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Finite element model reconstruction of welded tubular joints from incomplete point cloud scans

Jelle Plets (UGent) , Songhan Zhang (UGent) , Jiacheng Qi (UGent) , Kris Hectors (UGent) and Wim De Waele (UGent)
(2026) MARINE STRUCTURES. 109.
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Abstract
The safety and longevity of offshore structures depends on a correct identification and assessment of fatigue critical joints which determine the operational life. Standardized fatigue analysis of offshore structures relies on idealized cylindrical members and weld profiles. These simplifications fail to capture the stochastic nature of real weld geometries and surface irregularities, which are the primary drivers of local stress concentrations. While integrating 3D scanning technology into finite element analysis workflows enables the explicit consideration of as-built geometry, a significant challenge remains. In many cases, various critical regions (e.g. the weld roots) are physically inaccessible to the scanner, resulting in incomplete datasets. In the present work, a novel framework is proposed that automatically transforms (incomplete) raw tubular joint scans into well-meshed finite element models. In particular, the unscannable regions, including the inner walls, plug zones, and weld roots, are reconstructed based on known geometric parameters and existing standards. The framework is successfully applied to scans of four full-scale tubular joints from a decommissioned offshore jacket structure, showing its potential value for fatigue lifetime assessments.
Keywords
3D scan-to-FEA, As-built weld geometry, Tubular joint reconstruction, Automated mesh generation, Offshore structural fatigue, Weld root reconstruction

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MLA
Plets, Jelle, et al. “Finite Element Model Reconstruction of Welded Tubular Joints from Incomplete Point Cloud Scans.” MARINE STRUCTURES, vol. 109, 2026, doi:10.1016/j.marstruc.2026.104059.
APA
Plets, J., Zhang, S., Qi, J., Hectors, K., & De Waele, W. (2026). Finite element model reconstruction of welded tubular joints from incomplete point cloud scans. MARINE STRUCTURES, 109. https://doi.org/10.1016/j.marstruc.2026.104059
Chicago author-date
Plets, Jelle, Songhan Zhang, Jiacheng Qi, Kris Hectors, and Wim De Waele. 2026. “Finite Element Model Reconstruction of Welded Tubular Joints from Incomplete Point Cloud Scans.” MARINE STRUCTURES 109. https://doi.org/10.1016/j.marstruc.2026.104059.
Chicago author-date (all authors)
Plets, Jelle, Songhan Zhang, Jiacheng Qi, Kris Hectors, and Wim De Waele. 2026. “Finite Element Model Reconstruction of Welded Tubular Joints from Incomplete Point Cloud Scans.” MARINE STRUCTURES 109. doi:10.1016/j.marstruc.2026.104059.
Vancouver
1.
Plets J, Zhang S, Qi J, Hectors K, De Waele W. Finite element model reconstruction of welded tubular joints from incomplete point cloud scans. MARINE STRUCTURES. 2026;109.
IEEE
[1]
J. Plets, S. Zhang, J. Qi, K. Hectors, and W. De Waele, “Finite element model reconstruction of welded tubular joints from incomplete point cloud scans,” MARINE STRUCTURES, vol. 109, 2026.
@article{01KM32ADGE4D1GPAFVVRTV7T74,
  abstract     = {{The safety and longevity of offshore structures depends on a correct identification and assessment of fatigue critical joints which determine the operational life. Standardized fatigue analysis of offshore structures relies on idealized cylindrical members and weld profiles. These simplifications fail to capture the stochastic nature of real weld geometries and surface irregularities, which are the primary drivers of local stress concentrations. While integrating 3D scanning technology into finite element analysis workflows enables the explicit consideration of as-built geometry, a significant challenge remains. In many cases, various critical regions (e.g. the weld roots) are physically inaccessible to the scanner, resulting in incomplete datasets. In the present work, a novel framework is proposed that automatically transforms (incomplete) raw tubular joint scans into well-meshed finite element models. In particular, the unscannable regions, including the inner walls, plug zones, and weld roots, are reconstructed based on known geometric parameters and existing standards. The framework is successfully applied to scans of four full-scale tubular joints from a decommissioned offshore jacket structure, showing its potential value for fatigue lifetime assessments.}},
  articleno    = {{104059}},
  author       = {{Plets, Jelle and Zhang, Songhan and Qi, Jiacheng and Hectors, Kris and De Waele, Wim}},
  issn         = {{0951-8339}},
  journal      = {{MARINE STRUCTURES}},
  keywords     = {{3D scan-to-FEA,As-built weld geometry,Tubular joint reconstruction,Automated mesh generation,Offshore structural fatigue,Weld root reconstruction}},
  language     = {{eng}},
  pages        = {{16}},
  title        = {{Finite element model reconstruction of welded tubular joints from incomplete point cloud scans}},
  url          = {{http://doi.org/10.1016/j.marstruc.2026.104059}},
  volume       = {{109}},
  year         = {{2026}},
}
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