Inspection case study

De-Risking Demolition:
How To Prevent Structural Rework on a Complex Retrofit

Learn how XYZ Reality helped a global pharmaceuticals operator retrofit a 30+ year-old facility – catching 750mm structural errors before construction even began. By replacing outdated assumptions and reactive scans with real-time, on-site validation, the team avoided costly rework, accelerated timelines, and raised confidence across all trades.

THE PROJECT

Client:
Confidential

Project:
Pharmaceutical

Location:
Ireland

Client Background

A global operator in the life sciences sector embarked on a complex retrofit of a 30+ year-old facility. The project involved partial demolition, redesign, and integration of modern systems within a constrained existing structure. To de-risk the early-stage structural phase and ensure downstream build accuracy, the project team turned to XYZ Reality’s construction delivery platform.

Challenge

Legacy documentation and ageing plans made structural verification a high-risk endeavour. Much of the building’s skeleton – critical elements like columns and structural beams – was hidden behind plasterboard, making traditional verification methods unreliable and assumption-heavy.

Early coordination relied on old drawings and measurement from visible finishes. But inaccurate assumptions about structural positioning created a domino effect: electrical, HVAC, and containment systems, all of which rely on precise structural brackets, risked misalignment or clash during installation.

The traditional approach of periodic scanning couldn’t keep up. With surveyors not consistently on-site and scan data requiring time-intensive processing, feedback loops were slow and reactive. Errors were only discovered after the damage had been done – when timelines were already slipping, rework was unavoidable, and costs were escalating.

A clash was identified between the new structure and the new HVAC duct during the demolition phase.

Using Atom for clash detection, our team supported the design process.

Solution

XYZ Reality deployed its construction delivery platform, powered by engineering grade augmented reality™ (AR) and real-time project controls, to proactively validate design against on-site reality. Using the Atom™ headset, XYZ’s engineer conducted daily inspections to compare the design model against the actual structure during demolition – a critical window where the “skeleton” of the building becomes visible.

Key platform-driven actions included:

Live model alignment: Real-time overlays revealed significant discrepancies in beam positioning – some up to 750mm off from their design location.
Design corrections on-the-fly: Misaligned cross beams that didn’t connect to columns as intended were flagged and corrected before impacting downstream trades.
Demolition verification: The platform ensured that all elements scheduled for removal in Phase 1 were cleared – preventing timeline delays and costly revisits.

This approach wasn’t just about spotting issues. It was about giving the project team the confidence to build proactively, not reactively.

“This isn’t a phase we usually work in, but I’ve really enjoyed it. It’s been different, challenging – and actually quite exciting. What started as a way for me to track my own structural checks turned into something much bigger. We were able to present that work back to the client, and the feedback has been incredibly positive. It shows what’s possible when XYZ’s tech is used earlier in the process.”

- Conan Abrahams, Site Engineer, XYZ Reality

AR quality re-inspection implemented on the design changes that were made.

Results

With XYZ Reality’s platform embedded early in the project lifecycle, the team delivered value far beyond coordination:

Major design errors resolved before construction began
Zero assumptions needed – structural truth captured on site in real-time
Faster decision-making with immediate design-to-reality alignment
Reduced risk of rework and downstream clashes
Improved trust across disciplines, reinforcing a proactive culture on site.

Looking ahead

This project showcased the power of using XYZ Reality’s platform earlier in the construction lifecycle – proving that real-time validation during demolition can uncover critical issues before they impact delivery.

By integrating engineering-grade AR at this stage, the team avoided costly rework, increased confidence across trades, and set the foundation for a smoother, more coordinated build.

Ready to build smarter from day one?

See how XYZ Reality helps project teams detect errors before they become problems – accelerating timelines, reducing risk, and delivering with confidence.

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