Combining Unmanned Aerial Systems (UAS) with Advanced Digital Workflows to Support Transportation Infrastructure Inspections Was Projected to Reduce Hours Needed for Hazardous Work by 60 Percent under Forecasted Statewide Implementations.
A Prototype Evaluation in New York State Compared Conventional and UAS-Assisted Inspection Workflows for Transportation Infrastructure and Estimated Benefits for Statewide Deployment.
Albany, New York, United States
Buffalo
New York State Thruway Authority – SMART Grant Stage 1 Final Implementation Report
Summary Information
Regular transportation infrastructure inspections are essential for safety and reliability, but traditional methods can be resource-intensive, costly, and lack efficient, high-quality data collection methods. Funded by U.S. DOT’s Strengthening Mobility and Revolutionizing Transportation (SMART) Grants Program, the New York State Thruway Authority (NYSTA) tested prototype inspection approaches using unmanned aerial systems (UAS) and advanced digital workflows and compared with conventional infrastructure inspection practices. The project aimed to validate UAS inspection methods for bridges and other critical assets, integrate digital data collection with existing reporting systems, and support future predictive maintenance through digital modeling and advanced analytics. During the Stage 1 grant, NYSTA deployed UAS equipped with cameras and sensors to collect high-resolution imagery and data on structural condition. The project also developed digital forms, reporting workflows, training procedures, and safety policies to support repeatable and scalable operations. Field testing was conducted in 2024 on a bridge and overhead sign structures on a Thruway segment near downtown Buffalo and at several truss bridges near Albany, New York.
METHODOLOGY
NYSTA defined several key performance measures, including safety and reliability (e.g., reduction in lane closure duration, number of deployed vehicles, and required personnel), and agency efficiency (e.g., cost and direct savings). The evaluation compared conventional and UAS-supported inspection approaches at three levels: 1) a single infrastructure inspection prototype, 2) annual estimates over the NYSTA Thruway system, and 3) broader annual estimates across New York State DOT infrastructure. The project also assessed the end-to-end digital workflow, from UAS data collection and digital field forms to data processing and report generation. NYSTA compared UAS-supported and conventional inspections in Buffalo to evaluate the impact of a prototype on hazardous labor hours, congestion, and costs. Then, prototype-stage performance results were extrapolated to estimate the costs and benefits across the Thruway system and broader New York State infrastructure.
FINDINGS
- Statewide implementation of UAS-assisted inspection is projected to save more than $219 million annually based on improved safety, reduced congestion delay and operational efficiencies, and reduce highway employees’ hours of exposure to hazardous work conditions by approximately 60 percent.
- For safety and reliability, UAS-assisted inspections reduced lane closure time, required personnel, and deployed vehicles, improving safety for workers and motorists. The Buffalo field test showed a 40 percent efficiency improvement, while repeatable UAS data collection and digital models also supported more frequent monitoring, change detection, and predictive maintenance.
- For operational efficiency, the UAS-assisted inspection and digital workflows reduced reliance on under-bridge inspection units, bucket trucks, scaffolding, temporary traffic control and reduced field time, labor hours, and report generation time.
- Prototype: UAS reduced inspection costs from $11,200 to $4,200, yielding $7,000 in direct savings and $38,000 in total estimated savings for a single bridge.
- Projected at Scale: With UAS supported inspections, annual operational costs were projected to decrease from $12.07 million to $1.8 million for the NYSTA Thruway system and from $66.4 million to $34.32 million statewide. Estimated total annual savings were estimated at $19.56 million for the NYSTA Thruway system and $219.36 million statewide.
