Stacks such as flare stacks, waste gas flues, steam stacks, and silencers present some of the most complex and hazardous inspection environments in industrial settings. Overlooking damage or deterioration in these vertical structures can result in unplanned shutdowns, safety incidents, or costly emergency repairs.
At DJM Aerial Solutions, we provide safe, efficient, and cost-effective drone stack inspections — capturing high-resolution data without the need for scaffolding, rope access, or prolonged outages.
Why Drones Are the Smarter Choice for Stack Inspections
Traditional drone stack inspections – whether for flare stacks, waste gas flues, silencers, or steam stacks—typically require full operational shutdowns, scaffolding, or rope access teams. These methods are costly, time-intensive, and present significant safety risks.
At DJM Aerial Solutions, we perform external drone stack inspections remotely using advanced UAV systems—often without requiring a full site shutdown. For internal inspections, we work with your team to carry out surveys during planned outages, dramatically reducing downtime compared to traditional approaches.
Here’s how our service benefits your operation:
Minimised Shutdown Requirements
External inspections are performed while assets remain operational. For internal assessments, our rapid drone deployment reduces the duration and complexity of planned outages.
Improved Safety
All data is captured remotely, eliminating the need for scaffolding, rope access, or confined space entry, keeping personnel out of harm’s way.
Faster Turnaround
Our UAVs gather critical inspection data in a fraction of the time required for manual methods. Reports are typically delivered within 24–48 hours.
Comprehensive Imaging
Equipped with high-resolution and thermal sensors, our drones detect defects such as refractory damage, misaligned components, thermal anomalies, and structural degradation.
Every stack inspection we conduct is tailored to your facility’s specific requirements, taking into account asset type, height, access limitations, and operational status. Whether inspecting a flare stack, waste gas flue, silencer, or steam stack, our process is designed to deliver actionable insight with minimal disruption.
What We Inspect
Stack Tips, Outlets, and Exhaust Terminals
We assess structural integrity, carbon build-up, burn-back, alignment, and heat distortion—common failure points that can compromise performance and safety over time.
Main Stack Structure
High-resolution imagery is used to detect corrosion, cracking, surface delamination, loose fixtures, or deformation across the vertical body of the stack.
Ignition & Exhaust Monitoring Systems
Through radiometric thermal imaging, we verify functionality of pilot flames, ignition units, or emission points—even in low-activity or intermittent flow conditions.
Guy Wires, Bracing & Support Structures
Structural supports are reviewed for tension loss, misalignment, corrosion, or fatigue to ensure long-term stability, especially on ageing or coastal-exposed installations.
Anchor Points & Base Integrity
Where accessible, we inspect anchoring systems and foundations for corrosion, ground movement, or mechanical stress.
Specialists in High-Risk, Regulated Industrial Environments
Our inspection teams are highly experienced in operating within complex, safety-critical sectors, including:
- Oil & Gas Refineries
- Petrochemical Processing Facilities
- Power Generation Plants
- Chemical Storage and Handling Sites
DJM Aerial Solutions is fully CAA-certified and insured, operating in strict accordance with HSE regulations and industry-specific safety protocols. Every project is executed with professionalism and precision—from pre-flight planning and airspace coordination to on-site risk assessments and operational delivery. We manage all compliance requirements, allowing you to focus on asset integrity without added administrative burden.
Efficient, Insight-Driven Reporting
At DJM Aerial Solutions, we don’t just deliver drone footage—we provide comprehensive, actionable intelligence to support confident decision-making and proactive maintenance planning.
Our detailed post-inspection reports typically include:
- Annotated High-Resolution Imagery and Video
Clear visual evidence with precise defect tagging and location references. - Radiometric Thermal Data (where applicable)
Heat signatures that reveal anomalies invisible to the naked eye. - Expert Interpretation
Observations and analysis from qualified inspection professionals with engineering backgrounds. - Targeted Recommendations
Practical, prioritised guidance for maintenance, further investigation, or remedial action.
Protect Your Assets and People
Ready to Support Your Next Stack Inspection
Whether you’re preparing for planned maintenance, assessing post-incident damage, or aiming to reduce operational risk, DJM Aerial Solutions is here to support you.
We’ve partnered with asset operators across the UK to deliver efficient, high-precision stack inspections—covering flare stacks, waste gas flues, steam stacks, silencers, and more. Our drone-based solutions reduce downtime, enhance safety, and provide a clear return on investment with every deployment.