The Challenge

A leading automobile manufacturer was in the early stages of planning a new paint shop within its expansive production campus in Hosur, Tamil Nadu. To make informed design decisions, the project team needed a precise 3D representation of the proposed plot something that captured every existing element and condition, down to the finest detail.

The area identified for the new plant was part of a live industrial site. There was little existing data on the as-built conditions, and relying on outdated drawings would risk design conflicts later. They needed clarity a reliable, detailed foundation for early design development without interrupting ongoing operations.

Client’s Initial Hurdles

• The proposed plant area was located within a live industrial campus.
• Existing as-built data was either outdated or missing entirely.
• Relying on legacy drawings posed a high risk of design conflicts.
• There was an urgent need for accurate, real-world data to support early design development.
• The solution had to be non-intrusive and completed without disrupting ongoing site operations.

Why This Was Critical

What made accurate site data indispensable for the client?

To avoid design rework, they needed to know what already existed underground and above ground before developing the new layout.

Why couldn’t the project proceed with traditional surveying methods?

Time constraints and the complexity of services on-site meant manual methods were too slow and error-prone.

What risks were associated with using outdated or generic layout data?

Potential clashes with service lines or structural elements could delay construction and lead to costly redesigns.

How would an accurate 3D model aid multiple departments?

Everyone from civil to MEP to operations could refer to a single coordinated model to plan their respective scopes with confidence.

Why was georeferencing introduced in the model?

To ensure long-term usability and coordination with future design phases, the model needed to align precisely with the site’s real-world coordinates.

Gaps in Existing Information

There was no consolidated model of the site, no as-built documentation for the plot, and no way to accurately assess existing service lines. Without this foundational clarity, design work for the new plant could stall or misalign with physical constraints.

Why Specific Requirements Mattered

• The project site was part of an active production campus, so all work had to be non-intrusive.
• Speed and accuracy were critical to avoid delays and ensure reliable outputs.
• Models across all disciplines needed to be fully aligned and coordinated.
• Drawings had to reflect actual ground conditions assumptions were not an option.
• The as-built data served as the essential blueprint for all future design and planning.

The Desapex Solution

• Our team deployed laser scanning technology across the plot to capture millimeter-level precision.
• The data was processed into a detailed 3D model covering all disciplines.
• We introduced georeference points to ensure that the model could integrate seamlessly into upcoming design and planning workflows.
• Finally, we developed 2D as-built sheets for easy referencing on the ground.

Project Timeline & Milestones

• Week 1: On-site laser scanning completed
• Week 2–3: 3D model development across all disciplines
• Week 4: Drawing production and georeferencing finalized
• All deliverables submitted within a 4-week window

Software & Technology Used

• AutoCAD 2023
• Autodesk Revit 2023
• Navisworks Manage 2022
• Bluebeam Revu
• Recap
• Trimble viewer

The Real Business Value Delivered

• Rapid Data Collection: What once took months was achieved in weeks thanks to scanning and digital modeling.
• Design Confidence: Engineers now had verified data to base every design decision on.
• Service Line Visibility: The model clearly marked service lines for avoidance and planning.
• Simplified Reference: As-built drawings offered quick, area-specific insights at a glance.
• Better Visualization: The entire site could be explored in 3D with a single click, enhancing cross-team collaboration and planning.

What This Means for Future Projects

This project set a new standard for how the client approaches design within existing industrial sites. With a reality-based 3D model in place, their teams now have a reliable foundation to plan, coordinate, and execute future expansions with greater confidence and speed.

For the client, it validated that early investment in digital engineering leads to faster decisions, fewer errors, and better coordination across departments. The success here has encouraged them to adopt similar workflows for upcoming developments within the campus.

From Desapex’s perspective, the project reinforced our belief in the value of combining advanced technology with industry insight. It wasn’t just about delivering models it was about building clarity, reducing risk, and enabling smarter infrastructure planning.

A collaborative win that now serves as a blueprint for how modern industrial projects can begin informed, accurate, and future-ready.