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A digital leap forward

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Have you ever tried to put together self-assembly furniture only to find that a hole is slightly off? Suddenly the screws don’t fit, the pieces don’t line up and a simple task becomes a frustrating puzzle. Now imagine this on an industrial scale. Whether on a huge offshore platform or in a complex industrial plant, insulation boxes have to fit perfectly – down to the last millimetre.

For years, KAEFER’s surveyors relied on manual measurements, sketching designs by hand, carrying stacks of drawings and checking each dimension repeatedly. It was slow, time-consuming and even the smallest miscalculation meant rework, delays and frustration. And what if a single error crept in?

But the world of prefabrication is changing. Across industries, digital tools are replacing manual processes, increasing efficiency and improving quality. The question for KAEFER was: how can we bring insulation measurement into the digital age?

One of the answers was Digisurv, an intelligent measurement tool that seamlessly integrates with PrefabBase, KAEFER Norway’s digital workflow system. But more than just a tool, Digisurv represents a change in the way we work – smarter, faster and with fewer errors.

1. Could you give us a brief overview of Digisurv and its main purpose?

Digisurv is a tablet-based application used by surveyors to measure insulation boxes on both onshore and offshore projects. It provides a standardised and guided measurement process, reducing human error. The tool generates 100% complete 3D models, allowing surveyors to visualise the finished box before it is approved for production. It also automatically creates CNC-ready production files, eliminating the need for manual engineering.

2. How does Digisurv fit into the wider digital ecosystem?

Digisurv works in conjunction with PrefabBase, our project database. PrefabBase handles everything from documentation and ordering to invoicing, logistics and production control. While Digisurv collects field data, PrefabBase ensures that it is seamlessly integrated into the workflow.

3. What was the main motivation for developing Digisurv?

Before Digisurv, the surveying process was manual, time consuming and error prone. Surveyors relied on hand-drawn sketches, which then had to be interpreted by engineers before production could begin. With Digisurv, we have a completely digital workflow – from measurement to production – ensuring higher quality, better documentation and real-time project control.

4. How has the measurement process changed with Digisurv?

It’s a completely new approach. Surveyors now follow a step-by-step digital process that follows the project specifications. Instead of manually recording data, they input it into Digisurv, which instantly generates a 3D model and links it to PrefabBase. This speeds up production and minimises the risk of errors.

Each year KAEFER Norway prefabricates between 8,000 and 10,000 stainless steel insulation boxes. This number varies depending on the type of project – whether it’s maintenance, modification or new construction. Around 20% of these are Class 5 fire boxes, which require particularly high precision. KAEFER also produces a large number of prefabricated stainless-steel claddings and a growing proportion of Glassfiber Reinforced Plastic (GRP) products.

5. Can you give a practical example of how Digisurv has optimised the production of parts?

One of the biggest improvements is the automated drilling of rivet holes. Previously these were drilled manually – resulting in half a million individual drilling operations per year! Now the CNC machines drill the holes directly from the Digisurv 3D data. That’s a huge saving in time and labour.

6. Implementing a new system is never easy. What have been the biggest challenges?

The biggest hurdle was changing the way people work. Engineers, surveyors and production teams had to adapt to a digital-first approach, which took time and training. There was some initial scepticism, but once people saw the benefits – fewer errors, easier workflows and better project transparency – they became strong advocates for the system.

7. Were there any quick wins or unexpected benefits?

Yes! One surprise was how much easier it became for engineers to track project progress. They now have real-time visibility of every step of the process, reducing the need for constant status updates. In addition, even clients can access restricted parts of PrefabBase to monitor progress, allowing KAEFER teams to focus on execution rather than administrative reporting.

8. Digisurv has already transformed insulation measurement, but what’s next?

Continuous improvement is the key. The next big step is to incorporate insulation material into the 3D model. This will allow automated cutting of insulation using CNC machines, eliminating manual cutting processes and further improving efficiency.

9. Any advice for other teams looking to digitise their measurement process?

It’s a marathon, not a sprint! Innovation takes time and there will always be challenges along the way. But if you have a clear vision and strategy, the long-term benefits will far outweigh the initial hurdles. Be patient, be persistent, and never stop improving.

From offshore challenges to digital precision

Gone are the days of manual sketching, last-minute adjustments and costly rework. Digital tools have transformed the way we work, making processes smoother, faster and more accurate than ever before. With solutions like Digisurv, surveyors no longer have to battle the elements with pen and paper – they now have precision in the palm of their hand.

But this is just one step in a larger journey. At KAEFER, digital transformation is not about replacing expertise – it is about enhancing it. From automated cutting to real-time project tracking, digital solutions enable our teams to work smarter and focus on what really matters: delivering high-quality results with efficiency and precision.

Because at the heart of every innovation are the people who make it happen. And with the right tools and mindset, they’re ready to take on the next challenge – faster, smarter and more connected than ever before.

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