Using AI to make concrete inspection cheaper, safer and more sustainable

Concrete is the backbone of infrastructure around the world today, from dams and bridges to tunnels and industrial facilities. Keeping this vital building block of our economy and society safe and strong can be slow, expensive, and sometimes risky. At Kiwa, we are collaborating with Swedish startup Spotscale to change the game.

Under the flag of our Intelligent Inspection services, Kiwa is introducing a novel combination of advanced imaging, artificial intelligence, and expert analysis to enable owners to understand the condition of their concrete infrastructure like never before. Our new approach is paving the way for the inspection industry to enter the age of predictive maintenance. With this approach, asset managers can make smarter decisions, reduce costs, avoid exposing staff to high risks, and extend the lifespan of critical assets.

Concrete has long played an essential role in construction and infrastructure. Used in everything from reservoirs and runways, cable ducts to shipping docks, and drainage systems to residential, commercial and private buildings, it forms the foundation for our energy, transport and construction systems. While we once assumed concrete can last for centuries, we now know from experience how even the most massive structures can age and deteriorate, posing potentially huge safety and economic risk.

This makes maintaining concrete structures safely and efficiently an essential challenge. Conventional inspection methods are thorough, but can be costly, slow, and even dangerous for the teams involved. This is where, in recent decades, intelligent inspection services have been making a difference.

'Drones have already become a quite familiar part of inspections across industrial and energy sites,' says Jaakko Tuukkanen, Global Business Development & Key Account Manager, Business Sector Digital & Cyber Solutions at Kiwa. ‘By accessing hard-to-reach areas safely and efficiently, they have changed the way we do inspections. We are now moving far beyond that. Our use of advanced software and artificial intelligence solutions is taking inspection to an entirely new level.’

One key reason why Kiwa is partnering with Spotscale is that the Swedish company is highly specialized in transferring high-resolution imagery into precise, three-dimensional digital models. Spotscale’s platform, powered by Redetect AI™, uses photogrammetry and machine learning to identify cracks and other defects on concrete surfaces. The level of detail is minute: the system is able to detect signs of damage as small as 0.2 millimetres in size. Beyond its powerful level of accuracy, the platform enables engineers and consultants to visualize change over time, so that they can effectively plan maintenance based on data, not assumptions.

For new buildings, the AI tool can be used effectively to quality assure that new concrete structures are free from cracks. This facilitates the handover from the contracting companies to the property owner and simplify fulfilment contractual matters.

‘Customers often see the drone as the main part of the inspection, but it’s really what happens after that makes the difference,’ says Katarina Nylander, CEO of Spotscale. ‘The technology turns raw images into actionable knowledge. Kiwa is helping asset owners understand what’s happening inside their concrete. Together, we’re enabling customers to make better, safer and economically more efficient decisions about when and where to intervene.’

The Redetect AI system works by capturing overlapping images of entire concrete surfaces, usually collected with semi-automated drones. These images are then processed through photogrammetric software that calculates the exact position of each image to create a detailed 3D model.

Data collection and subsequent image processing is a highly qualified, continuous process. To achieve images of sufficient quality for photogrammetry and the detection of cracks as small as 0.2 millimetres, inspections must be carried out by trained drone pilots. Then, the AI software analyses the model, detecting the tiniest cracks and other signs of surface damage.

Each defect is geo-referenced and assigned an ID, allowing for easy comparison between inspections. ‘Over time, the software can show exactly how and where a crack is growing, giving engineers the ability to track deterioration long before it becomes a safety risk,’ explains Jaakko. ‘With traditional manual inspection methods, only the most visible damage tends to be recorded. Not only does this mean missing out on important information, it can also lead to varying results, depending on how well the manual work was carried out. The Redetect AI software eliminates this element of chance and human error, providing a consistent and measurable record of every surface inspected. This digital archive not only supports immediate decisions, but offers the ability to anticipate issues before they become serious.’

Already, Kiwa has completed numerous projects demonstrating the impact of our intelligent inspections services. In one case, a city government in the United States asked Kiwa to inspect a large storm drain tunnel running beneath a busy urban area. The goal was to check how nearby construction work might affect the tunnel’s condition before and after a major building project.

Covering 4,500 square meters of concrete, our team used a 45-megapixel Nikon D850 camera mounted on a custom vehicle rig with high-intensity lighting. In just a day and a half, the team captured 2,700 detailed images to document the tunnel’s surface down to the last 0.5-millimeter crack.

The processed 3D model gave engineers a clear digital record of the tunnel’s current state, with every visible crack automatically identified and mapped. This dataset now acts as a baseline for future comparisons and helps the city manage maintenance and insurance decisions with confidence.

One of the major benefits of this inspection approach is safety. Inspections that once involved rope access, scaffolding, and even manual climbing in hazardous conditions can now be performed from a distance. For the energy industry, where structures are often vast and complex, this saves time and cost as well as improving safety. Another benefit is that the technology reduces downtime, since inspections can be carried out while facilities remain operational.

Spotscale also enables more comprehensive data gathering. Instead of sampling small sections of a dam or bridge, our inspection teams can now capture every inch of the surface, including those that appear undamaged at first glance. This provides a complete picture, making it easier to identify patterns, catch emerging issues, and prioritize maintenance.

The environmental and economic benefits are significant too. High-precision inspection means asset owners can often delay costly replacements, extending the lifespan of existing structures, and reducing the environmental impact of new construction. ‘If your structure lasts ten years longer because you can maintain it proactively, that’s a huge saving, both financially and environmentally,’ notes Jaakko

Kiwa’s partnership with Spotscale is part of a broader integration of cutting-edge digital tools into our company’s inspection portfolio. While Spotscale provides the imaging and AI analysis, Kiwa’s specialists interpret the data, verify findings, and deliver actionable recommendations to our customers. This combination of human expertise and technology ensures results are accurate, meaningful and future-facing.

Looking ahead, Kiwa sees enormous potential to expand these shared capabilities beyond concrete. ’Technology is just one part of the story,’ says Jaakko. What really matters is how the technology is used.’ Spotscale’s Katarina adds, ‘With Kiwa’s knowledge of materials and infrastructure, and our ability to visualize every detail in 3D, we can give asset owners in many areas the confidence to plan for the long term.’

For Kiwa, the goal is clear: to offer customers a complete intelligent inspection service portfolio that combines cost savings, safety, efficiency, and insight. Whether it’s through photogrammetric imaging, AI-based defect detection, or advanced reporting tools, Kiwa continues to invest in technologies that empower its experts and deliver real value to customers. ‘As infrastructure around the world continues to age, solutions like these will play a key role in keeping it safe and reliable,’ observes Jaakko ‘By bringing together expertise with intelligent digital tools, Kiwa is helping to forge a future in which inspections are not just smarter, but predictive too, extending the lifespan of our world’s most critical assets.’