The Rise of Electric & Hybrid Construction Equipment

The global construction industry is on the verge of a transformation with the growing adoption of greener practices, specifically with the rise in use of electric and hybrid construction equipment. 

Traditionally, the construction industry has been a massive contributor to the greenhouse gas emissions. It accounts for ~36% of the global energy consumption and contributes to ~37% of GHG emissions globally, according to the United Nations Environment Program. 

It is estimated that ~6% of these emissions are a direct result of the use of fossil fuels to power and operate equipment and machinery used on-site. 

Hence, the construction equipment directly represents over 1% of global GHG emissions, generating ~400 metric tons of CO2 annually. 

As legislative and regulatory focus on enabling sustainable operations with greener equipment and machinery increases in countries, original equipment makers have undertaken steps with the aim to minimize the environmental impact of operating such products. 

Volvo has committed to converting nearly 35% of its machine sales to electric by 2030 and becoming a 100% fossil fuel free vehicle company by 2040. Therefore, the most prominent solution in the industry remains the adoption of electric or hybrid construction equipment.

Also Read: Greenhouse Gas Reduction Plan

A Market on the Rise

The global construction equipment market was estimated to be valued at ~$200 Bn in 2023. 

The market is projected to grow at a steady CAGR of ~6%, attaining a valuation of ~$300 billion by 2030. 

The market entered a recovery phase in 2023, driven by increasing infrastructure development and modernization projects across key regions. 

Governments and private sectors are investing heavily in building smarter cities, roads, and green energy infrastructure, which has boosted demand for construction equipment. 

The global markets witness sales of 1.1 – 1.2 million units annually, with electric vehicle numbers being in the range of 1,000-2,000 (~0.2%). 

Although the numbers for electric machinery are miniscule, the industry is projected to grow at a healthy rate over the next decade or more. 

A report by IDTechEx forecasts that electrical construction equipment market could attain a valuation of $126 billion by 2044, growing at a CAGR of 21% over a 20-year period. Currently, electric vehicles have a 15% share in the global mining equipment market.

Collective Action 

Pressure on the construction industry to reduce their net carbon footprint acts as a substantial tailwind for the electrification of the erstwhile diesel-powered fleets that are in operation globally. Electric machinery not only has zero emissions but also lowers the noise and air pollution at construction sites. Operators have even reported better comfort due to reduced vibrations resulting from the motors. 

Although the growth of electric construction equipment has been slow, governments in various countries are promoting their adoption. 

New York City joined hands with C40 Cities Climate Leadership Group in September 2024 to launch the North American Electric Construction Coalition. 

This initiative targets the development of the electric construction equipment market in North America. 

Cities like San Diego, Austin and Montreal have also joined this movement. This coalition of mayors from over 100 leading cities globally have agreed to reduce the emissions from all construction activities by 50% by 2030. 

Participating cities include Los Angeles, Oslo, Mexico City Budapest among many others. 

Another association called the EU DG Grow Big Buyers Initiative has declared a demand for emission free construction site machinery in 20% of public projects from 2025 and 50% of public projects from 2030. Participating cities include Amsterdam, Brussels, Budapest, Copenhagen, Helsinki, Lisbon, Oslo, Trondheim and Vienna.

In Norway, the domestic construction industry has started converting their entire diesel fleet into electric. The seven largest municipalities in the country signed a declaration to make all construction sites developed through public tenders’ emission free by 2025. 

Furthermore, they aim to make all private construction activities in cities emission-free by 2030 as well. Contractors are even rewarded for providing emission-free equipment and machinery. This led to an exponential growth in demand for electric equipment in Norway. Such initiatives are expected to be the driving force behind the albeit small but budding electric construction equipment market.

Economic & Environmental Benefits

Efforts to introduce electric/hybrid technology were made more than a decade ago but they didn’t cover significant ground within the industry. 

Komatsu introduced the world’s first hybrid hydraulic excavator back in 2008, which reduced fuel consumption by 25%. This production line was followed up to include 20 and 30-ton classes as well in 2016. Caterpillar's D7E dozer was also one of the first diesel-electric introduced in 2008. Caterpillar claimed that it had the capability to move 25% more material per gallon of fuel, improving productivity and at the same time reducing operational costs by 10%. 

Most hybrid models were introduced for the compact equipment segment owing to lighter duty cycles and hence seemed like a viable alternative. Despite additional advantages, the industry never caught on until Volvo declared in 2019 that it would shut down diesel powertrains for the compact equipment segment, marking a stronger inclination towards electrification. 

As the industry showed reception towards electrical vehicles, OEMs introduced similar options for the heavy equipment segment. 

Case Construction Equipment introduced the 580 EV, the world’s first fully electric backhoe loader. Liebherr developed LR 1200.1, the world’s first battery-powered crawler crane. It had a battery designed to last for eight hours. It was followed by the LB 16 unplugged, the first battery-powered drilling rig in the world, designed to last for 10 hours and could be recharged in 7 hours. 

Pilot projects such as the ones conducted by Skanska in early 2024 display the competitiveness of heavy electric equipment in large urban projects. Skanska utilized a Volvo CE 23-ton EC230 electric excavator in February 2024, which resulted in a 64% reduction in hourly carbon emissions and 74% reduction in hourly costs in a 90-day pilot period. 

Volvo also carried out a two-year test to compare the performance of electric construction vehicles with diesel powertrains. It utilized equipment such as electric-powered wheeled and crawler excavators, wheel loaders and load carriers, weighing between 3.5 – 30 tons. Results published in April 2024 found out that these machines can perform similar work as a standard diesel-powered variant in an urban construction environment. 

Leading players like Volvo CE, Caterpillar, and Komatsu have invested heavily in developing electric excavators, loaders, and other equipment. 

Introduced in 2019, Kuhn Schweiz (Komatsu) created the Elektro Dumper, a 45-ton mining truck with regenerative braking that eliminated the need for recharging, highlighting the innovation in energy efficiency. The company claimed that it prevented the discharge of 130 tons of CO2 and saved 50,000 liters of diesel annually.

A significant advantage of electric construction machines is their potential to achieve lower total costs of ownership (TCO) compared to diesel-powered machines. 

IDTechEx's analysis finds that for an average 10-tonne excavator, a diesel machine will require $6,500 per year in fuel alone, while charging for an electric alternative cost just $3,350 per year. Electric motors and lithium-ion batteries require minimal upkeep compared to diesel engines, leading to long-term cost savings for contractors. These are ideal for emission-restricted zones, such as urban centers and enclosed spaces, where diesel fumes pose health hazards.

Also Read: Lithium-ION Batteries are Changing the Face of Power Backup

Challenges and Opportunities

High upfront costs (50-100% of an equivalent diesel machine) and limited charging infrastructure remain predominant barriers. Analysis suggests that the total cost of ownership for an electric mini excavator would be more economical when considering the diesel fuel savings and reduced maintenance costs, which largely offsets the additional premium. 

However, for larger machines, the extra cost of electrification likely remains prohibitive, and OEMs will need significant regulatory and financial support to promote uptake. Heavy-duty machines exceeding 20 tons typically require over 300 kWh of energy to sustain a full eight-hour workday owing to demanding duty cycles.

However, the constraints of current battery technology necessitate large battery packs to fulfill this requirement. 

These large batteries pose challenges, including increased costs, significant onboard space demands, and extended charging durations, which could slow the advancement of larger machine size categories. 

Hydrogen fuel cell technology has emerged as a potential solution, but the technology comes with its own set of challenges and is yet to be implemented in its entirety within the industry.

Another primary concern with battery-electric equipment is charging time and charging infrastructure, particularly for machines used in remote areas with limited or no access to the power grid. 

In Norway and the Netherlands, projects have already explored battery swapping as a potential solution to address the energy demands of heavy-duty cycles.

Swappable battery technology was seen in the case of an electric asphalt paver developed by BAM Ifra in 2022. 

While acquiring multiple batteries involves additional upfront costs, this approach can effectively eliminate expenses associated with charging-related downtime during a project. 

In China, construction equipment manufacturers XCMG, LiuGong, and SINOMACH have adopted large battery systems equipped with dual-gun DC fast charging technology, capable of delivering up to 300 kW. 

A Greener Future

The transition to electric and hybrid construction equipment would mark a pivotal moment for the construction industry. Beyond its environmental impact, this evolution enhances operational efficiency and reduces costs, aligning with the broader goals of sustainability and profitability. As technological advancements continue, industry seems poised to embrace this green revolution on a global scale. 

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