3D Laser Scanning and CAD Reconstruction of a Sawmill – Digital Basis for a Retrofit Project

Initial Situation

For the planning of a comprehensive retrofit project in an existing sawmill operation, a reliable digital as-built basis was required.
The existing building structures had evolved over time and were not available in up-to-date technical documentation.

For planned modifications, extensions, and the integration of new plant equipment, precise geometric data was essential—particularly for load-bearing structures, roof geometries, traffic areas, and machine environments.

Conventional survey methods are of limited use in such facilities: complex geometries, restricted access areas, and large spatial dimensions make manual measurement time-consuming and error-prone.
For this reason, a complete 3D laser scan of the facility was commissioned, including the digital reconstruction of all relevant building elements.

Scope of Services

The project consisted of several coordinated work phases:

On-Site Laser Scanning

The on-site scanning was completed within two days. The following areas were captured:

• Building envelope
• Roof structures
• Production halls
• Traffic and storage areas
• Structurally or functionally relevant interior zones

The scan data was provided as a point cloud in E57 format, supplemented by a viewer for direct visual inspection.

Data Processing and Cleaning

The point cloud was cleaned, filtered, and segmented to prepare it for further processing and accurate modeling.

CAD Reconstruction in HiCAD / HELiOS

Based strictly on the scan data, the following elements were reconstructed:

• Main building geometry
• Roof landscapes
• Concrete and foundation areas
• Relevant geometries in proximity to machinery
• Section planes, reference levels, and planning axes

The modeling process was carried out with iterative coordination with the client’s project team.

Data Exchange and Project Integration

Collaboration was handled via a shared cloud workspace. The delivered data included:

• STEP files
• PDF views
• Updated CAD models reflecting design changes
• Supplementary screenshots and technical evaluations

Feedback cycles were managed through written markups, phone calls, and online meetings, allowing changes to be implemented efficiently.

Final Deliverables

The final project output included:

• A fully usable STEP model (~182 MB)
• Complete point cloud datasets
• Viewer files
• Structured project documentation

These datasets now form the basis for retrofit planning, interface construction, and subsequent plant integration.

Project Challenges

• Large and complex building structures
• Varying ceiling and roof heights
• Highly confined and difficult-to-access areas
• Lack of existing as-built documentation
• Requirement for millimeter-accurate data for steel construction and plant engineering

The use of 3D laser scanning enabled full digital capture of the facility without significant disruption to ongoing operations.

Client Benefits

• Precise geometric data as a reliable planning foundation
• Significant time savings compared to manual surveying
• Reduced risk through planning based on verified as-built data
• Direct usability in CAD, 3D engineering, and BIM workflows
• Complete digital documentation for future projects

Conclusion

By combining modern 3D laser scanning, professional data processing, and precise CAD reconstruction, a robust digital foundation was created for a large-scale retrofit project in a sawmill environment.

The delivered data ensures planning reliability, simplifies coordination between subsequent trades, and accelerates all further engineering steps.

The sawmill is not merely documented—it is prepared for the future.