Leading manufacturers and suppliers of construction equipment already recognize that powertrain electrification is poised to become a key zero-emission technology for construction machines. Many major engine suppliers, such as Cummins, Deutz, and Volvo Penta, are investing in electromobility research, and several original equipment manufacturers (OEMs) have already launched battery-powered construction machines as commercial products, including Volvo CE, JCB, and Komatsu. The new IDTechEx report, "Electric Vehicles in Construction 2022-2042," is an in-depth look at this emerging market, highlighting the technical and economic considerations of powertrain electrification across the diverse range of mobile construction machines and providing a comprehensive inventory of ongoing construction machine electrification projects worldwide.
The starting point for most original equipment manufacturers (OEMs) will be the smaller, compact machines, whose duty cycle requirements are relatively light. This means that the daily energy and power needs of the workday can be met with a practical lithium-ion battery size, electric motors, and a well-defined charging strategy. In fact, recognizing the potential for electrification in this segment, Volvo Construction Equipment has already committed to converting its entire range of compact wheel loaders and compact excavators to electric powertrains, completely halting its development of new diesel models. Other OEMs will follow suit.
However, given that excavators over 10 tons are responsible for around 46% of total CO2 emissions from construction vehicles, it is crucial that zero-emission solutions be developed for large machines. The demanding work cycles of these heavy vehicles mean that those over 20 tons require more than 300 kWh of energy to complete a full 8-hour workday. Projects in Norway and the Netherlands have already investigated solutions such as battery swapping and wired operation to meet the demands of these work cycles. In China, construction machinery manufacturers XCMG, LiuGong, and SINOMACH have opted for large battery systems with dual-barrel DC fast charging (up to 300 kW).
The total cost of ownership will be a critical factor in the deployment of electric machines. Electric machines cost more than diesel machines, primarily due to the cost of large battery packs. IDTechEx's analysis in the report suggests that the additional cost of an electric mini-excavator could be modest enough that the diesel fuel savings and reduced maintenance could largely offset the premium. However, for larger machines, the additional cost of electrification is likely to remain prohibitive, and original equipment manufacturers (OEMs) will need significant regulatory and financial support to promote adoption.
While reducing greenhouse gas emissions is crucial, other important factors are driving the electrification of machinery, particularly health and safety issues related to diesel engines on construction sites. The construction sector in the UK is responsible for the highest number of work-related cancer cases annually, approximately 8% of which are directly linked to diesel engine emissions. Construction is also a high-risk sector for noise-related illnesses. Electric machinery is significantly quieter and offers the potential to improve communication, safety, and productivity on the job site, while also reducing noise pollution in the surrounding area. Eliminating toxic exhaust emissions could improve air quality on and around construction sites, greatly enhancing the working environment for construction workers.
Given the need for zero-emission construction machinery, IDTechEx forecasts that by 2042 the global market for electric construction machinery will be worth $105 billion (CAGR 25.6%).
