Digital Dimensional Control: A Critical Tool for cost savings, risk mitigation, and precision in fabrication and construction

Digital Dimensional Control is a cutting-edge technology that ensures fabricated items meet the required specifications and tolerances before they are delivered to installation sites. By using high-resolution laser scanners, IMS captures precise measurements of fabricated components. This data is then compiled into detailed reports and sent to construction contractors, offering a clear assessment of the item's compliance with any potential out-of-tolerance conditions that may need addressing.

But Digital Dimensional Control is not just about verification—it is a risk prevention and mitigation tool. Its primary objective is to detect any potential fit-up issues well before fabricated items are shipped. By identifying discrepancies this early, Digital Dimensional Control prevents delays, costly rework, and unplanned issues during installation.

A Global Standard: The Korean Shipbuilding Industry's Adoption of Digital Dimensional Control

The power of Digital Dimensional Control is particularly evident in the Korean shipbuilding industry, one of the earliest adopters of laser scanning technology. When Korea transitioned to modular ship fabrication, the need for flawless interface points between various modules became critical. By deploying laser survey scanning tools, they ensured that each module would fit perfectly at every connection point—whether it was steel, pipe, conduit, etc. This allowed for the simultaneous fabrication of multiple ship modules, greatly increasing efficiency while ensuring a flawless fit when modules were brought together on-site.

Strategic Application in Project Planning

In the early stages of project planning, the Risk Register should identify situations where precision is paramount. For situations where components must fit perfectly the first time—without requiring modifications—Digital Dimensional Control should be considered a risk mitigation strategy. Project teams can evaluate the potential impact and likelihood of failure, determining whether Digital Dimensional Control should be incorporated into the project budget as a preventative measure.

Ultimately, the goal is zero unplanned events at the job site. By proactively addressing potential issues through digital dimensional control, projects can proceed smoothly with fewer surprises and delays.

 

Real-World Applications of Digital Dimensional Control:

1. Module Fabrication and Pre-Ship Scanning: IMS has deployed teams globally to laser survey scan fabricated modules prior to shipment. These scans ensure the accuracy of the fabricated parts. The teams also survey scan the foundations, anchor bolts, and the existing environment on-site to guarantee that the modules will fit perfectly upon installation.

 

2. Complex Vessels and High-Alloy Pipe Fabrication: For intricate equipment such as complex vessels or high-alloy, thick-walled piping systems, IMS uses laser survey scanning technology to measure and confirm dimensions before parts are shipped. With high-stakes projects like these, where precise fitment is crucial, Digital Dimensional Control ensures the fabricated items meet design criteria and perform as intended in the field.

 

3. Maintenance Exchange Tube Bundle Replacements: Turnarounds, where scheduled maintenance and equipment replacement happen, require flawless execution. IMS helps ensure that complex systems like tube bundles fit correctly by scanning and verifying the dimensions before the parts leave the fabrication shop. AI-powered simulations of the installation help pinpoint any potential issues, ensuring the replacement will occur without delays. 

   
   

4. Removal and Installation Lift Simulations: One of the most advanced applications of Digital Dimensional Control is its ability to simulate complex lifting and installation procedures. IMS can laser survey scan new or existing equipment, piping, or structures and integrate these scans with fabricated parts to simulate an entire installation process. These simulations help identify any potential barriers to installation, such as scaffolding that will be required to support installation. In some cases, a Removal or Dismantling Simulation can be created to identify whether additional steps—like relocation or bracing—are necessary.