The construction industry can work smarter while playing a leading role in the global effort to reduce greenhouse gas emissions. The transition to zero-emissions (ZE) construction machinery has been slow, hampered by high costs, technological challenges, and resistance to change. Especially regarding that last point, many operators would ask why their construction companies should invest in electric machines when Tier 4 Final diesel-powered ones get the job done? Well, electrification isn’t just about ZE. More on that in a minute.
Current ZE strategies focus on electrifying individual machines. Putting a ZE machine on a diesel site doesn’t work. That’s partly why adoption has been painful. Introducing a ZE machine means having new infrastructure and operations, all “fixed costs.” Instead, to be valuable, electrification needs to be spread across multiple units and use cases.
The Industry’s ZE Challenges
Globally, construction remains a top emitter of greenhouse gases, yet efforts to electrify construction machinery have been incremental.
Despite regulatory pressures by countries such as Norway and the Netherlands where there are mandates for ZE construction machinery. Diesel-powered equipment dominates. In 2022, 41,320 diesel-powered excavators were sold in North America alone, reflecting the industry’s slow pace of adopting electric alternatives.
The push for change in the U.S. relies largely on environmental, social, and governance (ESG) initiatives and corporate green policies. Although major OEMs like Caterpillar, Volvo, and Komatsu have developed ZE prototypes, these innovations are not widely available due to high production costs and uncertain returns. As a result, construction firms face limited options, often choosing between expensive prototypes or retrofitted third-party solutions.
The industry’s reluctance is understandable. Transitioning to electric equipment involves steep upfront costs, supply chain vulnerabilities, and potential technology obsolescence. And integrating battery systems into high-powered, off-highway applications presents unique engineering challenges that some firms lack the expertise to address.
What it Means to Electrify the Jobsite vs. a Single Machine
Think of how the manufacturers of battery-powered hand tools let users swap the same battery between a leaf blower, a grass trimmer, or chainsaw. Now picture that one-sized battery, but interchangeable across any brand or type of tool. With that concept in mind, envision a much larger battery, say 140 kWh, that off-highway machine owners can swap between a wheel loader, excavator, or compact machine. Modular systems not only optimize power usage but also minimize costs, enabling operators to customize battery capacity based on daily workloads.
Consider a job site with six machines. With the current electrification approach, each electric machine would require a dedicated battery with oversized capacity to ensure sufficient runtime, leading to wasted energy and higher costs. A modular system, however, allows energy to be allocated as needed (e.g., battery swapping), significantly reducing inefficiencies. Operators can swap battery modules between machines, share power on-site, provide power for lighting, heating or cooling, or recharge other modules quickly and conveniently.
And here’s why sitewide electrification is not only a smarter way to work than relying on conventional diesel engines but also goes beyond achieving ZE. Electrification can include software to control, monitor and report on a machine’s functions, which is more difficult with legacy diesel machines. The concept of a swappable battery module across all types of machines would include a software layer that enables an electric motor, smart controller, and thermal kit to regulate the battery module’s temperature to operate efficiently in all climates. And it would send information to equipment owners, rental companies, and distributors, so they know what kind of job their machines are doing, where they are located on a job site, how productive they are, and how much energy they are consuming.
Knowing that a battery module is running low enables an operator to swap a module in less time than it takes to fill up with diesel. If a rental company owns the machine, the battery module’s software alerts the firm to deliver one or more modules to the job site. The machine gets its fresh battery module when it is convenient for the operator to pause and swap batteries. This eliminates range anxiety and ensures the equipment owner is only paying for the battery power they need for the work on that job site, for that day. A system like this would also send reports that show the machine’s carbon footprint.
A Day in the Life of an Electrified Job Site
Imagine a construction site operating under the modular model. Six machines—two large excavators, a wheel loader, a mini track loader, and two skid steers, all working in tandem. Each machine is equipped with battery modules tailored to its specific energy needs. The excavators use four 140 kWh modules each, the wheel loader three 140 kWh modules, and the smaller machines one or two.
As the day progresses, the mini track loader’s battery module runs low. Instead of halting operations, the operator swaps the depleted module with a fully charged one from the site’s energy hub, akin to a row of diesel fuel tanks. Meanwhile, the excavator, which consumes energy at a higher rate, receives a “top-up” from the wheel loader, facilitated by a high voltage charging cord. This spells uninterrupted productivity without the need for oversized batteries or additional equipment.
At the end of the day, workers offload the used modules with a forklift at the energy hub for recharging. The modular system’s software analyzes energy consumption patterns, providing insights for the next day’s construction operations. By aligning energy supply with demand, the system maximizes efficiency while minimizing costs.
Retrofitting Diesel Machines: A Path Forward
The high cost of new electric machinery is a significant barrier for many construction firms. Retrofitting existing diesel machines offers an alternative that also extends the life of diesel-powered equipment that legislation might even outlaw. The process removes the diesel engine, fuel tank, and associated components, replacing them with electric motors and universal battery modules, while keeping all the hydraulic lines intact beyond the motor. These battery modules double as counterweights and are easier to maintain than traditional hydraulic systems.
Retrofitted machines provide several benefits:
- First, owners leverage existing equipment rather than purchasing new fleets.
- Second, the modular approach ensures the same battery modules power a range of machinery types and brands, from excavators to wheel loaders, reducing complexity and costs. Standardization simplifies maintenance and operations on job sites.
This adaptability helps contractors manage diverse projects with varying energy demands.
Clearing Barriers to Adoption
A modular energy system reduces the financial risks of electrifying machines by allowing operators to scale their energy investment based on needs. For instance, construction firms can start with a small number of battery modules and expand their capacity as projects grow. This pay-as-you-go model aligns costs with project requirements, making ZE solutions more accessible to smaller firms.
With a smart modular energy system (i.e., one that contains software for collecting data and managing energy), a project manager or rental company has real-time data to better deploy equipment and maintain project schedules. Advanced features, like predictive maintenance head off problems before they cause downtime–another way to work smarter.
Deploying the right modular energy system can also mitigate obsolescence. For example, my company’s ZQUIP power modules allow for a range of energy sources, including diesel, lithium-ion batteries and hydrogen fuel cells, so equipment owners and rental firms can deploy whatever power source the market chooses.
The standardization of power modules also simplifies supply chains, reducing costs tied to maintenance, storage, and logistics.
The Road Ahead: Scaling Modular Electrification
As mandates for ZE grow, the construction industry can balance concern for the environment with economics. Modular electrification offers a practical way forward. By focusing on retrofitting existing machinery and optimizing energy use through modular systems, the industry can move to a ZE future.
The modular model could also work for mining and agriculture. It is a solution for a variety of industries requiring high-powered, off-highway machinery. In the years ahead, as technology advances and regulatory pressures mount, modular power ought to become the standard for ZE construction. By embracing this model, the industry can run job sites and fleets efficiently, productively, and cost-effectively. The future of construction is not just electric–it’s modular power. Power packaged in that way meets the demands of a rapidly changing world.
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