The Power of Reality Capture in AEC Projects

The world of architecture, engineering, and construction (AEC) has always been a blend of creativity, precision, and collaboration. But ensuring accuracy and seamless teamwork in large-scale projects has often been a formidable challenge. Traditional methods of documenting existing conditions or aligning on project designs haven’t always kept pace with the demands of modern construction. Reality capture technology has emerged as a game-changer in this field, allowing teams to digitize real-world conditions and integrate them into design and construction workflows with unmatched accuracy and efficiency.

David Mueller, VDC Manager at Stellar, provided firsthand insights into how reality capture is transforming the AEC industry in a recent Tech Insider interview. “We’re always looking for improvements,” he explains, emphasizing how such tools are reshaping workflows. “[Being able] to take the real world and digitize it essentially increases the speed that we can design, and increases the accuracy of what we’re designing to.”

Reality capture refers to the use of advanced technologies—such as laser scanners, drones and 360-degree cameras—to create digital representations of the physical world. These tools allow project teams to generate point clouds, 3D models, and accurate site data, capturing existing conditions down to the finest detail.

Stellar is no stranger to reality capture tools, using the Leica RTC360 and BLK360 laser scanners extensively in its workflows. “We’re heavily involved in reality capture using our laser scanners,” he says. “We also have drones and 360 cameras that we utilize to collect existing conditions for our brownfield projects.” Combining these tools with robust design technologies helps teams bridge the gap between on-site realities and digital design processes, setting the foundation for accuracy, collaboration, and streamlined workflows.

Reality capture technology isn’t just about capturing data; it’s about transforming how teams collaborate, design, and execute. It addresses major challenges in the AEC industry, delivering the following benefits:

1. Enhanced Accuracy

Gone are the days of relying on outdated CAD files or as-built PDFs. Reality capture ensures that design and construction teams are working from up-to-date, precise field data. “It’s an accuracy upgrade from as-built PDFs or CAD files, going out and capturing what’s there,” says Mueller. This accuracy mitigates risks and ensures that all stakeholders can confidently make decisions based on real-world conditions.

2. Time Savings

Digital workflows powered by reality capture significantly reduce the time required for surveys and verifications, expediting overall project timelines. By digitizing field data, teams can move seamlessly from site to design, cutting down on manual rework and logistical delays. Mueller highlights this benefit succinctly: “Being able to take the real world and digitize it essentially increases the speed that we can design.”

3. Improved Collaboration

One of the most valuable aspects of reality capture is its impact on collaboration. By integrating digital site data into the shared design environment, all project teams—from office-based engineers to field crews—can work cohesively. “Taking the field-collected data back into the digital world increases the accuracy of the as-built at the end of the job,” explains Mueller. Unified, accurate data sets lead to smoother coordination and better communication.

4. Risk Mitigation

Reality capture helps teams foresee and resolve potential conflicts early in the project lifecycle. From detecting clashes in mechanical systems to verifying layouts for construction accuracy, these tools provide enormous value by reducing costly errors. Mueller reflects on this ROI, stating, “It’s easy to put a return on your investment when it’s finding problems … You just saved thousands of dollars.”

At Stellar, reality capture is deeply integrated into their processes, particularly for projects involving existing structures. The goal is clear—to align as-built conditions with design precision. “We sat down and looked at what is the best way to get the most accurate data from the real world, from the existing site, and digitize it so we can design around the actual conditions,” Mueller explains.

Using tools like the Leica laser scanners, Stellar collects detailed as-built data that is then fed into their design platforms, such as the Autodesk Construction Cloud. This workflow not only increases efficiency but also ensures that designs are grounded in the realities of the site. Whether it’s verifying the placement of new equipment or mapping out routing options, reality capture ensures that project outcomes align with on-site conditions.

By bringing point clouds and other digital data back into their collaborative environment, Stellar eliminates discrepancies between the design and construction phases. “We’re bringing that back into our model to verify what’s been laid out … creating an accurate representation of what’s done,” adds Mueller. This seamless interaction between physical and digital layers is what sets Stellar’s workflows apart.

Looking ahead, reality capture technology is just the beginning of a larger shift toward immersive digital workflows. Virtual reality (VR) and augmented reality (AR) are becoming key allies in enhancing collaboration and project visualization. For example, VR tools allow teams to conduct virtual design reviews together, creating an immersive understanding of the project. “We want to look at the design … put our VR headset on, meet virtually, and see each other within the design model,” Mueller shares.

Onsite, AR-enabled tools like tablets take things even further, helping teams identify potential mismatches in real time. Mueller shares a practical scenario where AR bridges the gap between design and execution: “You can take your tablet out in the field and, oh, there’s a duct here, [but] they installed it two feet to the right of design.” With AR, field changes can be caught immediately and corrected before larger issues arise, saving time and resources.

These technologies represent the next evolution of tools that bring designs to life and offer teams even greater confidence in their projects.

“Leica is such a name brand in this industry with technology. There are competitors out there that do things very similarly, but the support that I’ve gotten over the years from Leica—not just at Stellar, but at previous jobs using Leica equipment—the technical support and the speed that support comes to us and helps us resolve problems is unmatched.”

Mueller relates an example of working on a project in Nebraska, when his team was evaluating a laser scanner upgrade and considering the Leica RTC360. Despite harsh winter conditions, with temperatures plummeting to a “feels like” -22°F, the Leica representative, who was unaccustomed to cold weather, insisted on proceeding. “That was just a testament to Leica and their willingness to put it through the paces, put it to the test, see what it looks like,” he says. “It was a good time.”

Importantly, he adds, “We’re very happy with the product at the end of the day.”

Accuracy, collaboration, and risk mitigation—these are the cornerstones of successful AEC projects, and reality capture delivers them in spades. By providing precise, usable data and enabling seamless integration with digital workflows, this technology is eliminating inefficiencies and transforming how teams approach design and construction.

For Stellar, reality capture is more than a tool; it’s a critical element of a forward-thinking strategy. “Being able to take the real world and digitize it increases the accuracy of the as-built at the end of the job,” says Mueller.

Construction professionals looking to stay competitive should consider how reality capture can enhance their own processes. It’s not just an investment in technology—it’s an investment in accuracy, collaboration, and the future.

To discuss your needs with a building construction specialist, contact us.