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On the construction site of tomorrow

Composite image of the Hamm HD 12e VT tandem roller and the Vögele wheeled paver MINI 502e

All-electric paving and compaction

In Rangendingen, in the German federal state of Baden-Württemberg, Leonhard Weiss is counting on the concept of an all-electric construction site with e-machines from Hamm and Vögele to make the construction process safer and more cost-efficient and simultaneously reduce noise and CO₂ emissions.

Will construction sites with purely electric machine power soon become the standard? What changes does this development bring to the construction process and how do employees and nearby residents benefit from this technology? Construction contractor Leonhard Weiss has already gathered initial practical experiences with electrically-powered construction equipment and now wanted to get to know more about it. In the course of a power grid upgrade project in Rangendingen, Baden-Württemberg, only fully electric machines were used, including a Hamm roller and a Vögele wheeled paver.

Pioneering project

The pilot construction site in Rangendingen is part of the ‘NETZbaustelle der Zukunft’ (GRID Construction Site for the Future) – an ongoing programme initiated by Netze BW., the largest grid operator for power, gas and water in Baden-Württemberg. The pilot project served as a test to determine which measures can be used to carry out tomorrow's construction projects with lower emissions, less noise, a higher degree of digitalisation and greater safety. On this and other pilot construction sites, the power grid operator is initially investigating the technical feasibility and the effects of the use of all-electric construction equipment on the construction process.

E-machines from Vögele and Hamm

The road construction work followed on from the earthworks with electric construction equipment. Two new additions to the contractor’s fleet were used for the paving and compaction of the asphalt layer: a Hamm HD 12e VT tandem roller and a Vögele wheeled paver MINI 502e. The machines work with extremely low noise and local zero operating emissions, and are thus the ideal choice for use on urban construction projects with strict emission regulations. Their drive and material conveying systems and the wheeled paver's screed heating are fully electrically powered and are characterised by low energy consumption. The conclusion: both machines are in no way inferior to their diesel-powered counterparts in terms of quality and efficiency.

‘We are pleased to be able to contribute to the reduction of noise and environmental impacts here on the site through the use of all-electric construction equipment.’

Jean-Pierre Liedtke, Site Manager at Leonhard Weiss

HD 12e VT compacting the asphalt layer on a footpath with houses in the background.

HD 12e VT –
100% compaction performance, local zero operating emissions

Local zero operating emissions with all-electric drive system
Reduced noise emissions
Battery: equipped with a powerful 23.4 kWh lithium-ion-battery
Operating weight:2,670 kg
Centrifugal force:41/25 kN
No comprises in compaction performance
Maximum efficiency ensures long running and operating times
Sufficient power for a typical working day
Almost identical operating concept to that of the diesel-powered versions

Wheeled paver MINI 502e laying down an asphalt layer on a footpath in Rangendingen.

Wheeled paver MINI 502e – low-noise asphalt paving

The battery-electric drive enables local zero operating emissions
Battery: standard option with a storage capacity of 15 kWh, the optional version with 22 kWh was used in Rangendingen
Running time: up to two days of paving, depending on the battery option
Operating weight: 1,350 kg
Paving widths:0.25 m to 1.80 m, particularly suitable for paving small radii
Laydown rate up to 20 t/h
Ideal for urban paving applications
Almost identical operating concept to that of the diesel-powered versions

Before work begins: fast and easy charging

Both machines began their day’s work in Rangendingen with batteries fully charged through the night before – and had enough power to complete the construction project without topping up the batteries during the day. Both the wheeled paver and the roller had sufficient power for a running time of up to two days of paving.

In addition, the machines were able to be charged at power distribution boxes on the site, which enabled the paving team to familiarise themselves with the charging process. The current battery charge level of both machines could be quickly and easily read from the clearly laid out control panel.

The core element:
the battery

Lithium-ion batteries supply the power for the drive systems. In the case of the Hamm roller, the rechargeable battery with a storage capacity of 23.4 kWh is permanently integrated in the machine. It can be charged in two ways: via a rapid charging plug (400 V, CEE), or via a plug with a Schuko adapter (230 V). The battery for the MINI 502e is available in two different versions – with a capacity of 15 kWh or, alternatively, 22 kWh. The battery was charged via a standard 230-volt Schuko mains power socket.

The charging time for the HD 12e VT is around 4 hours, while charging the MINI 502e takes 5 to 7 hours, depending on the selected battery option.

Lithium-ion batteries supply the power for the drive systems.

On the MINI 502e, the charging device is easily accessible on the side of the machine.

As a further option, the battery of the HD 12e VT can also be charged via the rapid charger integrated in the machine.

The clearly laid out display provides information about the charge level.

View of the lithium-ion battery in the motor compartment of the roller.

Integrated rapid charger on the HD 12e VT

Display on the roller, which provides information about the charge level.

Fast paving of the new asphalt layer

Work got started with the MINI 502e. The clear advantage: controlling and monitoring the paving process was just as easy and comfortable as with the diesel-powered machines. What followed on from here called for precision. The resurfacing of the narrow, partly winding footpath on Königsberger Strasse would not have been possible with larger machines. In contrast, the compact wheeled paver needs very little room to manoeuvre and has a small turning circle. This enabled it to pave the 290 m long and 1.00 to 1.30 m wide surface course efficiently and in highest quality.

Material hopper of the MINI 502e, with worker checking the transfer of the asphalt mix.

Optimum material management

The MINI 502e has a large material hopper with a wide funnel-shaped opening, which was fed with material from the side by a wheel loader. This made the transfer of the asphalt mix to the paver a particularly convenient and clean process. The asphalt mix was spread across the entire working width by two fully electrically-driven spreading augers.

High compaction performance

The Hamm HD 12e VT roller compacted the paved asphalt immediately behind the Vögele paver. It is also an extremely quiet and clearly laid out machine with a simple handling concept. The team on the construction site was impressed by the high compaction force and precision of the small electric roller, which can compact precisely up to the edges. As is often the case on small construction sites, the HD 12e also demonstrated its advantages in use as a combination roller. The combination of dynamic compaction via the smooth drum and the kneading and rolling action of the rubber tyres not only enabled rapid compaction, but also ensured uniform surface sealing. By the way: in addition to the HD 12e VT, Hamm is the only roller manufacturer to offer a purely electrically-powered combination roller with oscillation, the HD 12e OT.

Thanks to the standing position, the operator always has an ideal overview of the construction process.

The wheeled undercarriage enables the paving of small radii.

Small and compact: the ideal credentials for paving the footpath.

Utmost manoeuvrability was essential for these curves.

The visibility of the drum is also perfect on the electrified roller models.

Thanks to the wasp waist of the machines, the machine operator has an unobstructed view of the surroundings in front of and alongside the machine.

An operator standing on the MINI 502e next to three other construction workers.

View of the wheeled undercarriage of the MINI 502e.

The MINI 502e paving the footpath in a tight curve.

View of the wheeled paver and the tight curve radius.

Roller compacting the footpath with the MINI 502e paving ahead of it.

At the end of the day?

A positive conclusion: both machines are in no way inferior to their diesel-powered counterparts in terms of performance and ease of handling. On top of this, they also impress with a good energy footprint: electric motors draw power only when they are actually under load. This is how the concept of an all-electric construction site works: it pays off economically and perfectly positions the construction company for taking on future tasks, as even strict regulatory requirements regarding noise protection and CO₂ reduction are fulfilled.