The Business Challenge

The client’s facility had evolved significantly over the years, with new equipment, changing workflows, and infrastructure upgrades having all taken place. However, one crucial piece was left behind: documentation.

The existing as-built drawings were now outdated, failing to represent the current state of the facility. This was a serious concern, especially since the client planned to expand operations by adding two additional conveyor lines and associated systems.

But there was more at stake, routine maintenance was already a headache. Teams regularly encountered inaccurate pipe locations, duct sizes, system mismatches, and missing documentation of structural and interior elements, leading to inefficiencies, risks, and downtime.

Without accurate as-builts, every future move whether for expansion, retrofitting, or even routine checks was going to be built on guesswork.

Client’s Initial Hurdles

• Existing as-built drawings were outdated and unreliable.
  
  
• Expansion plans were stalled due to lack of accurate facility data.
  
  
• Maintenance teams faced issues due to incorrect pipe and system layouts.
  
  
• Critical areas were undocumented or inaccessible for manual surveys.
  
  
• Traditional methods were time-consuming, risky, and lacked precision.

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Why This Was Critical

Why couldn’t the client move forward with expansion using existing drawings?
Because the drawings were outdated and didn’t reflect the current state of the facility. Any decisions based on them would have been based on assumptions risky and potentially very expensive.

What problems could arise from relying on inaccurate or incomplete information?
Misaligned installations, system clashes, delays during construction, and unexpected shutdowns during maintenance. Imagine installing a new conveyor line only to find it runs straight through an existing pipe you didn’t know was there.

Why was accuracy so important in this case?
The facility was dense with equipment and process systems. Even a small deviation—say, a pipe marked half a meter off—could create a domino effect of misaligned systems, safety hazards, and additional costs. The client needed precision, not estimates.

Why not use traditional methods like manual surveys?
Traditional methods would’ve taken months, required a large team, and still lacked the level of accuracy needed. Plus, human access to certain areas was nearly impossible due to physical or safety constraints.

What would’ve happened if the client didn’t solve this problem?
The expansion could have led to unexpected clashes, costly rework, project delays, and wasted investments. There was too much at stake to move forward without a clear picture of the existing conditions.

Gaps in Existing Information

The drawings on hand did not reflect the reality on site:

• No clear documentation of current piping and ducting layouts
  
  
• Unmapped interior conditions of the facility’s civil structure
  
  
• No accurate sizing or positional data of existing systems
  
  
• Lack of visual or spatial records for inaccessible or sensitive areas
  
  

This missing information wasn’t just a nuisance it was a barrier to decision-making.

Why Specific Requirements Mattered

To move forward, the client needed:

• Accurate 3D documentation of the existing facility
  
  
• A system that allowed virtual planning of modifications
  
  
• High-resolution detail to understand and avoid conflicts
  
  
• A safe way to present their facility to stakeholders without physical walkthroughs in sensitive areas
  
  

These weren't nice-to-haves they were must-haves to proceed with expansion, safely and efficiently.

The Desapex Solution

Desapex deployed a full Laser Scanning + Scan-to-BIM service to meet the client’s needs.

Step 1: On-Site Laser Scanning
Our team visited the site to identify key areas and scanned the facility using a Faro Laser Scanner, ensuring we captured every critical component, even in tight or hard-to-reach zones.

Step 2: Point Cloud Registration & Model Development
The scans were processed using Faro Scene to create a high-accuracy point cloud.
From there, we used Autodesk Revit 2021 to build an intelligent 3D BIM model, with Autodesk Navisworks Manage for collaborative review.

Step 3: Collaboration and Refinement
Using Autodesk BIM360, models and data were shared and reviewed in real-time with the client. This helped in discussing potential design changes and understanding where the new conveyor lines could be fitted without causing disruptions.

Software & Technology Used:

• Laser scanner - Faro (To capture existing conditions)
• Registration of point cloud - Faro Sense
• Modeling Software - Autodesk Revit 2021 (To create BIM model of existing conditions)
• Model Review Software - Autodesk Navisworks Manage 2021 (To review models and exchange comments and feedback with the client)
• Common Data Enviroment - Autodesk BIM360 (To exchange files and Scanned Data with the client)

Project Timeline & Key Milestones

Total Duration: 6 Weeks

• Weeks 1–2: Field visits, data capture, and scan registration‍
• Weeks 3–6: Model development, ongoing client reviews, and virtual walkthroughs to finalize proposed changes

The Real Business Value Delivered

The results were tangible:

• 4mm-level geometric accuracy helped eliminate guesswork entirely.
  
  
• The client received a fully navigable 3D model of their facility, with point cloud and 360° imagery a digital twin that became the foundation for all future planning.
  
  
• Decisions around adding conveyor lines could now be made confidently, based on verified spatial data.
  
  
• Maintenance became easier with accurate models for existing systems, significantly reducing future downtime.
  
  

Most importantly, the client avoided costly mistakes, rework, and site surprises.

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What This Means for Future Projects

This wasn’t just a one-time fix it was a digital transformation step for the facility.

The client now owns a highly accurate 3D BIM model and point cloud of their entire facility. Here’s how that changes the game going forward:

• Retrofitting & Expansion: Future upgrades or installations can now be virtually tested and coordinated with existing systems, avoiding physical conflicts or design errors.
  
  
• Maintenance Planning: Maintenance teams have clear visual access to hard-to-reach systems, reducing time, risk, and downtime.
  
  
• Safety & Compliance: Virtual walkthroughs can be used for safety planning, risk assessment, and audits especially in hazardous or restricted zones.
  
  
• Stakeholder Presentations: The 360 imagery and BIM model allow the client to visually present the plant and explain workflows to customers, partners, or regulatory bodies without physical tours.
  
  
• Centralized Data Source: With everything stored in a Common Data Environment (BIM 360), the model becomes a single source of truth for everyone from engineers to decision-makers.
  
  

Desapex not only solved the problem at hand we’ve set the foundation for smarter, safer, and more efficient facility management moving forward.