Reducing the Cost of Rework in Engineering Projects with 3D Scanning and RealityPlan™

In engineering and construction, rework is a costly reality. Many project budgets include up to 10% in reserve for rework costs, anticipating inevitable design changes, clash fixes, or equipment adjustments during construction. On large-scale projects, this reserve can translate into hundreds of thousands — or even millions — of dollars. And that’s before considering the hidden costs: schedule delays, resource inefficiencies, and disruption to operations.

Why the cost of rework is so high

The cost of rework in engineering projects often comes down to a single issue — design decisions based on incomplete or outdated as-built data. Traditional site measurements, manual surveys, and aging CAD drawings can miss small but critical details.

These inaccuracies typically surface in the field:

• A pipe won’t fit because of an unaccounted obstruction.
• Equipment needs to be resized or relocated mid-installation.
• A safety clearance is out of spec.

Each of these mistakes triggers rework, consuming both time and money.

The role of 3D scanning in reducing rework

3D scanning technology — also known as reality capture — allows project teams to begin design work with an exact digital replica of the existing site.
By scanning in the early project phases, teams can:

• Capture precise, millimeter-accurate as-built conditions.
• Identify potential design clashes before construction begins.
• Validate engineering assumptions with real-world data.

This proactive approach ensures that design models reflect what’s truly there, not just what’s shown on outdated drawings.

How RealityPlan™ transforms early-phase design

RealityPlan™ bridges the gap between reality capture and CAD-based design workflows.

With RealityPlan™, engineering teams can:

• View, navigate, and measure scanned sites in 3D with high accuracy.

 

• Overlay design models directly into the captured environment for side-by-side comparison.
  

 

 

• Run clash detection to identify problems before they become field issues.
  

 

By integrating RealityPlan™ into the early-phase design process, companies can dramatically reduce the likelihood of costly rework.

Learn more about how RealityConnect™ bridges RealityPlan™ and your CAD tools to keep designs accurate from day one.

From 10% contingency to design confidence

While it’s wise to keep a contingency budget, 3D scanning combined with RealityPlan™ can shift those funds from fixing errors to advancing project quality, safety, and innovation.

In other words: instead of reacting to problems, your team can design with confidence, knowing the real-world conditions from day one.

Bottom line: The cost of rework in engineering projects is high, but it’s not inevitable. By leveraging 3D scanning and RealityPlan, you can protect your budget, shorten project timelines, and ensure a smoother path from concept to completion.