Text: Susanne Hoecht, Video: TUM Medienproduktion
As in the automotive and agricultural sectors, the construction industry is also moving towards autonomy and sustainability. Assistance systems and software applications such as fleet management systems are already making it easier to operate construction machinery. The next step will be (partially) automated or even autonomous construction machinery or construction robots. Adrian Huber believes there is still some catching up to do regarding sustainability. He estimates that only one to two percent of construction machinery is fully sustainable.
A wide variety of application scenarios and environments make development complex
However, the challenges for researchers and developers of construction machinery are considerably more complex than in the automotive industry. There are a variety of machines on construction sites, including vibratory plates, excavators, or track dumpers, each covering different application scenarios. Every construction site is unique, and the environment constantly changes due to the weather, construction progress, people walking around, moving machines, new material deliveries, and changing storage locations. Added to this are extreme climatic conditions, ranging from up to 60 degrees in the United Arab Emirates or down to -40 degrees in Canada, as well as challenges with desert dust, monsoon rain, and extreme altitudes.
Legal and safety aspects also need to be clarified for the use of autonomous construction machinery. The operators' training level varies greatly, and there are language barriers due to the different countries of origin of the construction personnel.
Research work required for autonomous construction machinery
For construction machinery to become autonomous, new sensor systems must first be developed specially designed for the variable conditions on construction sites. These sensors must cope with the construction site's constantly changing environments and challenges. Alexander Schock-Schmidtke emphasizes that the framework conditions for autonomous construction machinery still need to be better researched and defined. It must be clarified which capabilities the machines must have for which applications, which data can be recorded by the sensors, and how this data is stored. The legal framework and the required safety distances are also of great importance. “In the end, what counts is what information I can get from the data for the construction site and the construction machine. On this basis, I can think about further automation steps in the next step,” explains Schock-Schmidtke.
Alternative drive concepts consist of a mix of hydrogen, fuel cells, electricity, or synthetic fuels
In addition to automation, sustainability plays a key role in developing construction machinery. In initial research, the fml found that 27 construction machinery manufacturers worldwide offer battery-electric drives, five use fuel cells, and four use hydrogen in combination with combustion engines. The scientists at fml assume that the drive type of the future will be a mix of these concepts.
The challenges of the different concepts and application scenarios are manifold. Hydrogen, for example, has a lower energy density than diesel, which requires more frequent refueling and makes logistics more complicated. “Refueling is also not quite as trivial,” explains Adrian Huber. Fuel cells are still experimental and have many weaknesses, especially regarding dynamic loads and the extreme conditions on construction sites. Battery electric drives are efficient and cost-effective, but the battery charging infrastructure is still inadequate in many regions. It has not been researched for construction sites in particular.
Requirements for practical use on the construction site
For autonomous construction machinery or machinery with alternative drive concepts to be used in practice, appropriate infrastructural requirements regarding energy requirements must be met on the construction site. It must be ensured that sufficient electricity is available. The supply of hydrogen or synthetic fuels is still minimal and very expensive.
The high acquisition costs for such construction machinery represent a further hurdle, with the result that only a few machines are currently in practical use. Alexander Schock-Schmidtke believes that rental models could be a solution to avoid these high costs and improve the flexibility and accessibility of the machines.
Another important aspect is the user-friendliness of the machines. Adrian Huber emphasizes that autonomous construction machinery must be intuitive to operate to increase acceptance on the construction site and maximize efficiency and productivity. It is also necessary to expand the range of skills of construction site personnel. Equipment operators must be able to operate and monitor several machines simultaneously to take advantage of the higher degree of autonomy.
Current research on construction machinery and construction logistics at the fml chair at bauma 2025
Anne Fischer explains that the chair is conducting intensive research into automation, assistance systems and energy management for alternative drive systems for construction machinery. The researchers are also working on data standards for construction machinery, the recognition of construction objects on the construction site, and developing digital twins for construction sites. These proof of concepts and prototypes are used to identify potential innovation opportunities for the construction industry.
Accordingly, the chair is presenting an autonomous dumper at bauma 2025. This compact construction machine can automatically transport bulk material from A to B on the construction site and load and unload itself. It has already been awarded the 2025 Innovation Prize by the German Association of the Construction Industry, Environmental and Mechanical Engineering (VDBUM). A paving robot, which can cut and lay paving stones individually or in complete layers, will be presented as a further demonstration object.
As part of the series of lectures in the Science Hub, the possible use of construction machine data will be discussed. According to Anne Fischer, a fair and neutral exchange of data is essential so that this can finally be used in construction practice. The fml chair is therefore working closely with construction companies, construction machinery manufacturers, third-party providers, and associations to establish such a data trust model in the industry on a sustainable basis, following the example of agriculture. Learn more on Thursday, 11 April 2025, between 12:30 and 13:00 in the Science Hub.
The Chair of Materials Handling, Material Flow, Logistics will be exhibiting at bauma from 7 to 11 April 2025 in the Science Hub in Hall B0. The lecture on “University contributions on the topic of ‘connected machines’" with Anne Fischer and Alexander Schock-Schmidtke will also occur on Thursday, 11 April 2025 between 12:30 p.m. and 1:00 p.m. in the Science Hub in Hall B0.
Links and Contact:
Chair of Materials Handling, Material Flow, Logistics (fml)
Alexander Schock-Schmidtke, M.Sc.