AI is Transforming Foundation Levelling
In construction, it all starts at ground level—literally. A perfectly poured slab is the first step in building anything from a humble bungalow to a glittering skyscraper. But here’s the rub: if that slab isn’t flat, the entire structure risks shifting, cracking, or crumbling before its time. Enter FLAT, the Flat and Level Analysis Tool, a smart solution cooked up by researchers at Oak Ridge National Laboratory (ORNL) to tackle one of construction’s most nagging headaches.
This isn’t just another digital gimmick. FLAT is an AI-powered tool that uses a 360-degree laser scan of a construction site to pinpoint irregularities in concrete slabs with astonishing speed and precision. Forget slow manual processes and the guesswork that comes with them—FLAT crunches the data using segmentation algorithms and machine learning to spit out a near-instant report on foundation levelness. Within a minute, builders know exactly where the trouble spots are, if any.
Old School vs New Tech
Traditionally, checking the levelness of a concrete slab involves a tedious routine. Workers mark out the slab with lines and walk it inch by inch using a manual profiling tool. It’s labour-intensive, time-consuming, and fraught with room for error. Worse still, any deviations not caught before the concrete sets can result in expensive rework, delays, and long-term structural concerns.
“With this digital tool, you can quickly get estimates for the foundation’s smoothness with minimal human involvement,” explains Nolan Hayes, a researcher at ORNL.
He added, “This enables faster building construction because FLAT can tell you within a minute if any mistakes were made and where they are.”
This is more than just an incremental improvement. Demonstrations at two housing developments revealed that FLAT slashed foundation measurement time by over 90%. That’s not a minor tweak; that’s a major shift.
How FLAT Works Its Magic
So, what’s going on under the hood? It starts with a laser scan. A 360-degree LiDAR device sweeps across the site, capturing precise measurements of every contour of the foundation. Then FLAT’s machine learning algorithms take over, segmenting the data and identifying any area that deviates from the acceptable levelness threshold.
And there’s no need for any prep work on the slab—another big tick in the convenience box. The tool is plug-and-play for contractors, meaning it can easily be deployed without additional labour or materials.
Key benefits include:
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Near real-time results (under 60 seconds)
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Over 90% time savings compared to manual methods
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No slab preparation needed
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Increased accuracy and consistency
What’s Next for FLAT?
While FLAT has already proved its mettle in traditional slab-on-grade housing developments, the research team has bigger ambitions. Future versions of the tool are being tested on a range of other foundation types, including suspended slabs, floor decking, and pier foundations.
Each of these applications presents unique challenges, but the underlying principle remains the same: levelness matters. As FLAT evolves, it’s expected to become a staple in all types of construction projects—from residential to commercial, from prefab units to high-rise towers.
“Our vision is to develop a suite of tools that apply this methodology to various construction scenarios,” Hayes said. “We’re not just solving one problem; we’re building a foundation for smarter construction across the board.”
Dollars, Deadlines and Durability
In construction, time is money. So when you can cut a crucial process by 90%, that translates directly into savings on labour, equipment, and project timelines. But there’s another equally important gain: improved quality.
Ensuring a foundation is flat and level from the start prevents a domino effect of structural issues down the line. That means fewer callbacks, fewer warranty claims, and more satisfied customers. For developers and contractors juggling multiple projects, that peace of mind is worth its weight in concrete.
Smart Tools for Smarter Building
AI and machine learning aren’t just buzzwords anymore. They’re actively reshaping how buildings are designed, managed, and built. From autonomous machinery to real-time data analytics and now foundation scanning, these tools are bringing precision and predictability to an industry long dominated by manual labour and variable conditions.
FLAT represents a critical step in that transformation. It removes ambiguity from a fundamental task and replaces it with confidence, speed, and digital insight.
A New Benchmark for the Industry
As more builders adopt digital workflows, tools like FLAT will become indispensable. It’s not about replacing skilled labour—far from it. It’s about giving those skilled professionals better instruments to do their job faster, more efficiently, and with fewer mistakes.
Looking forward, it wouldn’t be surprising to see regulatory bodies and building codes begin to mandate digital foundation scans as a standard part of the inspection process. And when that day comes, FLAT will already be ahead of the curve.
Concrete Confidence for the Future
AI-assisted construction tools are no longer the stuff of sci-fi. They’re here, they’re working, and they’re making a measurable difference. ORNL’s FLAT tool is a shining example of how innovation at the micro-level—a concrete slab, no less—can ripple out across an entire project lifecycle.
By combining the precision of laser scanning with the intelligence of machine learning, FLAT gives builders something invaluable: confidence that their project is starting on the right foot, from the ground up.
