The project “Hybrid 3D Inventory Data Acquisition and Model‑Based Inspection of Waterway Structures for Sustainable Lifecycle Management” ran from 1 December 2018 to 31 May 2022 and was funded under the German Federal Ministry of Transport and Digital Infrastructure with grant codes 19H18011A–E. Its aim was to merge kinematic object capture with industrial inspection methods to create a highly automated, partly autonomous hybrid inspection system for maritime and inland port infrastructure. The outcome is a mobile carrier and sensor platform, standardized inspection procedures, and a largely automated measurement, analysis and verification workflow that, according to the evaluation, speeds up turnaround times and improves planning for maintenance and construction.
Technically, the project delivered a compact, ship‑borne hybrid sensor platform that integrates multibeam sonar and laser scanning. A calibration concept was developed for simultaneous calibration of both sensors, ensuring accurate co‑registration of surface and underwater data. Kinematic data interfaces were defined to handle the high‑volume, multi‑pulse data streams, and a data flow architecture was established to guide data from acquisition through processing to storage. Real‑time measurement software was implemented to provide live feedback during surveys, while a visualization component allowed operators to view combined 3D point clouds and derived models in an integrated environment. A transformation module was added to harmonise all sensor data into a common coordinate system, enabling seamless fusion of surface and sub‑surface information.
The system’s performance was evaluated in several application scenarios. The tests confirmed that the hybrid platform can acquire high‑resolution 3D data of both above‑water and below‑water structures in a single pass, reducing the need for separate surveys. Damage detection and classification were automated through pattern‑recognition algorithms, producing quality parameters that feed directly into lifecycle‑engineering workflows. The evaluation also demonstrated that the integrated workflow shortens inspection cycles and provides more reliable data for maintenance planning, thereby lowering downtime and costly redesigns.
Beyond the technical deliverables, the project established a referenceable inspection process and defined object‑space quality parameters that underpin repeatable, non‑continuous inspections. Workflows were created to integrate surface and underwater data into lifecycle‑management systems, ensuring that digital models can be updated and maintained over time. The mobile carrier platform design, developed in collaboration with the port operator Niedersachsen Ports (NPorts), is fully transferable to other sea and inland ports, making the solution broadly applicable.
Collaboration involved five operational partners and one associate partner. The research partners were the Geodetic Institute (GIH) of the Leibniz University Hannover and the Fraunhofer Institute for Large Structures in Production Technology (IGP). Industry partners included WKC Hamburg GmbH and Dr. Hesse and Partner Ingenieure (dhp:i). The operational partner was Niedersachsen Ports, which provided real‑world testing grounds and helped shape the system’s usability. The associate partner was the Federal Waterways and Shipping Administration (WSV), which contributed regulatory expertise and helped align the system with existing standards. Together, the consortium combined academic research, industrial engineering, and practical port operations to deliver a robust, automated hybrid inspection system that enhances the efficiency and reliability of maritime infrastructure management.