Elios 3 Selected for Internal 3D Mapping in Nuclear Waste Removal Project at DOE Site

Key points:

• The IEC was tasked with removing radioactive calcine waste from a vault built in the 1950s, under a DOE contract.
• Before starting the removal, the IEC needed to create a 3D map of the vault’s interior to understand the environment and plan operations safely.
• After evaluating five options for 3D mapping, the IEC chose Flyability’s Elios 2 and later the Elios 3 drones due to their performance in high-radiation, confined spaces.

The Challenge: Mapping a High-Radiation Vault

The Idaho Environmental Coalition (IEC) is working on the massive Idaho Cleanup Project at the Idaho National Laboratory. As part of this effort, they were assigned the critical task of safely removing 220 cubic meters (720 cubic feet) of radioactive calcine—granular waste stored underground for over 60 years—from 6.1-meter-high concrete bins inside an old vault built in the 1950s.

These vaults weren’t designed with future waste retrieval in mind, making the task extremely complex. To address this, the CRP team developed a multi-step process that involves drilling holes through the vault’s thick roof, installing access risers, and using robotic systems to extract the waste. However, before any of this could begin, the team needed a clear understanding of what lay inside the vault.

Accurate 3D mapping of the vault’s interior was essential to identify obstructions like pipes, conduits, and structural supports. This would help ensure that core holes were drilled in the right locations so that access risers could be lowered without interference.

To achieve this, the CRP team explored two main methods: LiDAR and photogrammetry. While LiDAR offered more detailed data, the challenge was finding a way to collect it in such a tight, high-radiation space.

Evaluating Remote Mapping Solutions for a Confined Space

In 2019, the CRP team tried using a handheld LiDAR sensor, lowering it through a single hatch in the vault. But the limited mobility of the device resulted in incomplete scans with significant blind spots. To get a full 3D model, they needed a remote delivery system capable of reaching multiple vantage points within the vault.

Several solutions were considered, including modifying articulating arms, using helium blimps, or drilling additional access holes. However, these options came with high costs, technical risks, and logistical challenges.

Ultimately, the team evaluated a commercially available inspection drone and found that the Elios 2 met all the requirements. Though the Elios 3 was still in development at the time, the CRP team decided to use it once it was released, thanks to its integrated LiDAR sensor, which provided even more accurate and detailed 3D models.

The Elios 2 and 3 were chosen for their collision resilience, radiation tolerance, and ability to operate in confined, high-risk environments. Their proven track record in nuclear inspections made them a trusted choice for the project.

Testing the Elios 2

Before committing to the Elios 2, the CRP team conducted a test at a specially designed training site that replicated the conditions of the actual vault. The test confirmed that the drone could navigate the tight spaces, avoid obstacles, and collect high-quality photogrammetry data for 3D mapping.

Following the successful test, Flyability launched the Elios 3, which the CRP team quickly adopted for its enhanced capabilities, particularly its LiDAR system. This upgrade allowed for more precise and detailed 3D modeling, further improving the safety and efficiency of the calcine retrieval process.

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