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Building Expertise: Flyability and Holcim's North America Drone Days
Holcim has long been a pioneer in adopting innovative technologies, and one of their most impactful choices was integrating Elios drones into their operations. This decision was a key part of their broader "Plants of Tomorrow" initiative, aimed at embracing Industry 4.0 solutions across their global facilities. By leveraging drone technology, Holcim has not only improved efficiency but also enhanced safety and data accuracy.
The partnership between Flyability and Holcim began back in 2016 at the Eclepens site, where early prototypes were tested. Fast forward to 2024, and Holcim now operates a global fleet of 42 Elios drones, with over 100 trained pilots spread across multiple countries. This collaboration has allowed Holcim to lead in innovation, while Flyability continues its mission of sending drones into hazardous environments—keeping human inspectors out of harm’s way.
In the cement industry, Elios 3 drones have proven invaluable. They provide safe access to hard-to-reach areas like clinkers and silos, collecting both visual and LiDAR data. One of the standout features is their ability to function effectively in dusty conditions, ensuring accurate data collection even in challenging environments. This not only reduces risks for employees but also speeds up asset management, making it safer, faster, and more cost-effective.
In June 2024, Holcim and Flyability hosted the third edition of the Holcim Drone Days, with the second taking place in North America. Pilots from nine different sites across the region joined Flyability’s team at the Midlothian Plant in Texas. Building on the success of the 2023 event in Lausanne, this session featured expert talks, hands-on training, and opportunities for pilots to exchange ideas and experiences.
During the event, Flyability shared insights into future developments for the Elios drones, highlighting how they can evolve from simple inspection tools to integral parts of reporting and communication. James Comeau from Glencore Kidd Operations also shared his company’s journey from early adopters to full-time drone operators, offering valuable lessons for Holcim’s teams.
Holcim pilots also presented their own use cases, sharing how they’ve integrated drones into daily operations. These discussions helped identify new applications and quantify the benefits of drone usage across different plants. With participants ranging from beginners to seasoned professionals, the event fostered a culture of continuous learning and improvement.
A major focus of the training was adapting to real-world conditions, such as dust and limited visibility. Pilots practiced flying in confined spaces and learned best practices for navigating tough environments. They also tested the Elios 3’s Return-to-Signal feature, allowing them to push the limits of the drones safely.
Beyond basic inspections, the training highlighted the potential of Elios 3’s new payloads, including ultrasonic thickness measurement and surveying tools. Pilots explored how these can be used for stockpile volumetry, plant mapping, and digitalization. Discussions on Scan to BIM also opened new possibilities for the Plants of Tomorrow initiative.
The event wasn’t just about training—it was about building connections. Pilots had the chance to meet in person, share ideas, and learn from each other. Experienced pilots mentored newcomers, while everyone gained insight into what’s coming next from Flyability.
Overall, the North American Drone Days showcased Holcim’s commitment to innovation and safety. Led by David Hull and supported by Aaron Toles, the event reinforced the value of collaboration and knowledge-sharing. The Midlothian Plant manager also played a crucial role in making the event possible.
With the success of this first 2024 event, both Holcim and Flyability are looking forward to hosting more Drone Days in the future. Together, they’re building a drone program that sets a new standard in the industry, driving progress and safety in the world of industrial inspections.
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