practical Examples: LiDAR Scanning with the ELIOS 3

All examples anonymised. Duration and results are project-specific.

Tank SurveyLiDAR scan of a 10,000 m³ storage tank through a DN 600 manhole. Result: complete 3D point cloud. Deformation analysis shows tank floor subsidence of 12 mm compared to the previous year.

Boiler As-BuiltWater-tube boiler without current as-built drawings. LiDAR scan captures pipe routing, installed components, baffles – delivers CAD-compatible as-built drawing for maintenance planning.

Chimney Geometry80 m industrial chimney, interior survey of the lining. LiDAR shows deviations from target geometry and locates wear on the refractory lining.

Silo VolumeDetermination of residual volume in a partially-filled cement silo. LiDAR measures the surface of the bulk material and calculates the remaining volume.

Limits of Drone-Based LiDAR Scanning

No Wall ThicknessLiDAR measures the surface, not the material thickness. For wall thickness measurement UT (ultrasound) is required – also available as an optional payload for the ELIOS 3.

Reflective SurfacesHighly reflective surfaces (high-gloss polished stainless steel, water) can cause LiDAR measurement errors.

Dust and SteamDense dust or steam scatters the laser pulses and reduces range and accuracy. The ELIOS 3 has a dustproof mode, but limitations are possible under extreme dust loading.

Post-Processing RequiredThe raw data must be processed in the Flyability Cloud. Evaluation (colorization, surveying, reporting) requires time and expertise.

Large File SizesHigh-resolution point clouds generate files in the GB range. Powerful hardware for visualisation is recommended.

Your Contact

Dipl.-Ing. Karsten Lehrke
Project Manager & LiDAR Expert
LiDAR scanning in confined spaces has been our core capability since 2017. The ELIOS 3 reaches places where no terrestrial scanner can be positioned – and delivers centimetre-accurate 3D data.

Related Services

• Flyability ELIOS 3 – The indoor drone with integrated LiDAR sensor for precise 3D point clouds
• Industrial Inspection – LiDAR-supported industrial inspections with digital twins and surveying
• Tank Inspection – Survey tanks by LiDAR 3D scan and capture deformations to the centimetre
• Silo Inspection – Scan silos by drone and determine residual volume via LiDAR point cloud
• Chimney Inspection – Document chimney geometry and lining by LiDAR 3D scan

Frequently Asked Questions: LiDAR & 3D Scanning

How accurate is the LiDAR survey of the ELIOS 3?

Point precision is in the centimetre range (1σ). For industrial surveying and deformation analysis this is sufficient in most cases. For sub-centimetre accuracy a terrestrial scanner would be needed – which often cannot be brought into confined spaces.

Can I import the point cloud into my CAD system?

Yes. The ELIOS 3 delivers .las and .e57 formats that can be imported into standard CAD systems (AutoCAD, Revit, BIM 360, CloudCompare, FARO SCENE and others).

How long does a LiDAR scan with the drone take?

This depends on the size and complexity of the space. Flight time varies depending on plant size and sensor scope. Post-processing (colorization, surveying) comes afterwards – varying in duration depending on requirements. Contact us for an estimate for your specific situation.

Does a drone LiDAR scan replace a terrestrial 3D scan?

In confined spaces: in many cases yes, because a terrestrial scanner simply cannot be positioned there. In freely accessible areas terrestrial scanners offer higher accuracy (sub-mm). The ideal solution is often a combination: drone for interior spaces, terrestrial scanner for accessible areas.

Contact – LiDAR Scanning Enquiry

We scan your confined spaces with LiDAR and deliver point clouds, 3D models and surveying data – without human entry.