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Automatic Laser-based Geometry Capture for Finite Element Analysis of Weld Beads

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A Three-Dimensional Laser Scanning-Based Method for Dimensional Inspection of Large-Scale High-Speed Railway Precast

Zhiguo Zhang¹, Shihao Dou¹, Shaopeng Zhang²

¹School of Civil Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043, China.

Sensors (Basel, Switzerland)

|June 26, 2026

Summary

A new 3D laser-scanning method offers fast, accurate dimensional inspection for high-speed-rail precast box girders. This digital acceptance approach achieves millimeter precision, improving quality control in construction.

Keywords:

3D laser scanning exterior dimensional inspection high-speed railway prefabricated box girder point cloud data

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Area of Science:

Civil Engineering
Geomatics Engineering
Metrology

Background:

Large precast box girders are critical components in high-speed rail infrastructure.
Accurate dimensional inspection of these large structures is essential for ensuring structural integrity and safety.
Current inspection methods can be time-consuming and labor-intensive.

Purpose of the Study:

To develop and validate a rapid and precise 3D laser-scanning method for dimensional inspection of high-speed rail precast box girders.
To automate the quality control process for large precast concrete elements.
To achieve millimeter-level accuracy in geometric measurements.

Main Methods:

A 3D laser-scanning pipeline incorporating low-pass filtering and sequential registration for noise reduction.
Voxel filtering with curvature-aware enhancement for efficient point cloud processing (3-5× reduction).
K-nearest-neighbors, PCA, B-spline fitting, moving least squares, and CSS corner detection for geometric reconstruction and dimension extraction.

Main Results:

The method successfully reduces point cloud size while preserving critical geometric features.
Key dimensions are extracted with millimeter precision.
Field tests demonstrated absolute errors of less than or equal to 2.0 mm compared to manual measurements.

Conclusions:

The proposed 3D laser-scanning method provides a fast, accurate, and automated solution for the dimensional inspection of large high-speed rail precast box girders.
The technique is validated for reliable use in automated digital acceptance workflows.
This advancement contributes to improved quality assurance in modern railway construction.