How We Work
Connecting Engineering Models to Field Reality
Why Field Verify Costs You More Than You Think
A “field verify” stamp on a fabrication drawing is usually a warning sign. It means the model could not be fully trusted, and the risk has been pushed downstream to the field.
In brownfield industrial work, that disconnect between drawings and actual conditions is what drives non-fitup events, schedule overruns, and turnaround extensions. When a spool doesn’t fit, the cost is immediate: another fab cycle, another mobilization, more time off the critical path, and more downtime. On a refinery or gas processing facility, even a single day of extended outage can cost millions.
OnSite3D was built to eliminate that risk at the source. We capture existing conditions with engineering-grade laser scanning, coordinate work through VDC, and fabricate from verified field data so components fit before they ever reach site.
A Different Way to Execute
Design Basis
Traditional: Field verify assumption — drawings may not match reality
OnSite3D: Point cloud registered against design model, deviations flagged before fabrication
Fabrication Input
Traditional: IFC drawings with field-verify stamps
OnSite3D: Verified scan-to-model data — ABSA AQP certified weld procedures
Quality Assurance
Traditional: Manual tape measure QA at install
OnSite3D: Laser QA of every spool before it leaves the shop — 94%+ in-tolerance documented
Fit-Up Result
Traditional: Field rework common — reinstallation risk significant
OnSite3D: First-time fit-up by design — rework eliminated at source
Accountability
Traditional: Fragmented — survey, engineering, fab, field all separate vendors
OnSite3D: Single accountable partner from scan through installed deliverable
Proposal Turnaround
Traditional: Weeks of coordination across multiple firms
OnSite3D: 48-hour planning estimate — 75–80% proposal award rate
Deliverable
Traditional: Stamped drawings and a field crew best guess
OnSite3D: WebShare-hosted point cloud, deviation reports, fabricated spool — documented and traceable
Scan — Engineer — Fabricate — Install
Step 01 — Scan
High-accuracy laser scanning of existing conditions — structural, piping, tie-in points, and congested areas. Point cloud registered to project coordinate system and hosted on WebShare.
Step 02 — Coordinate
Point cloud registered against the design model. Clashes, deviations, and constructability issues are identified before anything is fabricated. This is where brownfield surprises get eliminated.
Step 03 — Engineer
Fabrication-ready packages developed from verified data. Full CWPs for piping, structural, and combo scopes. ABSA AQP certified stamp on weld procedures. OnSite3D owns the deliverable — not feeding an EPC stamp.
Step 04 — Fabricate
Spools fabricated in our RoboFab facility using tandem robotic GMAW/SMAW/GTAW. ABSA AQP certifications across CS, SS, Monel, and Inconel. Laser QA before every spool leaves the shop — every weld recorded.
Step 05 — Verify and Install
Virtual assemblies confirm fit-up digitally before the outage window opens. In-TA dimensional support resolves tie-in issues in real time. Post-TA as-built captures the permanent record for the next cycle.
Where Do You Start?
Every client relationship starts somewhere on this ladder. Most start with a scan. Most do not stay there.
Wedge — As-Built & Digital Twin
Services: As-Built, Digital Twin, Scan for Sale
Typical entry: $30K–$150K scan commission
What it unlocks: Validated facility data — feeds every downstream decision
Core — Scan-to-Fabrication
Services: Scan-to-Fabrication, Virtual Assemblies, Brownfield Engineering
Typical entry: $100K–$1.5M+
What it unlocks: First-time fit-up, eliminated rework, construction-ready packages
Anchor — Asset Programs
Services: Facility-Wide Asset Programs, Turnaround Frameworks, MSAs
Typical entry: $500K–$5M+ multi-year
What it unlocks: One vendor across the TA cycle, recurring facility intelligence, procurement credit
The as-built is the cheapest entry point. Once that data exists, the next brownfield modification, tie-in, or turnaround has a verified baseline to work from. That is where OnSite3D converts a scan into a fabricated, installed package.
What Makes This Different
Industrial-Focused Execution
Our workflows are built around real industrial project conditions, including active facilities, brownfield constraints, and compressed turnaround schedules. This is industrial execution, not generic AEC or VDC coordination.
Constructability-Driven Coordination
We focus on deliverables that improve installation in the field, not just model quality. Every step in our workflow is designed to reduce friction, minimise rework, and keep projects moving.
Integrated Digital Workflow
Scanning, VDC, engineering support, simulation, and fabrication coordination operate as one connected workflow, not a chain of disconnected vendors. When changes happen, you work with one accountable team.
Reduced Project Risk
Verified field conditions reduce the rework, turnaround extensions, and non-fitup events that drive project costs higher. Our 75–80% proposal award rate reflects the confidence producers place in our ability to deliver reliable project execution.
Three Regions. One Standard.
OnSite3D operates out of Calgary and Houston, with both offices following the same integrated workflows, QA standards, and ABSA AQP-certified fabrication protocols.
Western Canada remains our anchor market, including oil sands, SAGD, midstream, and petrochemical refining. We also support projects across the US Gulf Coast petrochemical sector and mining operations in Ontario, Quebec, and Labrador. Our VDC teams can work with third-party scan data, extending our Scan-to-Fab and Virtual Assembly workflows beyond facilities we have scanned ourselves.
Calgary, AB
587.325.9996 — Western Canada headquarters: oil sands, SAGD, brownfield tie-ins, TA support
Houston, TX
US Gulf Coast — petrochemical and refining
75–80%
Proposal award rate
48 hrs
Planning estimate turnaround
83 sites
Under active asset program
94.36%
Spool in-tolerance on laser QA
98%
Off-site prefabrication achieved
ABSA AQP
Certified — CS, SS, Monel, Inconel
Tell Us Your Scope
Send us the scope, the facility, and the timeline. We will come back with a planning estimate within 48 hours — what we would scan, how we would coordinate it, and what we would fabricate.
No commitment. No generic proposal. A real answer for your project.