This laser scanning FAQ answers the questions Australian maintenance managers, project engineers and mine surveyors ask most often before commissioning a 3D scan. We cover real-world accuracy, deliverables, datums, cost, turnaround and how scanning fits a shutdown window — answered from ISS field experience across the Pilbara, Bowen Basin and Hunter Valley. Where it matters, we name the equipment, standards and tolerances rather than speaking in generalities.
Key takeaways
- Expect 2-6 mm real-world point accuracy in a dusty operating plant from a terrestrial scanner such as the Leica RTC360 or FARO Focus, not the 1 mm laboratory figure on the spec sheet.
- A single scan station captures up to 2 million points per second over a 360 deg x 300 deg field of view; a typical processing plant needs 20-50 stations and 1-3 days on site.
- Register and georeference your point cloud to GDA2020 / MGA2020 horizontal and AHD vertical so scans tie into your existing mine grid and survey control.
- Indicative pricing runs roughly AUD 3,000-6,000 for a single asset or compact area and AUD 15,000-50,000+ for a full plant with intelligent 3D modelling.
- For aerial or drone-mounted LiDAR over a pit or stockpile, the operation must comply with CASA Part 101 and be flown under the operator's ReOC.
How accurate is industrial laser scanning?
Terrestrial laser scanners are quoted by manufacturers at headline figures such as 1 mm + 10 ppm (the Leica RTC360 specification), measured in controlled conditions on a high-reflectance target at close range. That is not what you get on a live site.
In a real industrial environment — dust, mixed surface reflectance, grazing incidence angles, steam and vibration — a well-executed scan delivers 2-6 mm point accuracy at typical working distances. Registration quality is the largest single variable: poorly tied scans can introduce 5-20 mm of error between stations, which is why we register against surveyed control rather than relying on cloud-to-cloud matching alone. For most as-built, clash-detection and dimensional-control work that 2-6 mm band is more than adequate. Where tighter tolerances are needed — flange faces, machined surfaces, alignment datums — we supplement scanning with total-station or close-range observation.
What deliverables do I actually receive?
The raw point cloud is rarely the end product. We scope deliverables to how you will use the data:
- Registered point cloud in E57, LAS/LAZ, RCP/RCS or PTX — for direct measurement and as reference data in your own CAD or BIM software.
- 2D drawings — plans, sections and elevations extracted at specified levels, supplied as DWG, DXF or PDF.
- 3D models — mesh for visualisation, or intelligent parametric models (Revit, IFC, STEP) for design, fabrication and clash detection.
- Analysis reports — clash and clearance checks, deviation analysis against design, stockpile and vessel volumes, and deformation comparison between scan epochs.
- Web viewer — a browser-based scene (Leica TruView or equivalent) so stakeholders can interrogate the data without specialist software.
We process in Leica Cyclone, Autodesk ReCap and Trimble RealWorks, so we can match whatever format sits downstream in your engineering workflow.
What datum and coordinate system will my scan use?
For any Australian industrial or mining project the point cloud should be georeferenced to the current national framework: GDA2020 with MGA2020 map grid coordinates for horizontal position and AHD (Australian Height Datum) for elevation. This lets the scan integrate cleanly with your existing as-builts, GIS and design models.
On mine sites we routinely transform into the local mine grid as well, so the deliverable speaks the same coordinate language your surveyors and engineers already use day to day. If you supply existing control marks or a mine grid definition, we tie the registration into them; if not, we establish control with GNSS and total station first. Getting the datum right at the registration stage avoids expensive re-work — a cloud delivered in the wrong grid is effectively a cloud you cannot trust against your drawings.
How much does laser scanning cost in Australia?
Cost is driven by area, complexity, access, mobilisation distance and — most of all — the deliverable. Raw registered point clouds are far cheaper than fully modelled intelligent 3D.
| Scope | Indicative cost (AUD) |
|---|---|
| Single asset or compact area, point cloud only | 3,000 - 6,000 |
| Multi-asset area with 2D drawings | 6,000 - 15,000 |
| Full plant, point cloud + intelligent 3D model | 15,000 - 50,000+ |
Remote-site mobilisation to the Pilbara, Bowen Basin or NT adds travel and FIFO costs, and out-of-hours or shutdown work attracts a premium of around 25-50%. The real return is not the line-item price — it is the rework, fabrication errors and repeat site visits that accurate as-built data eliminates. A single avoided clash on a retrofit tie-in usually covers the scan many times over.
Can scanning be done while the plant is operating?
Yes, in most cases. Laser scanning is non-contact and non-destructive, so it can be carried out in operational areas under the site's normal safety controls — no isolation required for the measurement itself. Moving plant such as conveyors or vehicles produces noise (points on moving objects streak across the cloud), but our processing removes that, and hot surfaces do not affect scanner operation.
For congested or hazardous zones, scanning is often safer than traditional survey because we capture detail from a safe standoff rather than sending a person to a measurement point at height or near rotating equipment. Some high-precision tasks — kiln, mill or crane-rail geometry — are still best captured cold during a shutdown to remove thermal distortion. We will advise during scoping whether operational scanning or a shutdown window suits your objective.
How does scanning fit into a shutdown or turnaround?
Shutdown windows are immovable and every hour of downtime is expensive, so scanning has to be planned to the schedule, not bolted on. Laser scanning is one of the fastest data-capture methods available: a complex asset that would take a survey crew a day to measure conventionally can be scanned in a couple of hours, capturing everything in the field of view rather than only the points someone thought to record.
The preparation rules are the same as any shutdown survey — confirm access and scaffolding in advance, clean the area, allow cooldown time where cold geometry matters, and nominate a site contact with decision authority. Because the scanner records the complete scene, it also future-proofs the outage: questions that surface weeks later can often be answered from the cloud without a return visit. See our guide on preparing for a plant shutdown survey for the full checklist.
Frequently asked questions
What is the difference between laser scanning and LiDAR?
They use the same underlying principle — emitting laser pulses and measuring the return to compute distance. In practice "laser scanning" usually refers to high-accuracy terrestrial (tripod-mounted) scanning, while "LiDAR" is most often used for mobile or drone-mounted systems covering large areas. Terrestrial scanning gives 2-6 mm accuracy; drone LiDAR is typically 2-5 cm vertical but covers a pit or stockpile in a single flight.
How long does processing take after the site work?
Field scanning is the quick part. Registration, cleaning and basic point-cloud delivery typically take 2-5 business days. Full intelligent 3D modelling or detailed 2D extraction adds 5-10 business days depending on complexity. We can prioritise rush processing for time-critical shutdown deliverables — flag it at scoping so we resource it.
Do I need a licensed surveyor for laser scanning?
For data that must be legally defensible or tied to a registered survey control network, a licensed surveyor should supervise the work. Mine surveying is also a statutory function under each state's mining safety legislation. ISS works under qualified surveyors, so where your project needs certified, control-connected accuracy, that requirement is covered.
How big are point cloud files and what do I need to open them?
A single high-resolution scan can be 0.5-2 GB; a full plant of 50 scans can total 20-100 GB before processing. To view and measure you need software such as Leica Cyclone, Autodesk ReCap, Bentley Pointools or the free CloudCompare. We always supply a browser-based viewer as well, so stakeholders without CAD software can still interrogate the data.
Will dust and reflective surfaces on site affect the scan?
They can. Dark or highly absorbent surfaces weaken the return signal and add noise, polished steel and water can cause spurious reflections, and airborne dust scatters pulses. We manage this through scanner positioning, multiple stations with overlap, appropriate resolution settings and processing filters. On exceptionally reflective targets we may add temporary matte targets or close-range observation to maintain accuracy.
Ready to scope a scan for your site? Whether it is a single asset, a full processing plant or an as-built capture during your next shutdown, ISS delivers control-connected point clouds and intelligent models across Australia using Leica scanning technology. Call 0407 057 015 to discuss your requirements and request a fixed-price quote tailored to your scope, datum and turnaround.