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.