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Revolutionising Cement Inspections: The Unparalleled ROI of Drone Technology

Elios 3

Last updated on

August 18, 2023


    In the bustling world of cement production, ensuring the structural integrity of chimney stacks is paramount. Traditional inspection methods, involving cranes and manual labour, are not only time-consuming but also costly.

    Enter the Flyability Elios 3 drone, a game-changer that offers a faster, more cost-effective, and detailed solution.

    Chimney Fault Detection

    Key Benefits

    1. Efficiency: The Elios 3 drone completed the inspection in just an hour, a stark contrast to the day-long process of traditional methods. This speed translates to an 8x efficiency boost.
    2. Cost-Effectiveness: By opting for a drone inspection, the cement plant saved a whopping 25,500 pounds, which would have otherwise been spent on crane setup over two days.
    3. Detailed Visualisation: The Elios 3 drone’s data facilitated the creation of a 3D model, enabling swift decision-making and serving as a valuable internal record.

    The Challenge:

    Cement production is a delicate balance between meeting high demands and ensuring machinery maintenance. The chimney stacks, vital to the cement production workflow, rarely require maintenance. However, any unexpected maintenance can halt production. So, when an engineer observed a slight tilt in a chimney stack, immediate action was imperative.

    Cloud Compare defect
    Cement stack defect

    The Elios 3 Solution:

    The cement plant’s in-house drone pilot employed the Elios 3 for an in-depth inspection. Unlike a mere external view, the drone provided both visual and LiDAR data, enabling a comprehensive photo-based inspection and a 3D model of the chimney’s condition. Traditional methods would have necessitated a costly crane, taking days to set up. But with Elios 3, the inspection was wrapped up in an hour, and the chimney was operational again within three hours.



    Post-inspection, the data revealed a significant issue: the inner sleeve of the stack was subsiding at the top, causing a lean. This discovery underscored the potential risks of further damage, partial collapse, and safety hazards. Thanks to the detailed 3D model, decision-makers could swiftly devise a maintenance plan. The entire repair process, from removing the damaged section to installing a new one, was completed in two weeks, showcasing the efficiency of the inspection workflow.

    The Future of Cement Plant Inspections:

    The Flyability Elios 3 drone’s success story at this cement plant underscores its potential ROI. Not only did it save 25,500 pounds on crane costs, but its rapid deployment also advanced the team by at least two days compared to traditional workflows. This case study serves as a testament to the Elios 3’s capabilities, emphasising its role in expediting processes, enhancing site awareness, and ultimately boosting ROI.

    Cement inspection

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