3D laser scanning and scan-to-BIM survey of a 4,000 sqm (approx. 43,000 sq ft) paint manufacturing plant in Kildare, capturing precise existing conditions of all racking, industrial equipment, and storage areas to support space optimisation and future manufacturing upgrades – completed while the plant remained fully operational.
Kildare, Ireland
4,000 sqm (approx. 43,000 sq ft)
Manufacturing & Industrial Facilities
An architecture and engineering firm needed precise existing-conditions data for a 4,000 sqm paint manufacturing plant in Kildare, to support a space optimisation project for storage and racking, alongside planning for future manufacturing equipment upgrades. The brief required more than a standard building survey – every piece of racking, industrial equipment, and storage area had to be mapped with enough precision that layout and upgrade decisions could be made directly from the data, alongside the plant’s architectural features.
The core challenge was that this all had to happen while the plant remained fully operational. Manufacturing plants don’t stop for a survey, and a paint facility in particular means working around active equipment, staff, and material movement throughout the space – the capture had to work around live operations without creating a safety issue or interrupting production.
The brief covered the full 4,000 sqm plant, with the priority being an exact, coordinated record of every racking system, item of industrial equipment, and storage area, alongside the building’s architectural features. The client needed this delivered as a coordinated Revit model and full CAD documentation, giving their team a reliable base to design space optimisation and equipment upgrades against, supported by a full 3D virtual tour of the plant.
We planned the capture around the plant’s operating schedule, sequencing the scan to work through the facility without disrupting manufacturing activity or creating hazards around active equipment. The full plant was captured with 3D LiDAR scanning at millimetre-level accuracy, with particular attention paid to every racking run, item of industrial equipment, and storage area, alongside the building’s architectural features.
The point cloud was registered and processed, and our BIM team produced a fully coordinated Revit model and CAD documentation, cross-checking the racking and equipment layout against the point cloud to ensure the data was precise enough to design space optimisation and future upgrades directly against it.
Complete as-built documentation including CAD, PDF, and a coordinated Revit model capturing every racking system, item of equipment, storage area, and architectural feature was delivered alongside a full 3D virtual tour of the plant, all completed without disrupting live manufacturing operations.
For the architecture and engineering firm leading the project, the value was a dataset precise enough to plan space optimisation and equipment upgrades directly from existing conditions, rather than working from assumptions or outdated records. For a working manufacturing facility, that meant upgrade and racking decisions could be made with confidence before a single change was made on site.
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