The Challenge

Over the years, the client’s facility had undergone major changes new equipment, shifting workflows, and infrastructure upgrades. But one critical aspect lagged behind: accurate documentation. The existing As-Built drawings were outdated and no longer reflected the current state of the facility. This posed a serious challenge, especially with plans underway to add two new conveyor lines and supporting systems. The impact was already being felt. Routine maintenance was a struggle, with teams facing mismatched systems, incorrect pipe and duct locations, and missing details on structural and interior elements leading to inefficiencies, safety risks, and costly downtime. Without reliable as-builts, any future expansion or retrofit would rely more on guesswork than informed decisions.

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• Existing as-built drawings were outdated and unreliable.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.

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Because the drawings were outdated and didn’t reflect the current state of the facility.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.

Why Specific Requirements Mattered

• 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 delivered a complete Laser Scanning + Scan-to-BIM service:

• Step 1: On-Site Laser Scanning: Our team conducted a site visit and used a Faro Laser Scanner to capture every critical detail even in tight or hard-to-access areas.
• Step 2: Point Cloud & BIM Development: We processed the scans in Faro Scene to generate a high-accuracy point cloud, then developed an intelligent 3D BIM model in Revit 2021, with Navisworks Manage for collaborative review.
• Step 3: Collaboration & Refinement: Through Autodesk BIM360, we shared models in real-time with the client, enabling efficient discussions on design adjustments and optimal placement of new conveyor lines.

Project Timeline & 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.

Software & Technology Used

• Faro Laser Scanner: Captured existing site conditions
• Faro Scene: Point cloud registration
• Autodesk Revit: BIM modeling
• Navisworks Manage: Model review and coordination
• Autodesk BIM360: File sharing and collaboration

The Real Business Value Delivered‍

The results were tangible:

• 4 mm-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

What This Means for Future Projects

This was more than a one-time fix it marked a digital transformation for the facility. The client now has a high-accuracy 3D BIM model and point cloud, enabling:

• Retrofitting & Expansion: Future upgrades can be virtually planned, avoiding design clashes and on-site conflicts.
• Maintenance Planning: Clear visuals of hard-to-reach areas reduce time, risk, and downtime.
• Safety & Compliance: Virtual walkthroughs support risk assessments, audits, and planning in restricted zones.
• Stakeholder Presentations: 360 imagery and BIM models help communicate workflows without physical tours.
• Centralized Data: BIM 360 serves as a single source of truth for all stakeholders.

Desapex laid the groundwork for smarter, safer, and more efficient facility management.