Germany’s largest aviation company · Mission critical

350,000 m² of maintenance operations, digitally captured in full.

350,000 m² of captured area, 22 buildings, six delivered BIM models.

Aircraft maintenance hall captured as a point cloud
Industry
Mission critical
Area
350,000 m²
Buildings
22
Period
since 2021, ongoing
Services
Reality capture, scan-to-BIM, digital twin operations, spatial intelligence pilot
Result
6 BIM models, over 100 captured machines
  • 350,000 m²

    captured area

  • 22

    buildings in one coordinate system

  • 6

    delivered BIM models

  • 100+

    captured machines with asset ID

Starting point

Aircraft maintenance facilities rank among the most demanding buildings there are. Halls with enormous spans, dense plant, an operation that does not pause.

Anyone planning here cannot rely on record drawings. Over decades, equipment was retrofitted, halls extended and utility routes rerouted. Documentation never followed reality.

Objective

  • Create a reliable digital basis for 22 buildings without interrupting maintenance operations.
  • Derive BIM models from the capture that planning and maintenance can use daily.
  • Build the data basis so that later AI functions can build on it without a new capture.

Approach

Capture ran section by section in windows released by operations. Large hall areas with mobile mapping, plant areas and equipment terrestrially, envelopes by drone.

Before every section the team set the control point network with a total station. All 22 buildings therefore sit in one shared coordinate system and match, even though they were captured at different times.

Six BIM models were derived from the point cloud to an agreed level of information need. Over 100 machines were built as separate components with asset tags.

Models and point clouds sit in the web viewer. Distributed teams work from the same basis without travelling for it.

What came of it

The data basis now carries the spatial intelligence pilot. Object detection and AI OCR run on the existing capture, without a single building being rescanned.

The effort happened once, the benefit keeps growing. That is precisely the strength of an AI-ready foundation.

We now have a basis both planning and maintenance can rely on. That was not the case before.
Senior Project Manager Germany’s largest aviation company

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