Accurate terrain mapping with 3D laser scan

How do you ensure an accurate representation of the current situation of complex terrain? In project HeraCless, the current Blast Furnaces 6 and 7 (Blast Furnace (BF)) and the Converter Gas Plant 2 (CGP2) will be replaced by a new Direct Reduce Plant (DRP) and an Electric Arc Furnace (EAF) to significantly reduce CO₂ emissions and realise the transition to more sustainable and therefore green steel production.

To get a clear picture of what lies within the intended and future area of ​​the new DRP and EAF, Iv performed a large-scale 3D laser scan. This scan provides accurate information on the current situation and forms the basis for further design and construction work.

Tata Steel IJmuiden is a complex terrain with a lot of traffic, containers and building materials, spread over different factories and zones with specific safety risks. In addition, weather conditions, such as reflections from precipitation, can also affect measurements.

The Leica P50 laser scanner is used to scan the entire terrain as accurately as possible. A setup is made every 30 metres, with the whole terrain mapped with approximately 500 setups. For extra precision, measurement targets and ‘cloud-to-cloud’ technology are used. Measuring control points every 100 metres with a total station achieves a 3 to 5 mm accuracy, essential for making connections to existing buildings and pipes.

The acquired point cloud is converted to Recap files and loaded into Navisworks. The project team is given access to an online viewer via the Leica Cyclone Enterprise environment, where they can view, measure and annotate the point cloud.

The scan provides accurate data for the design and installation of the new installations, thus contributing to an efficient construction process.