Case Study: Arrival 3D Scanning 25 Sorting Centers in the US Coast to Coast

Project Highlights

Project Name:

Sorting Centers (Amazon & UPS)

Location:

USA

Objective:

To conduct high-precision 3D laser scanning and create as-built documentation for planning, upgrades, and engineering use.

Project Size:

4–4.5 million sq. ft.

Deliverables:

Point Cloud Data

Category:

Warehouse

Technology Used:

Leica RTC360 laser scanner, Cyclone Registration 360

Project Overview

This case study showcases a large-scale 3D reality capture project carried out by Arrival 3D at multiple package sorting centers across the USA. Over the period of months, the Arrival 3D, Inc. team scanned high-traffic operational areas to ensure accurate as-built data. This data assists in planning, upgrades, and future engineering work for the facilities.

Client Overview

The client handles major package sorting centers throughout the USA. These facilities handle a large volume of parcels everyday and are dependent on machinery like complex conveyor systems, chutes, mezzanines, and loading operations or processes. They require highly accurate digital documentation of each center to help with modernization, upgrades, and operations.

Process and Execution

Initial Site Coordination: The team coordinated with facility management to plan scanning schedules without disturbing any ongoing work.
Survey Control Setup: Set up control loops and scanners throughout each facility to maintain accuracy and consistency.
Grade-Level Scanning: Scanning of ground operations, conveyors, docks, and structural elements under 3D scanning.
Elevated Scanning: Positioning and installation of LiDAR scanners on high levels and platforms to capture overhead systems, and equipment.
Data Registration and QA: Merging, aligning, and quality check of all data using control standards.
Delivery of As-Built Data: Provided clean, organized point clouds and documentation for engineering and planning teams.

Challenges and Solution

Active Operational Environments: Scanning process was difficult to continue while centers in workmode.
Solution: We scheduled scanning during off hours and coordinated closely with facility managers to ensure safety and limited disruption in regular work.
Large, Complex Facilities: Sites were varied in size and layout, with some facilities larger than 600,000 sq. ft.
Solution: We used strategic scanning plans, multiple scanners, and detailed survey control to ensure coverage and accuracy.
Elevated Structures: Many key components were located at height.
Solution: We performed elevated scanning from platforms to make sure complete vertical and horizontal documentation.
Logistics: Managing travel, scheduling, and consistency across locations nationwide was difficult.
Solution: We used standard scanning procedures, checklists, and file structures to get similar results across all 25 facilities.

Results and Benefits

Consistent and High-Accuracy Documentation: Every facility got precise and reliable as-built documentation.
Improved Planning and Engineering: The engineering teams can now design, upgrade using real-world digital data.
Faster Project Turnaround: Standard data delivery with reduced design time and improved coordination between departments.
Support for Future Expansion: The detailed point clouds act as long-term references, supporting future changes and operational planning.

Nationwide Standardization: This project established a unified data standard for all sorting centers, enhancing internal workflows and decision-making.

Highlights

Project Gallery

Solution

Key Insights

The Arrival 3D analysed the centers before starting the 3D laser scanning process to identify challenges. Based on the assessment, the scanning process was created to set up scanners and capture data. Multiple facilities have been captured in detail without hampering their regular work. The project objective to cover all centers and provide as-built documentation is achieved.