Issuu

2025 VOL. 6

globalhighways.com

DESIGN, CONSTRUCTION, MAINTENANCE & MANAGEMENT OF THE WORLD’S ROAD NETWORKS

Asphalt sphalt paving

Trialling new technology p34

Innovations in earthmoving p9 Key Project: Canada’s new bridge p32

EXTENDED DIGITAL CONTENT D1-D24

2025 VOL. 6

DIGITAL INSIGHTS

CONTRAFLOW

A selection of the editor's top stories from this month's online and social media channels...

On a road to nowhere

EDITOR, Mike Woof mwoof@ropl.com

“Why did the UK’s Department for Transport not accept that a longer tunnel with its portals further from Stonehenge would have been a better solution?”

Editorial Editor Mike Woof

Deputy Editor David Arminas Sub-Editor Elizabeth Kaye Editorial Contributors Shem Oirere, Kristina Smith, Mauro Nogarin, Eugene Gerden, Partha Basistha, Lucio Garofolo Editorial Consultant Geoff Hadwick

he fact that the current UK Government has cancelled the construction of the £1.7 billion Stonehenge Bypass project (for the second time in 20 years) should come as no great surprise. This highly controversial project involved the building of a 3.2km tunnel 200m away from the historic Stonehenge structure, a UNESCO World Heritage Site. The project also included a 13km stretch of dual carriageway, replacing the single lanes of the existing A303. For much of its length, the A303 is a dual-carriageway and the route carries heavy traffic volumes, providing an important link between the South-West and South-East of England. Traffic levels can be high in the summer months due to tourist vehicles. The road is also a key route for heavy-truck transport. The stretch running past Stonehenge is notorious for lengthy traffic delays. There are also safety concerns on this section. The need for a better road link is clear. But building any project in the area around Stonehenge presents major issues. This is one of the most important archaeological sites anywhere in the world. It ranks alongside the likes of the Pyramids at Giza in Egypt, the Pyramid of the Sun in Mexico, Machu Picchu in Peru, Pompeii in Italy, the Taj Mahal in India and the Great Wall of China. Experts are still discussing how and why Stonehenge was built, as well as what it was for. Its erection started around 3100 BC and finished around 1600 BC, with the stones for the famous circle being placed between 2400 BC and 2600 BC. The area around Stonehenge is also dotted with many pre-historic earth mounds marking burial places, as well as other points of archaeological importance, including the wooden Woodhenge that predates Stonehenge. Given the historic importance of the area, why did the UK’s Department for Transport not consider a longer tunnel with portals positioned further from Stonehenge? It would have been more costly, and the ground conditions are challenging for tunnel construction, but would have generated less resistance on archaeological or environmental grounds. End

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Global Highways (Print) ISSN 3049-8686 Global Highways (Online) ISSN 3049-8694

GLOBAL HIGHWAYS 2025 VOL. 6

CONTENTS 2025 VOL. 6

03 CONTRAFLOW

2025 VOL. 6

globalhighways.com

The UK’s Stonehenge bypass project is cancelled, again

06 NEWS & CONTRACTS

Hitachi’s rebranding plan; Hamburg project halts; twin TBM project in Sydney; tunnelling in Romania; Norwegian bridge construction

DESIGN, CONSTRUCTION, MAINTENANCE & MANAGEMENT OF THE WORLD’S ROAD NETWORKS

COVER STORY

ASPHALT PAVING

18 CONSTRUCTION TECHNOLOGY

Digital twins with Smart Construction; Trimble’s deals with Kobelco and Hyundai; AI for Leica Geosystems; Bentley year in infrastructure

Asphalt sphalt paving

EXTENDED DIGITAL CONTENT D1-D24

Trialling new technology p34

See page 34

Innovations in earthmoving p9 Key Project: Canada’s new bridge p32

22 IRF

IRF World Road Statistics – published; 3rd Annual

24 IRF

09 EARTHMOVING

A trial of innovative paving is being carried out in the UK by Holcim, testing a novel asphalt grade and using sophisticated technology from Topcon and the Wirtgen Group

26 HIGHWAY & SAFETY Advances in systems for highway & safety will reduce risks for road users

IRF Global Europe, & Central Asia Congress; IRF Global membership benefits

New dozers from Caterpillar and Hyundai; Liebherr unveils new technology and complete Generation 8 dozer range

EXCLUSIVE DIGITAL CONTENT BETWEEN PAGES 33-34

EUROFILE

NEWS D17-D21

World Cement Association price warning; Norway’s Fiskefjord tunnel finished; Komatsu Smart Quarry Site (SQSite) solution

KEY PROJECT REPORT P32-33 & D1-D5

Construction of Canada’s new Pattullo Bridge replacement should be complete by the close of 2025

D6 RECYCLING D7-D8 EQUIPMENT D9 SKIDMARKS

NORTH AMERICA

NEWS D11-D16

Delaware River bridge replacement; Collapsed Francis Scott Key Bridge; Plans launched for 24.4km Florida toll road; Repairs for I-40 in North Carolina

GLOBAL HIGHWAYS 2025 VOL. 6

EMERGENT

NEWS D22-D23

Kenya-Uganda expressway; Bridge for Ho Chi Minh City; Reunion coastal road; Bahrain Airport road link

Extended features & latest digital content globalhighways.com

Positives and negatives for machinery sales

Bonus Digital Content

REPORT

Construction of Canada’s new Pattullo Bridge replacement should be complete by the close of 2025

34 ASPHALT PAVING

Holcim using Topcon and Wirtgen technology for paving trial; new Dynapac SD paver used in Germany; Vögele paving at night on historic site

38 ASPHALT PLANTS

46 ENGINES

Retrofitting an Ermont plant in France; fast Lintec installation in China; Brazil location for new Benninghoven plant

Volvo Penta establishes a technician training programme; Hyundai’s new engine; Rolls Royce producing 2000 series in China

42 ROAD RECYCLING

48 CONCRETE PAVING

MB Crushing recycling onsite; screening bucket from Simex; Rotar’s latest cutter attachment; new recycling plant for Heidelberg

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Mike Woof Editor

“Those who remain flexible will still have opportunities in a fragmented global market”

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32 KEY PROJECT

he business situation for machinery and equipment manufacturing companies from Germany and Europe continues to show both positive and negative aspects. There are significant regional differences, which is reflected in the results of the latest VDMA Business Climate Survey for Brazil, China, India, and the USA. While the signals in India and Brazil are predominantly positive, the mood in China and the US is more subdued. "The results of the survey show once again that VDMA members assess the business outlook in the individual countries very differently. India is a ray of hope for them, with stable business development in these challenging times. In Brazil, they are confronted with weakening demand, and in China, their business is slowly emerging from stagnation. In the US, German subsidiaries are struggling with the consequences of trade policy decisions," said Anke Uhlig, VDMA Economics and Statistics. India remains the most reliable market among the countries surveyed. Business sentiment among the Indian subsidiaries of VDMA members has remained at a consistently high level since autumn 2024, despite high US tariffs and weak demand from Europe. Of the companies surveyed, 55% expect an improvement in the next six months, while another 41% consider a stable situation to be realistic. The VDMA Business Climate Survey shows that the international sales markets of European machinery and equipment manufacturing companies still drift apart. India and Brazil remain pillars of growth, while VDMA members in China are suffering from competition and those in the US from trade policy pressures. "Global uncertainties and tariffs are challenging German and European machinery and equipment manufacturing. Today, differentiated market strategies and a strong local presence are crucial. Those who remain flexible will still have opportunities in a fragmented global market," summarised Uhlig.

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NEWS

HITACHI REBRANDING AS LANDCROS Hitachi Construction Machinery plans to rebrand as LANDCROS, effective April 2027, as part of a transformation of the business

to customers around the world in construction and mining. Francesco Quaranta, HCM Europe president & CEO, said: “LANDCROS represents our commitment to go beyond machinery, empowering customers with intelligent, connected, and sustainable solutions. It is based on a partnership philosophy, working openly with technology leaders,

integrating cutting-edge digital and AI capabilities into machines that symbolise reliability in the construction

Work on a key link in Hamburg has been stopped following a court ruling

Hamburg motorway construction halted Construction work for the A26 Autobahn route for Hamburg in Germany has been halted. This follows a ruling by the Federal Administrative Court in Leipzig and work on the planned A26East harbour Autobahn has been stopped on environmental grounds. This follows a lawsuit by the environmental bodies NABU and BUND Hamburg. The route of the A26 East stretch, facing the legal action, runs between Moorburg and

Stillhorn. The issue is that the alignment runs through moorland areas. But NABU has suggested that the existing main port route could be upgraded instead of building the new A26. The A26 route was also intended to provide additional connection between the A1 in the west of the city and the A7 in the east of the city, which are two of the busiest Autobahn routes in Germany.

GLOBAL HIGHWAYS 2025 VOL. 6

MASSIVE TUNNEL PROJECT FOR SYDNEY, AUSTRALIA

The TBM drive for Sydney’s Western Harbour Tunnel project will commence once the drilling machines have been made ready in the recently completed twin launch caverns. The two TBMs are the largest such machines in the Southern Hemisphere and have been named Barangaroo and Patyegarang. They will drive dual bores a distance of 1.5km and at a depth of 50m below sea level. The 1.5km tunnel section will be a key stretch of the 6.5km link that The famous Sydney Harbour Bridge will benefit from lower traffic volumes once the new project is complete in 2028

he firm explains that as the construction and mining industries are entering a new era, there are demands for faster, smarter, and more sustainable ways to build infrastructure, with fewer skilled operators, lower costs, and tighter deadlines. The company explains that LANDCROS expresses the company’s determination to deliver innovative solutions

industry, whilst creating a reimagined customer experience from ground to cloud.”

connects the Warringah Freeway and the Rozelle Interchange. Once the Western Harbour Tunnel is completed in 2028, the link will provide three lanes in either direction and will help to lower traffic levels on other major routes in Sydney. Traffic is expected to drop by 35% for the Western Distributor, 20% for the Harbour Tunnel and 17% for the famous Sydney Harbour Bridge.

INDIA PROJECT CONTROVERSY

The proposed $2 billion road-tunnel project for South Bengaluru is attracting further controversy. The 17km route runs underneath the historic Lalbagh Botanical Gardens, a serious cause for concern. Some believe that the 15m diameter tunnels, around 50-100m underground, could pose an environmental threat to the sensitive ecosystem of the famous gardens. There are concerns, too, that construction work could also cause issues for the Lalbagh Rok, a Peninsular Gneiss National Geological Monument.

Extended features & latest digital content globalhighways.com

STRENGTHENING INFRASTRUCTURE FOR THE NEXT GENERATION

For additional product information and services please visit: ammann.com GMP-2249-02-EN | © Ammann Group

NEWS

Challenging Norwegian bridge project

DRILLING FOR €836 MILLION ROMANIA PROJECT

When the Sibiu-Pitesti stretch of Romania’s A1 motorway is complete, this will boost trade and tourism for the historic region of the country

Drilling and blasting work is underway in Romania for the Robesti Tunnel which will form part of the Sibiu-Pitești stretch of the A1 motorway

riving the 900m tunnel will require removing 200,000m3 of material and the use of 70tonnes of explosives, while the contracting team is expected to use around 60,000m3 of concrete and 4,000tonnes of reinforcement. Section 2 of the motorway between Boita and Cornetu measures just over 31km in length but is challenging due to mountainous terrain. This section will require the construction of 48 viaducts and bridges as well as seven tunnel stretches, with the work costing €836 million and due for completion in 2028. Construction is being carried out by a Turkish contracting consortium comprising Cengiz and Mapa and is being managed by Romania’s National Road Infrastructure

Administration Company (CNAIR). Section 3 presents similar challenges because the 37.4km alignment is also in mountainous terrain. This €1 billion contract is being built by Webuild and will feature 52 bridges, as well as tunnels. A TBM is being used to drive the 1.78km tunnel at Poiana which is part of Section 3. The 1.35km Momaia tunnel in section 4 is being built by Austrian contractor PORR, using the NATM technique. Meanwhile, construction is also underway for Romania’s A7 highway project. The 96km route links Focani and Bacu. The project is being carried out jointly by Technostrade, Spedition, SA & PE Construct and is being managed by the Moldova Wants Highway Association (MVA).

GLOBAL HIGHWAYS 2025 VOL. 6

Cranes from Liebherr are playing a key role in the construction of a highly challenging bridge project at the edge of the Sognefjord in Western Norway. The Ytre Steinsund Bridge is a cantilever structure due for completion by the end of 2026 and will boost connectivity between coastal areas near Hardbakke. Four Liebherr EC-H series tower cranes are playing key

roles in the project, operating reliably despite the tough conditions. The Sognefjord coastline is known for winds, rough seas and challenging weather conditions. Steel and concrete elements are delivered by boat and lifted directly from the moving vessel onto the bridge. These operations are possible with accurate crane technology delivering full performance under extreme conditions.

Cranes from Liebherr are playing a key role in the construction of a bridge in Norway, despite challenging weather conditions

FINLAND-SWEDEN TUNNEL AND BRIDGE LINK

A study is now being carried out for the proposed tunnel and bridge link to connect Sweden and Finland. Running between the Swedish capital, Stockholm, and the Finnish city of Turku, the alignment would link Swedish and Finnish islands, including the island of Åland. With an estimated cost anywhere from €10-20 billion, the project is controversial both on grounds of cost and environmental concerns. The study for the project has support from the Confederation of Finnish Industries (EK).

CHINESE ROAD BRIDGE COLLAPSES

A highway bridge in China’s South-Western Sichuan Province has collapsed partially, following a landslide.

The 758m bridge was completed earlier this year and was built by Sichuan Road & Bridge Group. Heavy rainfall in the area is believed to have triggered the landslide, which ripped away the approach at one end of the bridge. Cracks had appeared the day before the collapse and the stretch of road was closed to traffic by police. The Chinese authorities are undertaking an investigation into the cause of the collapse.

$46.3 BILLION UAE INFRASTRUCTURE INVESTMENT

The UAE is planning to spend $46.3 billion on transport infrastructure development between now and 2030. One of the biggest projects will be for a fourth federal highway measuring 120km. This will feature six lanes in either direction and will be able to carry up to 360,000 vehicles/day.

Extended features & latest digital content globalhighways.com

EARTHMOVING

DOZING EFFICIENCY: LIEBHERR, CATERPILLAR, HYUNDAI New bulldozers from Caterpillar and Hyundai are said to offer higher efficiency and performance and Liebherr has completed its Generation 8 line-up of crawler dozers

he latest bulldozers from Caterpillar and Hyundai are said to offer performance gains, as well as greater working efficiency. Both companies are offering new models that deliver higher productivity and benefit from the latest smart control technology. Meanwhile, Liebherr is offering a full lineup of the latest Generation 8 crawler dozers, ranging from the compact PR 716 up to the topof-the-range PR 776 G8. This latest generation combines engineering advancements with robust reliability, offering high-performance solutions for construction projects around the world. These new machines can utilise the latest in machinecontrol systems, helping optimise operations for contractors. Production takes place at the Liebherr facility in Telfs, Austria, which has recently Global Highways Magazine for industry-related discussion

undergone significant investments to strengthen capacity and future-readiness.

Caterpillar advanced technology Caterpillar says that its next-generation D8 dozer features advanced technology designed to provide faster and more accurate results. The long undercarriage is said to deliver high-penetration forces and efficient dozing performance. The Cat C15 engine offers 271kW, an increase in power over the previous model, allowing it to handle a wider range of tasks. The next-generation cab offers more space than the previous design and features an integrated rollover protective structure (ROPS), as well as 17% more visibility. It can be removed in 30 minutes to allow access for servicing.

ABOVE Caterpillar’s new Next Generation D8 dozer offers greater connectivity than previous models, as well as the capability for remote operation

GLOBAL HIGHWAYS 2025 VOL. 6

EARTHMOVING

The touchscreen display has built-in, key-features assistance to give operators an overview of the machine. When the machine is in reverse, the rearview-camera feed shows in the display. Assist-technology features minimise operator input, boosting productivity for less experienced operators and decreasing effort and fatigue, while delivering quicker and more precise outcomes. Cat Assist with Attachment Reader Option (ARO) are standard features and they include: stable blade, traction control, steer assist, blade load monitor, autoRip, autoCarry, Cat Grade and slope indicate. Featuring an external connector for installation of a roof-mounted unit, the machine is also remote-control ready. Cat Command for Dozing allows remote dozer operation when working in hazardous environments. Portable and lightweight, the Command console provides line-of-sight remote control up to 400m for optimum visibility. The remote control can be used at greater distances using camera equipment and the station features a comfortable seat, familiar controls and allows the use of Grade, Payload, Assist and other technologies using the included touchscreen. The next-generation D8 dozer design enables a wide range of machine connectivity. The Remote Troubleshoot tool allows the Cat dealer to perform dozer diagnostic testing remotely. And Remote Flash enables on-board software updates without a technician.

Hyundai mid-weight best-in-class Hyundai Construction Equipment claims that its powerful mid-weight dozer delivers best-in-class power and tractive effort, precise grading and a range of smart technologies.

For the latest news, extended features and videos on earthmoving and soil compaction visit the website globalhighways.com

"As the cab can be tilted rearwards, there is good access to the driveline and hydraulics"

The new HD130 offers fully electrohydraulic controls and 2D blade dozing assist function as standard. It also has a narrow nose with inline precleaner and large windows for high visibility, as well as a 117kW engine providing best-in-class power output. The tiling cab allows access to major driveline components while the durable undercarriage offers long service life. Power comes from a proven Perkins 4.4 litre diesel, delivering 710Nm of torque. An Eco Mode can be selected for lighter grading duties, lowering the hydraulic-pump power output and reducing fuel consumption by 5%. Auto-idle and auto-shutdown features help to reduce fuel use over the working shift. The machine has a reversible, hydraulically driven cooling fan for the engine and hydraulic oils, with an electrically driven fan for the charge air cooler that can also be reversed to clean out the core. The cooling system is located towards the rear of the machine, rather than in front of the operator. This keeps cooling cores situated out of dusty areas behind the blade while allowing a slim engine canopy that maximises visibility to the blade tips. Daily service points are reached from ground level through access doors. As the cab can be tilted rearwards, there is good access to the driveline and hydraulics. A variable displacement axial piston pump provides high hydraulic flow. The two-speed transmission offers a maximum travel speed of up to 9km/h, while maximum gradeability is 35o. There are two six-way, power-tilt angle dozer options. A 3.54m3 XL blade is standard, while a 4.18m3 capacity LGP blade is available as an option.

The new Hyundai HD130 dozer competes in the 13tonne class and can be used with advanced machinecontrol tools

GLOBAL HIGHWAYS 2025 VOL. 6

Extended features & latest digital content globalhighways.com

Komatsu WA485-11

The WA485-11 features the latest Komatsu Hydraulic Mechanical Transmission (K-HMT) and a powerful 271 kW next-gen engine, delivering exceptional productivity and fuel efficiency. Its all-new cabin prioritizes ergonomics, with a clear digital dashboard, a joystick steering system for seamless machine control, and new levers for an ultralow fatigue driving experience. The optional Aggregate Handling specification enables efficient loading of 28-ton trucks in just three passes. Komatsu Europe International N.V. · Mechelsesteenweg 586 · B-1800 Vilvoorde · Belgium · All rights reserved

Komatsu_WA485-11_210x297en.indd 1

komatsu.eu 12.11.2025 12:46:34

EARTHMOVING

A two-way mechanical adjustment also allows the operator to set the blade pitch, from 54 to 58o. The HD130A has an operating weight of 15.3tonnes with the LGP blade, and 14.5tonnes in XL configuration. The standard 2D blade dozing assist function can be programmed to the required finish grade. The machine controls blade functions, without the need for lasers or GPS control. A draw bar is offered and the machine can be equipped with piping for a parallel ripper. The ROPS/FOPS cab rides on CabSus mounts to dampen vibrations and provide protection for the operator against impacts. Glazed doors provide an unobstructed view of the blade, with the engine air pre-cleaner hidden beneath the canopy, improving visibility further. Standard features include a rearview camera and four high-illumination LED working lights. Electro-hydraulic controls are standard in the HD130A to meet the needs of all operator skill levels. Ergonomically designed joysticks, with integral armrests, deliver low-effort control for minimum fatigue. The HD130A is equipped with Hyundai’s Hi MATE remote-management system as standard. Using GPS technology, telematic monitoring provides realtime machine-operating data, including location information.

Liebherr - futuristic forces in motion Liebherr’s Generation 8 series spans a wide range of operating weights and power outputs to meet diverse construction-site requirements. The PR 716 G8, with an operating weight of 13.3 tonnes is ideal for compact, precise work. The PR 776 G8, weighing up to 73.19 tonnes and delivering 565kW is designed for the most challenging heavy-duty tasks. All Generation 8 models feature a hydrostatic travel drive that ensures smooth, precise movement,

GLOBAL HIGHWAYS 2025 VOL. 6

ABOVE Shaping the future with every push, Liebherr’s Generation 8 crawler dozer in action

maximising efficiency across all operating conditions. Integrated driver-assistance systems support operators by automatically controlling blade positioning for accurate grading, reducing fatigue and improving productivity on long shifts. The machine cabs have been designed with operator comfort as a priority, featuring fully adjustable suspended seats, advanced climate control, large windows for optimal visibility and intuitive touchscreen displays for easy control of functions. In addition, the Generation 8 dozers offer optimised fuel efficiency and low emissions, combining high

Extended features & latest digital content globalhighways.com

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EARTHMOVING

performance with sustainable operation. These enhancements make the machines highly versatile, capable of handling everything from largescale earthmoving to fine grading and slope work. Generation 8 crawler dozers are engineered for diverse applications, including urban infrastructure projects, mining operations, road construction and environmental projects. Their robust undercarriage, powerful engines and adaptable blade configurations make them suitable for a wide range of terrain - from soft soils and sand to rocky landscapes. The PR 716 G8 and PR 726 G8 are particularly effective in precision tasks such as trenching, landscaping and fine grading. Both the 736 and the 746 are the perfect bridging machines to more demanding jobsites, while the larger crawler dozers from PR 756 G8 and PR 776 G8 excel in heavy-duty earthmoving, dam construction and quarry operations. The machines are GNSS-ready and have smart ECO modes that allow operators to execute tasks fully automatically with high accuracy, while minimising fuel consumption. In addition, the hydrostatic drivetrain delivers up to 20% fuel savings compared to conventional drivetrains, further enhancing efficiency. The availability of multiple blade types, including sixway and straight blades, ensures flexibility for diverse job requirements and site conditions. These machines are built to operate reliably in extreme climates, from hot and arid regions to cold and wet environments, making them a trusted choice for construction companies around the world.

Liebherr invests in Telfs site To support the production of the Generation 8 lineup, Liebherr has made substantial investments in its Telfs facility. These upgrades encompass expanded manufacturing capacity which have reduced lead

GLOBAL HIGHWAYS 2025 VOL. 6

“Futuristic force in motion, Liebherr’s Generation 8 crawler dozers lead the way"

times, advanced assembly lines, and the introduction of energy-efficient production technologies. Notably, a new logistics centre has taken effect at a cost of around €35 million, plus a new administration building, including a customer hospitality area, and substantial investments in the R&D department. The investments not only enhance output but also ensure that the facility retains its high manufacturing standards, meeting the growing demand for high-performance machinery across global markets. Liebherr is also reinforcing its readiness for future innovation by integrating smart manufacturing processes and quality-control systems. These measures guarantee that every Generation 8 machine meets the company’s stringent standards for reliability, safety and performance. The new Generation 8 crawler dozers are ready to support construction projects worldwide, offering contractors a combination of strength, precision and efficiency. Liebherr provides comprehensive aftersales support, including operator training, technical services, and spare-parts supply, ensuring long-term operational readiness. By combining advanced machine technology with global service networks, Liebherr enables customers to complete projects on time, within budget and with high-quality results. The Generation 8 crawler dozers mark a significant step in Liebherr’s mission to equip construction sites globally with powerful, precise and sustainable machinery. By combining innovative design, versatile applications and long-term support, Liebherr continues to strengthen its position as a trusted partner for infrastructure development worldwide. End www.liebherr.com www.cat.com www.hyundai-ce.eu

Extended features & latest digital content globalhighways.com

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EARTHMOVING

INNOVATIVE EARTHMOVING

Liebherr is working on innovative earthmoving solutions that could deliver a lower total cost of ownership (TCO) for customers – Mike Woof reports

iebherr is working on some radical technologies for off-highway machines that will be applicable to markets such as earthmoving, quarrying and mining. The company demonstrated some of these systems at the bauma 2025 event but continues to refine the systems. According to Dr Manuel Böst, in charge of R&D and emerging technologies at Liebherr’s Bischofshofen facility, these technologies have moved beyond being prototypes for demonstration and are now undergoing field trials in working sites. The solutions have been developed to deliver safe and practical remote control of machines working in hazardous locations. Solutions have also been developed to offer autonomous operation of machines. And another radical development is for a totally autonomous, self-balancing electric hauler that features just two wheels. Dr Böst explained that the firm is working on these new systems to meet key challenges for the construction, quarrying and mining sectors. There is a worldwide shortage of people wanting to enter these industries, which new technology could help to address. Furthermore, these new systems could also help address other challenges such as safety, decarbonisation, increasingly tough regulations and even urbanisation. Dr Böst said that the remote, semiautonomous and autonomous technology will help address the shortage of operators by taking over some of the simple and repetitive tasks. However, he said

GLOBAL HIGHWAYS 2025 VOL. 6

ABOVE The simulator has been developed jointly by Liebherr and Tenstar and allows operators to be trained on various types of machines in safety

“We want to use existing technology as much as possible. You don’t even need 5G.”

that this will not replace the need for people to operate machines. “The human operator will still be needed for more complex tasks.” The latest Liebherr remote-control system, LirReCon, allows machines to be operated from a remote location and utilises available technology from the firm. However, the system can only be fitted to the firm’s newer generation machines and not to earlier models. Florian Falbesoner, Group Manager Technology and Advanced Engineering, at Liebherr Telfs, commented: “We want to use existing technology as much as possible. You don’t even need 5G.” The system uses private IP-based communications which offer the necessary cyber-security according to Falbesoner, and he added; “Data security will be a big issue.” The system is based on existing assistance systems and even allows long-distance tele-operation for use on sites that are hard or dangerous to access. Remote diagnostics also allow firms to optimise operations through data collection. The autonomous system takes technology one step further. When a machine is delivered to site, an operator can drive the piece of equipment around first. This allows the machine to ‘learn’ the work area. Falbesoner said: “You don’t need special expertise to do this.” The firm has been evaluating its autonomous technology in working areas, with the system having Extended features & latest digital content globalhighways.com

EARTHMOVING

notched up more than 3,000 hours. The technology can learn from a worksite and make decisions on routes. Falbesoner said: “The machine never does the same job twice. You can monitor it from anywhere in the world.” Human machine operators are still a focus for Liebherr, however. To assist in training operators safely, Liebherr has developed a sophisticated simulator in partnership with specialist firm Tenstar. The units have controls similar to Liebherr machines and can be used to simulate a wide range of machines. These can be used for basic training of inexperienced operators or for training more experienced operators for more specific tasks. The units can be bought by customers with large equipment fleets but are also being supplied to Liebherr dealers. Customers can access these to ensure operators are kept up to date with training requirements in a safe environment, without risking either personnel or machines. Liebherr has also developed a simple and costeffective 3D grading system for use with dozers. This

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ABOVE LEFT The SL1 is an innovative, prototype, autonomous system for hauling that could be scaled up in size for larger operations ABOVE RIGHT The PR776 dozer is the largest model in Liebherr’s dozer range and is now available as part of the Generation Series BELOW Dozers are built to order on the line at the firm’s factory in Telfs, Austria

is claimed to optimise working and offer consistently high-performance results, while reducing fuel consumption by up to 10% at the same time. This is available as an alternative to machine-control technology, although Liebherr customers can also specify systems from Leica Geosystems, Topcon, Trimble, and now Unicontrol, from the factory. Perhaps the most radical system being worked on by Liebherr is its innovative hauler, the S1, a novel solution to haulage requirements. This compact machine is able to carry 500kg and is self-balancing, with direct electric drive to each of its two wheels. According to Altan Enginalev, CEO-S1 Vision at Liebherr, the concept is entirely scalable. Larger versions could be built for heavy-duty earthmoving operations and using available truck tyre technology would allow maximum payloads of up to 130tonnes. Enginalev said: “It has one axle and one axis for movement and balance. The machine is able to pivot and turn on the spot. This was designed as autonomous and self-balancing.” Enginalev added that it features electric drive and is driverless, allowing it to be used in difficult operations with restricted space, such as tunnelling. “We built it and it works. Now that we know it works, the next step is to scale it up. The future is one step ahead,” he added. As it has no cab, there is no need to consider operator comfort so the S1 has no need for suspension. This keeps its design simple, reducing the number of components required. The simple body can tip to release its load. Sensors and LiDAR systems ensure that the S1 can identify obstacles in front and behind. The unit can be guided by GPS although versions for underground use would be able to utilise localised systems to determine position. Inertial measurement units (IMUs) will also likely help the units to geolocate. Whether the unit requires a gyroscope for stability or how it balances have not been revealed and the firm is reluctant to reveal many technical details until the S1 has undergone more testing. End www.liebherr.com GLOBAL HIGHWAYS 2025 VOL. 6

CONSTRUCTION TECHNOLOGY

HARNESSING THE POWER OF DIGITAL TWINS

Bart Vingerhoets, senior commercial manager at Komatsu Smart Construction, says that adopting digital twins in earthmoving projects can address some of the challenges, such as labour shortages and rising materials costs, currently facing the earthmoving sector

he European Centre for the Development of Vocational Training (Cedefop) has estimated 4.2 million construction-worker job openings will need to be filled in Europe between 2022 and 2035 to meet projected demand. With an ageing workforce, rising project requirements and a shortage of skilled labour, investment in training and innovative technologies is essential for construction. Digital twins are revolutionising earthmoving projects by providing a continuous up-to-date representation of a jobsite. Data within a digital twin can be utilised by AI systems to help optimise resource allocation. By simulating different scenarios, such as fleet compositions or sequencing project milestones, AI can assist project managers in deploying machinery and labour, boosting productivity and allowing workers to focus on other tasks. In terms of training, digital twins assist in upskilling the workforce by improving progress tracking and enabling online logging of completed work, providing a reference for future maintenance or modifications. In addition, digital twins enable real-time tracking of progress, supporting managers in making decisions and resolving issues, minimising downtime and keeping projects on schedule. Collaboration between the workforce is enhanced because stakeholders can access the virtual site model, facilitating communication and feedback. Automating data analysis and reporting frees up time spent on administrative tasks, allowing the workforce to focus on critical tasks, leading to improved outcomes in projects. A key jobsite focus is delivering projects on time and within budget. Digital twins enable predictive maintenance through real-time monitoring, reducing downtime and increasing efficiency. Solutions such as the Smart Construction Dashboard provide an interactive 3D model that updates continuously in real time via various data streams. This platform allows users to visualise

GLOBAL HIGHWAYS 2025 VOL. 6

operations, analyse performance and provides data to run predictive assessments based on historical trends. Digital twins allow better-informed decisionmaking while boosting productivity and minimising reliance on guesswork to keep projects on track. This reduces delays, cuts rework requirements and minimises idling, enabling projects to run more efficiently. Improving safety is a major focus for the industry. Through the virtual jobsite, managers can boost workplace safety by identifying and mitigating potential hazards. By analysing real-time data, operators can detect potential risks and run safety trials before executing them, ensuring that the operation is successful. Sensors and IoT technology enable the digital twin to track workers, vehicles and equipment, alerting the team when an issue arises. This capability allows for quick, reactive responses to mitigate risks and hazards. Additionally, site managers can monitor the site virtually, reducing travel time and fuel consumption as well as eliminating the need to visit hard-to-reach or dangerous environments. For Sina Motsch, site manager for HEITKAMP Corporate Group, it was crucial that she made effective use of site information. By utilising Dashboard by Komatsu Smart Construction, Motsch was able to collect as-built data from the dozer to generate an accurate digital twin that was automatically updated as the site changed. The digital twin enabled Motsch to discover delays, developments or issues across the jobsite, without having to visit. Through Dashboard, project managers can track materials and progress as it happens, resulting in a wider status understanding and informing quick decision-making. As technology and digital solutions advance, we can expect to see an increase in earthmoving operators adopting these innovations to meet industry demands and enhance their operations. End smartconstruction.io

ABOVE Digital twins offer the potential for huge savings in earthmoving

ABOVE Bart Vingerhoets is senior commercial manager at Komatsu Smart Construction

ABOVE Sina Motsch, site manager for HEITKAMP Corporate Group, used Dashboard to collect as-built data

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CONSTRUCTION TECHNOLOGY

A NEW COLLABORATION FOR 2D A new collaboration makes the Trimble Earthworks grade control platform 2D guidance and control systems available directly through select Kobelco dealers in North America. This new offering, launched as Kobelco’s certified Trimble Earthworks 2D grade control program, is now available at Kobelco’s dealers across North America, enhancing machine productivity and jobsite precision. Kobelco has offered a Trimble Ready option from the factory on multiple machine models since 2017. But this new development now allows customers in North America to acquire excavators pre-equipped with Trimble Earthworks and receive training, service and support directly from their Kobelco dealer. This program enables certified Kobelco dealers to offer and install Trimble 2D machine guidance and control systems and offers customers a pathway to all the benefits of grade control technology, including 3D grade control. This provides solutions whether customers are seeking consistent grade accuracy with full manual control or semi-autonomous excavation with automated boom and bucket movement. Kobelco has established a certification process for dealers. Training includes online courses and in-person sessions covering both sales and technical service. Participating locations are also required to have demonstration equipment, a spare parts inventory and a technology champion.

By becoming certified, dealers gain the ability to offer pre-configured Trimble Earthworks 2D solutions alongside machine purchases. They can also deliver faster installation with Kobelco factory sensor mounts on select models and offer support upgrades to Trimble Earthworks 3D grade control through the SITECH distribution channel. www.trimble.com

ABOVE Kobelco customers in North America can now have Trimble 2D grade control systems available through selected Kobelco dealers

3D for dozers A Trimble Ready 3D option is now available for the new line of Hyundai HD130A bulldozers for customers around the world. A Trimble Ready version of the HD130A was announced for customers in North America in late 2024. This option allows HD130A bulldozers to be shipped directly from the factory equipped with a Trimble Ready kit for onsite installation of the Trimble Earthworks grade control platform on both the new Hyundai HD130A XL and the new HD130A LGP. The tool puts the project design in the cab of the dozer and automatically adjusts the blade’s position, enabling operators of all skill levels to work faster, more productively and with greater accuracy. In addition to the Trimble Ready version of the new dozer line, Trimble and Hyundai are also committed to collaborating on operator-assist features for construction machines, as well as an increased focus on cloud collaboration. Trimble’s SITECH dealer channel and select authorised resellers provide installation services, personalised training and local technical support for the Trimble Earthworks 3D grade control platform installed on Hyundai HD130A bulldozers.

Customers for Hyundai’s HD130A dozer have the option of a Trimble Ready 3D package for the machine

www.trimble.com

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CONSTRUCTION TECHNOLOGY

AI FOR TOTAL STATIONS Leica Geosystems is now offering its all-new Leica TS20 robotic total station. This total station is said to accelerate fieldwork, simplify daily work, streamline repetitive tasks and avoid costly mistakes. The TS20 incorporates insights gained from surveying practitioners to ensure it is tailored to real-world needs. A Neural Processing Unit (NPU) powers edge AI, enabling the Leica TS20 to optimise workflows autonomously, identify potential mistakes before they happen, and ensure reliable measurements while safeguarding data privacy. AI-powered target search and automatic target recognition (ATR) enable the TS20 to automatically search, aim, and measure even in adverse weather conditions like rain or mist, or when working with reflective tapes. AI-Detect recognises the target type and alerts surveyors when their target does not match the type they selected in the software. AI-Follow (available as a software update post-launch) saves time by following the Leica AP20 AutoPole even when the line of sight is interrupted.

ABOVE Powered by advanced edge AI, the TS20 is claimed to advance automation in surveying

For the latest news, extended features and videos relating to Construction Technology visit the website

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The world’s first robotic total station with an IP66 rating, the TS20 is protected against dust and water. The total station blends traditional models with state-of-the-art components. It offers advanced communication sensors with mobile internet connectivity for data sharing and IoT readiness. Fast, maintenance-free motors speed up the instrument, making it dependable and reducing the cost of ownership. A new electronic distance measurement (EDM) system delivers distances with higher frequency. And new, high-speed processors accelerate tasks such as startup times or processing tasks. The TS20 works with Leica Geosystems’ existing software and cloud ecosystem, accessories, and the AP20 AutoPole. Exclusive to the TS20, GeoCloud Protect offers smart safety features like remote locating and locking. TS20 operators can access the total station’s location on a map and, in case of theft, mark it stolen and lock the total station so it can neither be used or serviced. End www.leica-geosystems.com

Machine-control option for Develon Develon and Leica Geosystems, part of Hexagon, have announced that the Leica MC1 3D machine-control solution is now available as an aftermarket kit for all Develon 9 Series Crawler Excavators. This advanced system is designed to integrate with Develon's existing 2D sensors and calibration systems, ensuring a smooth

and efficient upgrade to 3D technology for customers across the entire 9 Series line-up. At the heart of the Series 9 excavators is an advanced, open-control architecture that allows real-time communication between the excavator’s built-in sensors and the 3D machinecontrol package from Leica Geosystems.

GLOBAL HIGHWAYS 2025 VOL. 6

Through this control-level integration, operators can access Leica Geosystems’ precise 3D automation while continuing to benefit from Develon’s industry-leading 2D technologies, including Virtual Wall for defining safe operation boundaries, Weighing System for real-time load measurement, and Advanced

Lift Assist for enhanced lifting stability. Upgrading to 3D is a straightforward process. Customers install the Leica MC1 3D aftermarket kit, and with the Series 9 controller managing communication between internal and external systems, the package can be utilised.

www.eu.develon-ce.com www.leica-geosystems.com

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CONSTRUCTION TECHNOLOGY

BENTLEY YEAR IN INFRASTRUCTURE Infrastructure software specialist Bentley Systems held its Year in Infrastructure Awards event 2025 in Amsterdam in the Netherlands, highlighting the latest and best in construction engineering. The firm also announced the winners of its annual Year in Infrastructure Awards for 2025. In Roads and Highways, the three contenders came from Australia, China and Malaysia. The Australian project was for revamp work to the congested Warringah Freeway on the north side of Sydney, New South Wales. The Chinese project was for a scenic stretch of road running along the border with Vietnam and linking the Detian waterfall with Shuolong in GuangXi Province. The Malaysian project was for the construction of the Sabah-Sarawak link road. Meanwhile, in the Bridges and Tunnels category, the contenders were from Brazil, Italy and the US. The Brazilian project was for the construction of the 12.4km Itaparica bridge linking Salvador with Itaparica Island. The Italian project was for the development of a digital solution for remote identification of construction problems with tunnel structures. The US project was for the redevelopment of the waterfront area of Philadelphia in Pennsylvania, with the construction of a new bridge connection and a new park on a deck above the I-95 highway. The winner in the Roads and Highway category was Indonesia’s Sabah-Sarawak

Highway. The winner in the Bridges and Tunnels category was Italferr’s innovative remote tunnel-inspection technology. Technology was in focus and Bentley Systems CEO Nicholas Cumins highlighted the importance of artificial intelligence (AI), explaining that this is revolutionising construction, delivering projects faster and more efficiently. There are challenges though, and he said, “AI is driving a global build-up of data centres and infrastructure is struggling to cope.” The need for AI as a tool to assist with project development is acute and he said, “There aren’t enough engineers in the world to do all the work that is needed.” Cumins explained that AI is transforming infrastructure development with around 50% of the projects submitted to the Bentley Systems Innovation Awards utilising AI to some degree. However, he cautioned, “AI must remain a collaborative process.” Unlike some technology firms, Bentley Systems operates an opt-in process for its customers who wish their projects to be part of the AI learning process. Clients for Bentley Systems who do not want their data utilised for AI learning can ensure this remains protected. The firm also made two major announcements regarding its software technology. One was for the Bentley Infrastructure Cloud Connect system,

a new foundational layer for Bentley Infrastructure Cloud. Connect provides a connected data environment for infrastructure professionals using project and asset data, improving collaboration across the infrastructure lifecycle. The other new product announcement was for reality modelling services from Cesium, advancing its open platform for the built and natural environment. It also unveiled geospatial capabilities for project delivery and asset performance and a new immersive engagement application for infrastructure teams and stakeholders, all powered by Cesium. In addition, Bentley has established a digitalisation partnership with EARTHBRAIN, a joint venture between Komatsu, NTT Docomo Business and Nomura Research Institute. This collaboration builds on the existing partnership established in 2019 between Komatsu and Cesium. Through the new partnership, Smart Construction will incorporate Bentley Systems’ open, AI-powered digital-twin technology and applications to enable workflows that span the construction lifecycle. By linking the construction process, the partnership will help digitalise working, boosting safety, productivity, and sustainability. These new capabilities in smart construction will be available initially in Japan with the opportunity to expand globally.

www.bentley.com

Bentley Systems announced the award winners at its Year in Infrastructure 2025 event

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ASSOCIATIONS

INTERNATIONAL ROAD FEDERATION NEWS

3rd IRF Annual Europe & Central Asia Regional Congress, held in Bulgaria, Strengthens Cooperation

IRF Global Unites Industry Stakeholders in Sofia

he International Road Federation (IRF Global), in collaboration with the Institute of Transportation Engineering, successfully hosted the 3rd IRF Annual Europe & Central Asia Regional Congress and the XVIIIth Bulgarian National Transport Infrastructure Conference on October 14-16 in Sofia, Bulgaria. Held under the theme “Reimagining Regional Corridors: Safe, Resilient, Connected & Future-Ready”, the congress brought together more than 150 speakers and delegates from more than 30 countries to discuss the future of regional mobility. The congress highlighted innovative policies, emerging technologies and sustainable strategies driving the evolution of road and transport infrastructure across Europe and Central Asia.

Technology and Innovation Take Centre Stage

A Hub for Regional and International Collaboration The congress served as a premier platform for government officials, multilateral institutions, academia and industry leaders to exchange insights and discuss key priorities for the sector. Discussions focused on advancing regional connectivity, digitalisation, safety and

GLOBAL HIGHWAYS 2025 VOL.6

resilience, emphasising the importance of cross-border partnerships and collective action. Through a combination of executive panels and technical sessions, participants explored investment frameworks and policy innovations aimed at accelerating the transition toward safer, greener and smarter transport systems.

Running alongside the conference, a technical exhibition featured stateof-the-art technologies and equipment transforming the mobility landscape. Exhibitors showcased smart mobility platforms, sustainable construction materials, intelligent safety systems and next-generation maintenance tools, offering attendees a firsthand look at the innovations shaping tomorrow’s roads.

Advancing a Shared Vision for the Future With an active network spanning more than 120 countries, IRF Global continues to play a vital role in strengthening institutional capacity, promoting knowledge exchange and advancing sustainable mobility worldwide. End

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INTERNATIONAL ROAD FEDERATION NEWS

IRF Global Membership: Connecting the world’s transport professionals IRF membership connects you to a global network where knowledge, collaboration and advocacy turn into real-world impact

or more than 77 years, the International Road Federation (IRF Global) has been a leading force in shaping the global transport sector. Founded in 1948 in Washington, DC, the IRF has maintained a presence across six continents, bringing together governments, private companies and research institutions to build safer, smarter and more resilient roads.

IRF membership connects you to a global network where knowledge, collaboration and advocacy turn into real-world impact Membership of IRF Global gives organisations and professionals unparalleled access to experience and knowledge accumulated over decades of

international work. Through its global network, members can engage in meaningful advocacy, contributing to policy dialogues and influencing standards while also gaining practical guidance and technical support for infrastructure projects.

Building Skills and Supporting Tomorrow’s Transport Leaders IRF Global also emphasises training and capacity building, offering certified courses, workshops and webinars that cover road safety, sustainable infrastructure, and emerging technologies. Members benefit from exposure to best practices developed worldwide, ensuring they stay at the forefront of innovation. In addition, the programme supports the next generation through educational scholarships,

including the prestigious IRF Fellowship, helping students and researchers advance in the sector.

Visibility and Business Opportunities Beyond knowledge, membership opens doors to tangible business opportunities, connecting organisations to potential partners, stakeholders and global projects. Members’ initiatives and innovations are promoted internationally, giving them visibility and influence on a scale that few other platforms can offer.

Be Part of the Global Movement Join IRF Today

Join the IRF family and build a ‘Better Roads, Better World’. Scan the QR for more information or visit

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become part of a global movement dedicated to advancing safer, smarter and more connected transport systems, turning knowledge, collaboration and advocacy into measurable impact. End

www.irf.global/membership Email: info@irf.global

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INTERNATIONAL ROAD FEDERATION NEWS

Mind the Infrastructure Gap A recent new study from the IRF shows that low-income countries have only 1.7% of the world’s roads

ow-income countries account for just 1.7% of the world’s road networks, exposing deep global infrastructure inequalities that limit connectivity, accessibility and economic growth. The International Road Federation’s World Road Statistics (WRS) 2025 Edition shows that a reliable and extensive road network is vital for any economy, especially for low-income countries. Welldeveloped roads move people and goods efficiently, open access to markets and services and enable sustainable growth. By bringing communities closer and shortening the distance between people, markets and opportunities, roads foster inclusion and integration within and across regions. The study presents total road network length in kilometres for countries worldwide, disaggregated by road class from motorways and highways to main or national, secondary or other roads. It also classifies countries by geographic region and income level, enabling comparative analysis across different development contexts.

WRS data shows that global road networks are unevenly distributed, with the majority of total road length concentrated in higher-income countries. Countries classified as highincome account for the largest share of the world’s road

GLOBAL HIGHWAYS 2025 VOL.6

network (44.8%). This is followed by upper middle-income (29.7%) and lower middleincome (23.8%) countries (Figure 1). In stark contrast, lowincome countries account for only 1.7% of the global total. This limited share of low-

income countries is primarily the result of constrained public investment capacity and insufficient maintenance of existing networks. Such deficits in road infrastructure compound broader structural and economic challenges, restricting lowincome countries’ ability to accelerate development, attract investment and move toward a more higher income status. A regional breakdown of road networks shows persistent disparities in infrastructure development. East Asia and the Pacific hold the largest share of the global road network (26.5%), followed by Europe and Central Asia (19.7%), North America (18.8%), and South Asia (18.3%) (Figure 2). Together, these regions account for 83.3% of the global road infrastructure, reflecting their stronger economic bases and institutional capacities

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INTERNATIONAL ROAD FEDERATION NEWS

Figure 1: Global road network distribution by income level (Latest available road network data per country up to 2023)

in economic capacity but also from geographic realities and institutional readiness. Regions with vast land areas and difficult terrain face compounded challenges in building and managing road networks. Bridging this divide calls for targeted investment strategies, improved maintenance planning and innovative financing models that can adapt to local contexts. Strengthening road infrastructure where it is most lacking is not only a matter of connectivity. It is a prerequisite for inclusive growth, regional integration and long-term economic resilience.

Explore the IRF World Road Statistics The new IRF World Road Statistics (WRS) 2025 edition features updated data for over 200 countries and more than 200 indicators. Key topics covered include road networks, traffic volumes, multimodal transport comparisons, vehicles in use, road accidents, expenditures and revenues. The IRF Data Warehouse offers free, intuitive, interactive tools that allow users to perform in-depth analyses, compare multiple metrics and generate customised time-series charts. End For more detailed information on key statistical indicators in the road and transport sector – whether for a specific country or a global overview, please visit the IRF World Road Statistics website or email us at stats@irfofficial.org.



The WRS Road Data Snapshot Series was developed by IRF, with the support of the TotalEnergies Foundation and the Michelin Corporate Foundation. 

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29.7%

44.8%

23.8%  High income  Upper middle income  Lower middle income  Low income

1.7%

Figure 2: Global road network distribution by geographical location (Latest available up to 2023) 26.5% 19.7% 18.8% 18.3% 8.1% 5.6% 3.0%

 East Asia and Pacific  Europe and Central Asia  North America  South Asia  Latin America and the Caribbean  Sub-Saharan Africa  Middle East and North Africa

Figure 3: Share of global area versus road network by region (Latest available road network data per country up to 2023)  % of Global Land Area

 % of Global Road Network

5.6%

Sub-Saharan Africa South Asia

18.4% 18.3%

3.7%

North America Middle East and 3.0% North Africa

8.6% 8.1%

Latin America and Caribbean

15.4% 19.7% 21.2%

Europe and Central Asia East Asia and Pacific

18.8%

13.8%

18.9% 15 20

26.5% 25

Percentage of Global Total (%)

GLOBAL HIGHWAYS 2025 VOL.6

for sustained infrastructure investment. In contrast, Latin America and the Caribbean (8.1%), the Middle East and North Africa (3%), and Sub-Saharan Africa (5.6%) together make up only 16.7% of the global road network. This imbalance becomes even clearer when comparing each region’s share of the global road network with its share of total land area (Figure 3). Sub-Saharan Africa, accounting for 18.4% of the world’s land area but only 5.6% of the global road network, and Latin America and the Caribbean, with 15.4% of land area and 8.1% of the global road network, together show the widest disparities between vast territories and limited infrastructure coverage. This imbalance highlights how much of the developing world’s territory remains underserved by road infrastructure. These regions with smaller network shares continue to face structural barriers such as limited financing, challenging geography and weak asset management systems, all of which constrain connectivity and economic competitiveness. By contrast, South Asia stands out at the opposite end of the spectrum. It accounts for nearly 20% of the world’s road networks while covering only about 3% of global land area evidence of high infrastructure density and the intensity of transport demand in this populous region. Overall, WRS data demonstrates that disparities in global road infrastructure stem not only from differences

HIGHWAYS MANAGEMENT & SAFETY

HIGHWAY MAINTENANCE

PEDESTRIAN HYBRID BEACONS

Pedestrian hybrid beacons - not that common in the US - were developed for use in Arizona in 2019 but have only been installed in a few states. A recent academic report based on driver-behaviour data throws some light on just how safe pedestrians might be ABOVE Pedestrian hybrid beacons are very effective at locations where three or more lanes will be crossed or annual average daily traffic volumes are above 9,000, according to the US Department of Transportation (image courtesy Massachusetts Department of Transportation)

BELOW Sequence for a pedestrian hybrid beacon (source: MUTCD 2023 Edition, Chapter 4J, FHWA)

rivers in the US state of Massachusetts are struggling with new hybrid traffic signals and crosswalks, leading to potentially dangerous situations for pedestrians. According to research from the University of Massachusetts at Amherst, drivers are “stopping early, failing to stop or rolling through” at the 40 installations. This suggests that drivers need more awareness of the rules around the new crosswalk design. A report by the university is based on its academic research paper, An Evaluation of Driver Comprehension of the Pedestrian Hybrid Beacon*. The report was published in Transportation Research Record and considers how Massachusetts drivers behave at pedestrian hybrid beacons, PHBs. A PHB is a type of crosswalk device increasingly found at midblock crosswalks where there is not a full traffic signal. Because installation of more beacons is planned, the university warned that “confusion is a real safety issue”. PHBs have five phases of indications that communicate to motorists what to do, which allows for a greater flow of traffic than a traditional stop light while maintaining higher pedestrian visibility than similar beacon designs.

5. Alternating flashing red during pedestrian change interval

GLOBAL HIGHWAYS 2025 VOL.6

FR Y

SR Y

3. Steady yellow

The researchers found that across 10 sites within Massachusetts, on average, nearly a quarter of drivers drove through during the solid red phase, the equivalent of running a red light. Meanwhile, 65% of drivers drove through the flashing red regardless of pedestrian presence – similar to running a stop sign. Angelina Caggiano, lead study author and a PhD candidate in transportation engineering at UMass Amherst, said a lot of the drivers in the 65% bracket during the flashing red are drivers who are waiting in the line of cars, but then they roll through when their turn comes. “That’s especially problematic for….. shared-use path locations because there are going to

2. Flashing yellow upon activation

Rolling through

1. Dark until activated

The PHB remains “dark” when no pedestrian has activated it, and drivers proceed as usual. When a pedestrian pushes the walk button, the yellow indication begins to flash, indicating that cars should slow down. The yellow indication turns solid, telling drivers, “prepare to stop.” When the PHB transitions to solid red, drivers are required to stop and yield to pedestrian traffic, which sees a traditional “walk” indication. Finally, flashing red means stop and proceed if the crosswalk is clear, as a driver would do at any stop sign.

4. Steady red during pedestrian walk interval

R Y

6. Dark again until activated

Legend

SY Steady yellow FY Flashing yellow SR Steady red FR Flashing red

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HIGHWAYS MANAGEMENT & SAFETY

HIGHWAY MAINTENANCE

be cyclists, runners or people traveling at faster speeds trying to catch that flashing red interval to cross the street before the walk signal ends. Whereas cars are now rolling through and they may not see those secondary pedestrians.” At the same time, there were instances of stopping too soon, causing further confusion for drivers. Overall, 9% of drivers stopped when the lights were dark and 19% of drivers stopped during the flashing yellow phase; during both phases drivers are expected to proceed or proceed slowly. Another 30% of drivers stopped during the solid yellow. “That makes sense because even if we’re approaching a traffic signal, there are going to be some people that stop when that traffic signal turns yellow, anticipating that it’s going to turn red,” said Caggiano. They’re stopping because they see a pedestrian and they’re going to allow them to cross, regardless of what the PHB is communicating,” says Caggiano. This early stopping, as Caggiano calls it, doesn’t cause an immediate issue for the pedestrian because they see a car stop and they choose to cross. However, it does cause driver confusion when the following cars then see a red light but no pedestrians at the crosswalk. This may contribute to unsafe instances of cars driving through the solid or flashing red lights if drivers incorrectly assume that no pedestrians are present.

Road types The researchers also found that the type of roadway impacted how drivers interacted with the beacon. On

four-lane roads, there was less premature stopping. However, there were also lower rates of stopping during the red-light phases: 29% drove through the solid red and 69% drove through flashing red. "Local authorities should consider whether these systems are suitable for locations where there’s a steady stream of pedestrians and cyclists,” says Michael Knodler, a professor of engineering in the Riccio College of Engineering at UMass Amherst and one of the paper’s authors. Driver performance for correctly stopping during the solid red phase was best at urban, two-lane roads, noted Knodler, who is also a director of the UMass Transportation Center. Only 11% of drivers failed to stop. There was still some stopping confusion in the other phases, but drivers were generally more compliant than at other sites. Caggiano says that most of these successful beacons are in the Somerville and Cambridge area, where both drivers and pedestrians seem generally more familiar with the PHB system. Pedestrians were more likely to push the button and wait for that walk indication, as opposed to drivers stopping for them early, and then crossing the road. Pedestrian behaviour will be the subject of a future paper.

Michael Knodler Professor of Engineering , Riccio College of Engineering

What the FWA says In the US, nearly 74% of pedestrian fatalities occur at non-intersection locations and vehicle speeds are often a major contributing factor, according to the US Department of Transportation. As a safety strategy

SAFETY BARRIERS FOR TUNNELS & BRIDGES > narrow footprint > free standing & anchored > temporary & permanent > containment level T3 – H4b

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"Local authorities should consider whether these systems are suitable for locations where there’s a steady stream of pedestrians and cyclists"

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HIGHWAYS MANAGEMENT & SAFETY

TRAFFIC MANAGEMENT

to address this pedestrian crash risk, the PHB is an intermediate option between a flashing beacon and a full pedestrian signal because it assigns right of way and provides positive stop control. It also allows motorists to proceed once the pedestrian has cleared their side of the travel lane or lanes, reducing vehicle delay. The PHB, previously called the HAWK - High Intensity Activated CrossWalK - was developed in the city of Tucson, Arizona, in the late 1990s to improve the safety of vulnerable road users at crossings of major arterials at minor street intersections. Initial studies in Tucson found driver-yielding compliance when PHB signals were activated to be over 90% and the number of traffic lanes did not impact compliance. Yet, only several states have installed PHBs and they remain controversial. The Department of Transportation’s Federal Highway Administration has, however, produced a report on their use and application locations. PHBs are specifically to help pedestrians safely cross higher-speed roadways at mid-block crossings and uncontrolled intersections. The ‘beacon head’ consists of two red lenses above a single yellow lens. The lenses remain "dark" until a pedestrian desiring to cross the street pushes the call button to activate the beacon, which then initiates a yellow-to-red lighting sequence consisting of flashing and steady lights that directs motorists to slow and come to a stop and provides the right-of-way to the pedestrian to safely cross the roadway before going dark again. In general, PHBs are used where it is difficult for pedestrians to cross a roadway, such as when gaps in traffic are not sufficient or speed limits exceed 35mph

When the PHB transitions to solid red, drivers must stop and yield to pedestrian traffic, which sees a traditional “walk” indication (image courtesy Massachusetts Department of Transportation)

For an explanatory video from the Massachusetts Department of Transportation on how to use PHBs

CLICK/SCAN HERE

(55kph). They are very effective at locations where three or more lanes will be crossed or traffic volumes are above 9,000 average daily traffic. Installation of a PHB must also include a marked crosswalk and pedestrian countdown signal. If PHBs are not already familiar to a community, agencies should conduct appropriate education and outreach as part of implementation. More information is available on the website of the University of Massachusetts at Amherst. End *The academic study - An Evaluation of Driver Comprehension of the Pedestrian Hybrid Beacon - was published in February in the Journal of Safety Research and is available free from Science Direct.

Early detection with Pavemetrics LCMS As road networks age and budgets tighten, maintaining infrastructure efficiently has become a shared challenge for agencies worldwide. Reliable, repeatable data is now essential - and that’s where Pavemetrics’ Laser Crack Measurement System (LCMS) plays a key role. Designed for traffic-speed operation, the LCMS captures high-resolution 3D images of cracks, ruts, texture and geometry - all in a single pass. This approach minimises disruption to traffic and field crews while delivering full network coverage in a fraction of the time required by traditional methods. But efficiency is only part of the story. The real advantage lies in foresight. By combining world-leading pavement

imaging with unmatched clarity and repeatability, Pavemetrics enables engineers to detect early signs of deterioration and act before small issues become costly repairs. The result is proactive maintenance that extends asset lifespan and optimises long-term performance. Reliable, consistent data turns uncertainty into action helping infrastructure owners see clearly, plan ahead and focus their resources where they’ll have the greatest impact. Used in more than 55 countries, Pavemetrics technology continues to support a global shift toward smarter, safer and more sustainable pavement management.

www.pavemetrics.com

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WORLD-LEADING PAVEMENT IMAGING. — UNMATCHED CLARITY POWERING SMARTER DECISIONS

LCMS MEASUREMENT CAPABILITIES CRACKING

ROUGHNESS (IRI)

RUTTING

BLEEDING

POTHOLES

MACROTEXTURE

PATCHING

ROAD GEOMETRY

CONCRETE JOINTS

LANE MARKINGS

SEALED CRACKING

AND MORE

DISCOVER THE POWER OF LCMS AT WWW.PAVEMETRICS.COM | INFO@PAVEMETRICS.COM

HIGHWAYS MANAGEMENT & SAFETY

TUNNEL SAFETY

REBLOC: WHEN SPACE IS CRITICAL No barrier-installation setting is more critical than on bridges and in tunnels because of limited spaces and equally limited fast access for emergency vehicles - not to mention additional hazards, including fire and smoke

N 1317 is a European Norm established in 1998 that defines common testing and certification procedures for road-restraint systems. It is also now used in many countries outside Europe and has become an international benchmark for evaluating the performance of these systems. Implementing effective vehicle-restraint systems for bridges and tunnels presents specific challenges, such as prohibiting the anchoring of a system into the ground. Furthermore, maintenance and construction activities in these areas often do not allow for extended lane closures, making rapid installation and removal an urgent necessity. In the end, safety barriers must be scalable to provide safe containment across a wide range of impact scenarios, from light passenger cars to heavy-goods vehicles (HGVs). REBLOC offers a wide range of temporary and permanent precast-concrete safety barriers designed precisely to address these challenges. Tested in accordance with EN 1317 containment levels T3 through H4b, REBLOC provides the appropriate level of protection for varying traffic conditions and vehicle categories. Precast-concrete barriers are ideally suited for use in confined and sensitive locations such as bridges and tunnels. Those safety barriers feature a compact footprint, making them especially effective where space is limited. On bridges, freestanding versions eliminate the need for drilling or anchoring into the bridge deck, thereby preserving structural integrity. Despite the absence of fixed installations, their stability and performance remain proven, ensuring reliable vehicle containment without compromising the underlying infrastructure. In tunnels, every centimetre counts. Precast-

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ABOVE REBLOC’s proprietary coupling technology means no loose components are needed, allowing barriers to be installed and dismantled rapidly

BELOW Safety barriers must be scalable to provide safe containment across a wide range of impact scenarios - from light passenger cars to heavy-goods vehicles

concrete barriers deliver high containment performance while occupying minimal space. Both freestanding and anchored variants can be installed swiftly and efficiently, reducing downtime and limiting disruption to tunnel operations. A strength of the REBLOC system lies in its proprietary coupling technology - no loose components are needed. This greatly simplifies deployment, allowing barriers to be installed and dismantled rapidly. Such efficiency is vital for minimising traffic disruption and protecting road workers during installation. The system is particularly advantageous for temporary traffic management schemes or emergency interventions. With barrier systems tested to all available containment levels under EN 1317, REBLOC ensures the right degree of protection for every project. While lower categories of containment levels offer suitable protection for passenger vehicles, higher containment levels are engineered to resist impacts involving HGVs. This scalability enables project planners to select solutions tailored to the specific risk profiles of different bridge and tunnel environments. As traffic volumes increase and infrastructure continues to age, bridges and tunnels remain critical yet vulnerable parts of the European road network. Addressing their safety challenges requires innovative, adaptable solutions. EN 1317-compliant REBLOC concrete barriers offer exactly that: high performance, space-efficient design, and rapid deployment. By integrating such systems into infrastructure planning and maintenance strategies, road safety can be significantly improved. End www.rebloc.com

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Maximum visibility leading the way Rain, darkness, poor visibility – this is when road markings have to prove their worth. That’s exactly what SWARCO‘s high-performance systems are made for. In combination with SWARCO SOLIDPLUS premium glass beads, they deliver top-level retroreflection – consistently stable and far above standard values. Their durability makes high-performance systems the No. 1 economic solution – thanks to longer service life, reduced maintenance cycles, and enhanced road safety. SWARCO | The Better Way. Every Day.

FIND OUT MORE: www.swarco.com/rms

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Pattullo Bridge:

CABLE ACCESS David Arminas REPORTS

Western Canada’s new 1.2km Pattullo Bridge is another new crossing of the Fraser River near Vancouver. Making an access system for maintaining the cables of the suspension structure was the task of Spencer Bridge Engineering in the UK Demolition of the 87-year-old original steel arch Pattullo Bridge will start next year (image courtesy BC Government)

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f all goes to plan, New Year’s day 2026 will be a time to celebrate for thousands of Vancouver area drivers, pedestrian and cyclists. They will have another new four-lane bridge spanning the Fraser River on Canada’s Pacific coast. The 1.2km-long cablestayed Pattullo Bridge - a replacement for the similarly named old steel arch structure - was built at a cost of around CAN$1.22 billion and carries highway 1A/99A. According to the provincial British Columbia Transport Investment Corporation in its 2020 report, the province entered into a performance-based, fixed-price contract in February that year with Fraser Crossing Partners and its legal entity Fraser Crossing Project Corporation (FCPC). The agreement was to design, build and partially finance the project over five and three-quarter years and with a fixed price of CAN$967.5 million. Work was expected to start soon after signing the deal with FCPC, in late spring 2020. But the covid pandemic and supply-chain disruptions, especially regarding steel and cable production, pushed back delivery.

GLOBAL HIGHWAYS 2025 VOL.6

BELOW Artist impression of the situation: in foreground, the old steel arch bridge and new suspension bridge behind it, with Sky Train commuter elevated train bridge in the background (image courtesy BC Transportation Investment Corporation, Project Report: Pattullo Bridge Replacement)

Work eventually started on the four-lane cablestayed Pattullo Bridge replacement in April 2021 with opening scheduled for late 2024. However, several delays have pushed back the opening to the end of this year. The cost when complete is now estimated to be around CAN$1.22 billion. The nearby old bridge will be demolished. Like the old bridge, the new one will link the cities of Surrey and New Westminster across the Fraser River, one of metropolitan Vancouver’s most heavily trafficked commuter corridors. The official name of the new bridge will, however, eventually be changed. It will be chosen jointly by the Musqueam First Nation and the Kwantlen First Nation groups, the indigenous peoples of the lower Fraser River area that includes metropolitan Vancouver. The design of the new toll-free bridge allows for expansion from the current four lanes to six lanes. Importantly, to encourage greater alternative mobility, the bridge has two lanes - one for pedestrians and one for cyclists - on either side of the deck. The lanes are physically separated from live traffic by a high wall.

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WHO’S WHO Fraser Crossing Partners is a 50/50 joint venture between Acciona and Aecon. The team includes: • Acciona Construccion • Acciona Infrastructure Canada • Aecon Group • Aecon Constructors, a division of Aecon Construction Group • Leonhardt, Andra und Partner Beratende Ingenieure VBI • Hatch Corporation • EXP Services • Working on behalf of Fraser Crossing Constructors Spencer Group has designed, manufactured, tested and commissioned a semi-permanent access system to enable maintenance engineers to inspect all elements of the bridge’s stay cables

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Approach sections under construction (image courtesy B.C. Ministry of Transportation and Transit/Flickr)

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Artist's impression: the new bridge accommodates cyclists and pedestrians (image courtesy BC Transportation Investment Corporation, Project Report: Pattullo Bridge Replacement)

Meanwhile, the traffic lanes have a barrier median running the length of the deck - a safety feature which is absent on the old 1937 truss bridge. In February, three people died in a head-on collision.

Cable maintenance The new bridge’s defining feature is a 168m tall central tower whose final stay cables were fabricated in the UK. To maintain the cables, the UK-based specialist firm Spencer Bridge Engineering was called in to create a bespoke cable access solution. The system spent around a month in transit to the site, arriving this autumn, according to the company. Spencer is based in the northern English city of Hull where the system underwent successful factory acceptance testing - witnessed by representatives of the Canadian client, Fraser Crossing Constructors General Partners and a third-party checker.

"Our in-house designer’s extensive knowledge and experience enabled us to develop this system to provide the safest and most effective access solution" Spencer’s senior design engineer Harry Towle says the concept for the Pattullo Bridge cable access system is unique in several ways and has been a “particularly complex” project. But, he says, one of Spencer Bridge Engineering’s biggest strengths is its collaborative approach to all projects. The cradle element, which transports personnel to the desired inspection location, operates similarly to a cable car, moving up and down a track rope. The cradle will be electrically hoisted up and down the main track rope. It will also vertically move up and down to enable personnel to inspect the stay cable wires throughout the lifespan of the bridge.

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EXISTING PATTULLO BRIDGE* Lane (3m)

Lane (3m)

Sidewalk (2m)

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ORIGINAL PATTULLO BRIDGE British Columbia. It is a fourlane 1.2km truss structure and has no physical separation of the four lanes which - despite a temporary bollard separation - has led to fatal collisions over the years. The bridge’s narrow lanes and lack of a permanent median divider have meant essential night-time lane closures. The banning of wide heavy-goods vehicles and a proposal to install radar to control speeding drivers were considered but not implemented. However, oversized commercial vehicles are banned from the bridge.

Preparation works for demolition of the old bridge include construction of crane pads underneath and adjacent to the bridge and a temporary access road through the centre of a nearby park to connect the crane pad work area to Old Yale Road. This temporary access road will be used to haul materials as sections of the Pattullo Bridge are removed. Removal of the on-land structures will start early next year and continue until mid2027. Once the preparation activities are complete and

LEFT Spencer’s cradle chassis can be quickly adjusted to adapt to the various stay cable angles on the bridge, from the longest (320m) at 24° incline, to the shortest (50m) at 72° incline (image courtesy Spencer Bridge Engineering)

The cradle chassis can be quickly adjusted to adapt to the various stay cable angles on the bridge, from the longest (320m) at 24° incline, to the shortest (50m) at 72° incline. This ensures that the cradle remains level throughout the inspection operation at all locations. “The winching system, which incorporates a bespoke control system with numerous sensing devices and key safety features, has not been done before,” said Towle. “But our in-house designer’s extensive knowledge and experience enabled us to develop this system to provide the safest and most effective access solution. The system has also been designed and built to European standards, but is operating under Canadian standards, which has meant that the design journey has had to satisfy dual compliance.” End • For more information about Spencer Bridge Engineering, visit: www.thespencergroup.co.uk/our-work/bridges

NEW BRIDGE* Multi-use path (3.5m)

Shoulder (2m)

Lane (3.6m)

the new bridge is open to traffic, removal of the onland structures in both New Westminster and Surrey will begin. As removal of the on-land structures gets underway, so will the removal of the abovewater structures, during the same period. This includes the bridge deck, steel truss and archway and foundations. As the above-water structures are removed, removal of the concrete below-water structures will begin autumn 2026 with completion of the project by the end of 2027.

Lane (3.6m)

* Dimensions are rounded ** Barrier widths (not shown) are included in bridge width Global Highways Magazine for industry-related discussion

Shoulder (1m)

LEFT The new bridge is twice as wide as the old bridge (image courtesy BC Transportation Investment Corporation, Project Report: Pattullo Bridge Replacement)

29m**

TransLink, formally the South Coast British Columbia Transportation Authority and previously the Greater Vancouver Transportation Authority, is responsible for Metro Vancouver’s regional transportation, including public transport, major roads and bridges. In 2008, TransLink decided to build a replacement bridge for the Pattullo Bridge rather than refurbish the ageing structure. The 87-year-old througharch steel bridge was named in honour of Thomas Dufferin Pattullo, the 22nd Premier of

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RIGHT The new and the old bridges on the left with the Sky Train commuter elevated train bridge to the right BELOW RIGHT Bridge deck work at the north approach in New Westminster (September 2025) (image courtesy BC Transportation Investment Corporation, Project Report: Pattullo Bridge Replacement) BOTTOM RIGHT Looking down the length of the support tower (image courtesy BC Transportation Investment Corporation, Project Report: Pattullo Bridge Replacement)

SPENCER GROUP: MAINTAINING HISTORY The Spencer Group was founded by the now executive chairman Charlie Spencer in 1989 and is headquartered in Hull, northern England. It has a track record of superior maintenance and repair work on some of the world’s most iconic bridges. This includes major refurbishment on the historic Menai Suspension Bridge across the Menai Strait between the island of Anglesey and mainland north Wales - ahead of the structure’s 200th anniversary next year. Spencer Group’s specialist bridges team has global experience in high-level bridge works. It developed the Cable Crawler gantry system to enable vital dehumidification work to prevent corrosion of cables on the Severn Bridge across the Severn Estuary - the southern border between England and Wales. It has also worked on Scotland’s 2.5km-long Forth Road Suspension Bridge which opened in 1964 - at the time the longest suspension bridge in the world outside the US. The 33m-wide and 156m-high bridge spans the Firth of Forth, connecting Edinburgh at South Queensferry to Fife at North Queensferry. The longest span is 1km. Other UK projects include the Humber Suspension Bridge, which opened in 1981 - a 2.2km single-span structure near Kingston upon Hull in Yorkshire, England. The structure is 155m-high and has a longest span of 1.4km. Meanwhile, internationally, Spencer has worked on the Älvsborg Suspension Bridge, nearly 1km long over the Göta älv (river) in Gothenburg, Sweden, connecting the island of Hisingen with the mainland. In Denmark, Spencer has helped maintain the Great Belt Bridge, a multi-element 18km fixed-link bridge crossing the Great Belt strait between the Danish islands of Zealand and Funen. It consists of a road suspension bridge and a railway tunnel between Zealand and the small island Sprogø, in the middle of the Great Belt, and a box-girder bridge for both road and rail traffic between Sprogø and Funen. • For more information about Spencer Bridge Engineering, visit:

www.thespencergroup.co.uk/our-work/bridges

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RECYCLING

Increased recycling power ROTAR says that its new XL models within its RCC concrete cutter range are ideal for working on demolition projects and allow for efficient materials recycling. These tools integrate ROTAR’s Ramplifier technology, which doubles cylinder power on demand, delivering exceptional cutting forces for the toughest reinforced concrete. The new RCC XL models (20, 25, 30, and 45) continue that tradition with a 100mm wider jaw opening and deeper cutting edges, making them ideal for demanding demolition and recycling applications. The sophisticated Ramplifier system is a self-regulating

power booster that activates additional hydraulic pressure only when needed, reaching up to 700bar. This ensures high cutting power with minimal wear, reduced cycle times, and high efficiency. The RCC series also offers flexible rotation options (hydraulic or mechanical “Hide & Turn”) and replaceable crusher teeth and cutting blades for easy maintenance. Offering performance, power management, rugged construction and reliability, the RCC XL series delivers effective performance in demolition and recycling works. www.rotar.com

A new facility at Heidelberg Materials’ B&A facility near Bristol in the UK will recycle excavated materials for use as construction aggregates

RECYCLING EXCAVATED WASTE Heidelberg Materials has invested in setting up the UK’s largest excavated wasterecycling wash plant. This new facility allows the recycling of large quantities of excavated waste and is located at the firm’s Bristolbased B&A Group site. The facility will provide the firm’s customers with a reliable supply of highquality recycled aggregates for use in projects, with a high percentage of the material being used in road repairs and construction. B&A Group is a leading construction soil- and aggregate-recycling company and became part of Heidelberg Materials in May 2024. The firm says that the £8 million investment forms part of the company’s commitment to conserving natural materials and promoting the circular economy. The

recycled materials produced can be used to replace primary aggregate in a range of products including concrete and asphalt. The new wash plant separates, washes and processes up to 400,000 tonnes of excavated waste/year from construction, demolition and industrial sites, public works and utility projects, to provide a reliable source of high-quality recycled aggregates. The plant is fitted with a drainage and water-recovery system to capture and recirculate the water used, minimising its impact on the environment. “Our new bespoke wash plant enables on-site recovery and washing of material, turning soil into recycled aggregates, helping meet increasing demand for more sustainable construction products,” said Helen Griffin, managing director at B&A

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Group. “It also diverts more material from landfill and on-site washing helps meet environmental permit standards and avoids contamination concerns, supporting regulatory compliance.” The new plant can process inert soils into fine and coarse aggregates. “Our new recycling wash plant at B&A Group is the first of a number we have planned to enable us to increase our capacity of recycled products,” said Richard Wilcock, recycling director at Heidelberg Materials UK. “It is part of our strategy to enable our customers to build more, with less and another step towards achieving our aim to deliver 50% of our revenue from sustainable products by 2030.”

www.heidelbergmaterials.co.uk

GLOBAL HIGHWAYS 2025 VOL. 6

EQUIPMENT

HYDROGEN LOADER TEST FOR STRABAG STRABAG is carrying out testing of Liebherr’s innovative hydrogen-fuelled wheeled loader. The machine is being tested under a trial basis at the Kanzelstein quarry in Gratkorn, Austria. STRABAG plans to test the new machine intensively over a two-year period, running it at least 50 hours/week. The test is part of a programme by STRABAG to reduce its carbon profile. Fuels represent STRABAG’s largest source of CO2 emissions – around 40% of the group’s total emissions are attributable to construction machinery, commercial vehicles and cars. “To become climate-neutral by 2040, we need effective solutions – and converting our construction machinery to renewable technologies is an essential lever. We are pursuing our sustainability path consistently, science-based and open to all technologies. The test run of the hydrogen-powered wheeled loader is an example of what sustainable operation and the decarbonisation of our large-scale equipment can look like,” said STRABAG CEO, Stefan Kratochwill. Converting heavy-construction machinery to sustainable drive technologies remains a challenge because there is still no marketready solution. The hydrogen engine of the wheeled loader represents an important approach with great potential. “Besides its

STRABAG is carrying out testing of Liebherr’s innovative hydrogen-fuelled wheeled loader as part of a plan to reduce carbon emissions

positive impact on climate protection, this technology helps maintain a high level of value creation and technological expertise in Western Europe. It strengthens supply-chain resilience and offers strategic advantages,” explains Dr-Ing Herbert Pfab, technical managing director of Liebherr-Werk Bischofshofen GmbH.

For the practical test, a dedicated hydrogen filling station has been set up at the quarry to allow straightforward refuelling of the wheeled loader. As a strong regional partner, Energie Steiermark contributes vital local expertise and will ensure the hydrogen supply for the station on site. According to internal calculations, operating the hydrogen-powered wheeled loader will save around 37,500 litres of diesel and cut CO2 emissions by approximately 100 tonnes/year. www.liebherr.com

Electric quarrying with Kleemann

Electric crushing machines are allowing a Swedish quarry firm to reduce running costs and carbon emissions

A Swedish contractor is using electric drive for the entire crushing and screening process. The coupled plant train from Kleemann consists of a MOBICAT MC 120 PRO jaw crusher, a MOBICONE MCO 110 PRO cone crusher, and a MOBISCREEN MSC

GLOBAL HIGHWAYS 2025 VOL. 6

953 EVO screening plant. Cost efficiency and a need to reduce carbon emissions have been key factors in the switch to electric power for the firm. There is now quite a difference to the way the company previously handled materials processing.

Today, the entire plant train is exclusively electrically powered. “Our decision to go fully electric was motivated by energy-saving considerations and the desire to reduce emissions," explained Freddie Erickson, coowner of Kentas Last & Schakt. However, the investment will pay off in financial terms. The company estimates that the operating costs otherwise incurred by diesel fuel consumption are more or less cut by half when using an electric-power supply. The procedures are also simpler and save valuable time: no daily refuelling, no warmup times, and, as the electrical systems are more reliable, maintenance tasks are also easier and less complex. The conditions at the location also justified the Swedish company’s project from a financial and logistical point of view. A substantial sum was invested in infrastructure measures, including a transformer station and the laying of underground power-supply lines. There was no state funding.

www.wirtgen-group.com

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EQUIPMENT

ADVANCED REMOTE CONTROL FAE now offers important functions for users of its RCU55, RCU75 or RCU120 remote-controlled tracked carriers. This function allows tracked carriers to be moved safely and quickly using only the FAE App because external equipment is no longer required to transport the vehicle in the event of a signal failure. The new function makes it possible to switch the diesel engine on and off and manage its rotation speed, drive and steer the vehicle (including in reverse), raise or lower the attachment and make the track width wider or smaller. This new function will come as standard on all new RCU55, RCU75 and RCU120 vehicles. It is also available as a retrofit on request, while the FAE App is available for both iPhone and Android OS. This new app allows users to monitor machine-operation data, such as fuel economy and working pressure. The FAE app displays failures, with a description of the malfunction and the parts involved. It also allows users to export problem reports if maintenance or repairs are needed. Users receive required maintenance alerts, including hours remaining until the next scheduled maintenance and work needed.

In addition, the firm is offering its new RWL/SSL wheel saw for skid steers. Suiting trenching works, the RWL/SSL is compatible with skid steers from 37-56kW and can make channels up to 350mm deep with modular widths of 2.5, 3 or 5cm. The depth indicator allows for precise management of working

depth, while the self-levelling skids and optimised side output maintain that depth and keep the trench free of waste. The RWL/ SSL can be equipped with the Basic WSS Water Spray System to reduce dust and cool teeth. www.fae-group.com

FAE’s new app allows more efficient operation of its remote-tracked carrier unit

Versatile quick coupler from Steelwrist

The proven coupler technology Steelwrist, developed for large machines, is now available for use with compact machines also

Steelwrist says that its new SQ40 quick coupler offers increased versatility and efficiency for heavy-duty applications such as demolition. The new SQ40 automatic coupler can be used on compact excavators and allows for quick changes of high flow-powered work tools. This is said to offer the same efficiency

as the existing larger SQ couplers. The new SQ40 is said to make it easier to change powered work tools without an operator having to leave the cab. The SQ40 unit is now available as a fully automatic machine coupler for use with compact excavators The SQ technology allows a user to connect both hydraulics and electrical signals in one

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movement. With the introduction of the new SQ40 size, Steelwrist’s product range includes eight different SQ quick coupler models (SQ40-SQ90), for excavators from 2-70tonnes. The new SQ40 is specifically designed for the growing segment of compact excavators from 2-7tonnes. Extensive development ensures that the new SQ40 automatic coupler allows the flow required to power demanding hydraulic work tools. The SQ40 coupler is optimised to achieve a flow of 70litres/ min, thanks to a new and innovative coupling that provides 40% more flow area compared to a standard coupling. The SQ40 follows the S40 standard so it is compatible with existing work tools, without requiring costly modifications. Its modular construction enables fast upgrades from S to SQ, with simplified hose routing and easy installation of male couplings integrated into the rear tool shaft. This also means that hose routing is flexible and can be adapted to a wide range of hydraulic work tools.

www.steelwrist.com

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SKIDMARKS

"Our Skidmarks page is highly rated by readers. Your input could help make this page even more entertaining. If you come across any amusing road-related stories, pictures or videos, email me at mwoof@ropl.com"

Mike Woof

ROADWORKER RESCUE

In France a cyclist, aged 77, suffered a traumatic incident when he crashed his bicycle, falling more than 40m down a slope, into a riverbed. Injured in the fall, he couldn’t climb the slope, with passing drivers unable to hear his cries for help. It was three days before he was heard, at last, by some road maintenance workers, who then called the emergency services. As the man had been returning from a shopping trip for food, he was able to sustain himself with the provisions, and the three bottles of wine that he’d bought. A helicopter took him to hospital but he was not seriously injured.

HOW FAST?

A former police officer in the UK is regretting his decision to press the pedal to the metal. He was recorded travelling at 240km/h in his modified VW Golf on a stretch of the A421. Footage shot inside his vehicle by a friend showed him reaching a top speed of 265km/h at one point. The

man was given a suspended sentence but had to carry out community work, as well as being banned from driving. Also in the UK, a driver received a 27-week suspended sentence and a 12-month driving ban. Footage of the Portsmouth driver had been posted on social media, showing him drifting his pink BMW round a roundabout at a car meet. Both drivers learned the hard way that the police continuously monitor footage posted on social media.

DELIVERY GONE WRONG

A truck driver in the UK is, perhaps, reviewing his decision-making process, following a dispute over a delivery. The driver had delivered a load of bricks but then argued with a person at the delivery facility about safety procedures during unloading. The enraged driver then tried to hit the worker with his truck. This incident was recorded on CCTV at the facility. The driver was charged with dangerous driving.

EDITOR'S PHOTO OF THE MONTH Entering the green hell – image courtesy of Mike Woof

ELECTRIC POWER

To those thinking electric cars are new, think again. Alternative-power sources have figured in speed records since the late 19th century. In fact, the first six World Land Speed Records set by cars were all made by electric vehicles in the short period between 1898 and 1899, the last of these driven (most famously) by Camille Jenatzy when his torpedo-shaped vehicle managed to top 105km/h. The next speed record was set by a steam-powered car, and it was not until 1902 that a Mors car, with an internal combustion engine and driven by William Vanderbilt, was able to seize the eighth World Land

Speed Record at 120km/h. In 1906, the land speed record was broken by a steampowered Stanley Steamer, at 204km/h. This record, for the fastest steam-powered vehicle, remained until 2009. Meanwhile, aviation pioneer Glen Curtiss hit 219km/h on his fragile V8 motorcycle (now on display in the Smithsonian Collection in Washington DC) in 1907, but the driveshaft broke so his attempt was not counted officially. Since the 1960s, numerous world land speed records have been made and broken by jet turbine and rocket power. The current record holder is Andy Green who broke the sound barrier in his twin jet vehicle in 1997.

The lost vacuum

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The owner of a robot vacuum cleaner in Australia is wishing he had paid closer attention to the device. The small robot made its bid for freedom and exited the household in Queensland when a door was left open. It trundled down the drive of the home and crossed a pavement, as if unsure how to clean the surface. It then darted onto a road and was promptly squashed flat by a passing vehicle. The car was not damaged in the impact although the vacuum cleaner was beyond repair.

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CONSTRUCTION EQUIPMENT AND TECHNOLOGY 2025

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UNIQUE CONTENT AND INSIGHT FOCUSED ON KEY TRENDS IN THE GLOBAL CONSTRUCTION EQUIPMENT AND TECHNOLOGY MARKET FROM THE INDUSTRY’S BEST-INFORMED AND MOST INFLUENTIAL SOURCES

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How recycled plastic-based modified asphalt mixtures perform at low temperatures

Reactive modification of bitumen offers advantages over additives that work physically

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Topcon's Ray O'Connor and Ivan Di Federico talks to Global Highway p22

p26 Visibility is the key parameter for efficient road markings, needed for human drivers and machine vision

Digitalisation and modelling for the Lower Thames Crossing

The Maybach mining heap: onsite with Komatsu in Germany

IT’S ALL ABOUT PROFIT, PEOPLE AND THE PLANET

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Data for generating connected sites: Jennifer Thomson, CPO, MachineMax

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NEWS

Not long now: the Pattullo Bridge replacement should be open by the end of the year (image courtesy BC Government)

PATTULLO BRIDGE COMPLETION BY END OF YEAR The cable-stayed bridge, featuring a 168m-tall central tower, will replace the existing 88-year-old Patullo Bridge near Vancouver, Canada, that has connected the cities of Surrey and New Westminster since 1937

ritish Columbia's new US$865 million Pattullo Bridge replacement project near Vancouver is on track for completion by the end of 2025. The cable-stayed bridge, featuring a 1.68m-tall central tower, will replace the 88-year-old structure that has connected the cities of Surrey and New Westminster since 1937. Fraser Crossing Partners, a joint venture between Aecon Group and Acciona Infrastructure Canada, was awarded the design-build-finance contract in 2020 with an initial value of US$743 million and expected completion by 2023. However, the COVID-19 pandemic, supply chain disruptions, labour shortages and health restrictions caused nearly two years of delays and increased costs. The Transportation Investment Corporation confirms the project remains on budget following scope and schedule revisions, with all major components erected and final cable installations expected this autumn. The new bridge will include four lanes - that are wider than on the old bridge - with capacity for expansion to six lanes as well as enhanced safety features and lanes for pedestrians and cyclists that

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are physically separated from traffic lanes. There will also be a median barrier separating the opposing traffic lanes, unlike on the old bridge which will be demolished when the new structure is open to traffic. Meanwhile, Caroline Wawzonek, finance minister of the Northwest Territories, north of British Columbia, said that critical infrastructure projects in Canada's North are finally gaining traction. The Mackenzie Valley Highway is an all-season 400km road that connects southern Canada to the Arctic Ocean. It replaces the seasonal ice-road system available for short winTer periods when the lake ice is thick enough to support heavy vehicles. The Mackenzie Valley Highway project will require federal investment of about US$2.5 billion. The Arctic Economic and Security Corridor is a project that involves developing a mineral-rich region known as the Slave Geological Province and building related infrastructure such as an all-season road, requiring more than US$1.41 billion in federal funding. The Taltson Hydro Expansion is a US$2.5 billion energy initiative that involves the construction of 320km of transmission lines to connect 11 communities and industry via a unified grid. End

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NEWS

New $1.6 billion Florida toll road

Plans are in hand in Florida for a new 24.4km toll-road link designed to alleviate congestion in parts of Orange County and Osecola County. The project is expected to cost nearly $1.6 billion to construct and is being managed by the Central Florida Expressway Authority (CFX). The new SR 534 link will run between Nova Road in St Cloud and SR 417, close to Boggy Creek. Construction is expected to commence in 2027 and the project will provide an alternative route accessing Orlando International Airport. The route will help alleviate congestion on Narcoosee Road, Boggy Creek and Cyrils Drive. However, there are some environmental concerns about the planned alignment as part of it passes through Split Oak Forest.

OUTER BANKS BRIDGE

BELOW North Carolina’s Outer Banks are popular with tourists for the stunning beauty but also known for ferocious weather conditions, with a new bridge providing muchneeded congestion relief as well as an emergency escape route

between US 158 and NC 12 across Currituck Sound. This would help reduce congestion and improve the flow of evacuation traffic in the event of an extreme weather incident, for which the area is known. Located on the Atlantic Coast, the Outer Banks experiences some of the most severe hurricanes and storms anywhere in the world. The bridge crossing was first proposed as far back as the 1970s but only since 2008 has the project been discussed on more concrete terms. The proposed bridge design is for a structure featuring pre-stressed concrete beams with a concrete deck on top. This would sit on piles driven into place from barges. Given the ferocious storms and the ever-present danger of scour, the structure would have to be engineered to withstand extreme conditions. End

onstruction work is being planned for the $1 billion project to build the Mid-Currituck Bridge in North Carolina. The tolled bridge, stretching around 11km, will be located in the Outer Banks area which can be subject to tempestuous weather. This new bridge will provide an alternative to the Wright Memorial bridge carrying US 158. The Wright Memorial Bridge is located at the southern end of Currituck County into Dare County and experiences heavy congestion during holiday periods. It also can be congested as an emergency exit route in the event of the severe storms that sweep the Outer Banks. Building the new Mid-Currituck Bridge would provide a second crossing for the sound, to the north of the existing Wright Memorial Bridge. The new bridge would provide an additional connection

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NEWS

BRIDGE REPLACEMENT PROJECT COSTING MORE

Replacing the Francis Scott Key Bridge could cost $5.2 billion

eplacement of the collapsed Francis Scott Key Bridge in Maryland could now cost as much as $5.2 billion. The bridge collapsed when a large container vessel collided with it. The vessel’s crew had alerted the bridge authorities to the ship losing power and steerage and traffic was stopped, but bridge workers carrying out maintenance were

ABOVE Replacing the collapsed Francis Scott Key Bridge will now cost significantly more than had originally been expected

not able to escape and were killed by the collapse. Higher material costs and the need for improved protection technology for the supports are major factors in the increased price of the project. Meanwhile, it now looks as if it will be 2030 before the new bridge will be completed. This is two years later than had originally been envisaged. End

Three major transport infrastructure projects are planned for Florida, with a total cost of over $1 billion. One is for 27km of express lanes for I-4 in Hillsborough County. Another is for a new interchange linking I-95 and the Florida Turnpike. The third is for an extension of the Central Polk Parkway in Polk County. The projects will reduce travel times and congestion levels, while limiting the risk of crashes and boosting safety for drivers. The $500 million project to add express lanes to I-4 in Hillsborough County is intended to cut congestion and journey times for drivers. Construction is expected to commence in 2028. Meanwhile, the $447 million interchange in Martin County will provide a new ramp between I-95 and the Florida Turnpike, with the latter also benefiting from widening work to boost capacity. This project is being managed by the Florida Department of Transportation. The $134 million Central Polk Parkway extension will deliver a 4km toll road and is due for completion in 2031. A new interchange will be built to improve the connection with US 17 while the intersection with State Road 60 will be signalised.

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Three major Florida projects

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$2.4 BILLION LOUISIANA BRIDGE Construction work will start for the $2.4 billion Louisiana bridge

“Southwest Louisiana residents have waited decades for a new I-10 Calcasieu River Bridge"

BELOW Work will commence for Louisiana’s new Calcasieu River Bridge in 2026

Impact Statement (EIS), with results indicating a high likelihood of success. The project will include a lower bridge with tolling, more lanes and enhanced lighting. The existing 2km-long, 16m-wide Calcasieu River Bridge was officially called the Louisiana Memorial World War II Bridge when it was opened in 1951. It has decorative iron work with crossed guns integrated into the railings. The crossed pistols emblem will be a feature of the new bridge also, reflecting the history of the area and its past links with piracy. Governor Jeff Landry said that the project going forward will deliver a bridge that meets all modern travel standards, while expanding the I-10 corridor will help the economic growth of Louisiana. “Getting this deal secured in a way that was best suited for the Southwest Louisiana region was one of my administration’s top goals when I took office,” said Governor Landry. “With today’s signature, we have proven that we are committed to investing in infrastructure that will significantly benefit Louisiana and the I-10 corridor and give the Lake Charles region a potential revenue stream for generations to come.” LA DOTD Secretary Joe Donahue said this project has been years in the making, and the updated bridge will improve journeys for the thousands of travellers who cross it daily. “Southwest Louisiana residents have waited decades for a new I-10 Calcasieu River Bridge,” he said. “Now, it’s more than just a pipe dream. We at DOTD are pleased to see this project advance. Motorists can look forward to an upgraded bridge that will be in line with today’s regulations.” End

ork will start for Louisiana’s new $2.4 billion Calcasieu River Bridge in March 2026. The new tolled bridge will carry I-10 across Lake Charles, replacing the existing structure and with completion due in 2031. The project is being carried out by a joint venture, Calcasieu Bridge Partners, which comprises Plenary Americas, Acciona Concesiones and Sacyr Infrastructure USA. The client for the new bridge is the Louisiana Department of Transportation and Development (LA DOTD). The work is needed as the existing Calcasieu River Bridge no longer meets current requirements and is narrow, lacks shoulders, and has steep approach grades. Scheduled to open in 2031, the new bridge will be lower and not as steep , featuring more lanes, full shoulders, and roadway lighting. The project is for an 8.8km traffic corridor that links Ryan Street in Lake Charles with the I-210 and I-10 interchange at Westlake. The construction work involves building the new bridge and the approaches, as well as interstate links and ramps, I-10 service roads and interchanges at PPG Drive, Sampson Street, and North Lakeshore/Ryan Street. The interchanges link with various state roads and local roads. In addition, Sampson Street will be elevated over the railroad tracks to eliminate blockages from trains. The bridge predates the interstate and opened to traffic in 1952 as part of US Highway 90. During the 1960s the bridge was made part of I-10. The bridge handles around 90,000 vehicles/day, far in excess of the 37,000 vehicles/day it was designed for. The LA DOTD has studied the feasibility of tolling in connection with preparation of an Environmental

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GOLDEN GATE REFURB

NEWS

A $1 billion refurbishment of California’s Golden Gate bridge is planned

alifornia’s iconic Golden Gate Bridge is to benefit from $1 billion worth of improvement works. The upgrade is required to ensure that the historic bridge is better able to cope with seismic events. Sitting on the San Andreas fault line California is known for its periodic earthquakes, which can be severe. The iconic Golden Gate bridge opened to traffic in 1937 and has been seen as an emblem of the city of San Francisco and of US engineering excellence. Constructed to a high standard and heavily overengineered, the bridge has coped well with the years, although it has benefited from regular maintenance and upgrades during its working life. The suspender ropes were replaced in the mid-1970s while the bridge deck was replaced in the mid-1980s, for example. Planning for the new work to make the bridge better able to cope with major earthquakes has taken

ABOVE California’s iconic Golden Gate Bridge is to benefit from improvements to make it more resistant to earthquakes

years by the Golden Gate Bridge, Highway and Transportation District. Phase 1 and Phase 2 of the seismic retrofit work were carried out between 1997 and 2008. Phase 3A of the project was completed in 2014. Phase 3BI of the seismic retrofit work is scheduled to commence in 2026 and will take 11 years to complete. The 1,965m deck and both 227m support towers will benefit from reinforcement. Steel reinforcement 12m-high and 50mm-thick will be fixed to the towers while a new steel lattice will be installed under the deck. Massive shock absorbers will also be installed to the bridge. The work is being funded jointly by the California Department of Transportation, federal sources and the state. A $400 million grant is being provided by the US Department of Transportation via the Federal Highway Administration (FHWA). End

Repair work for the I-40 highway in North Carolina will now take until 2028 to complete, with the project expected to cost $1.6 billion. A section in Pigeon River Gorge suffered severe damage due to flooding caused by Hurricane Helene in September of 2024. A new causeway has been built as part of the project. However, the repairs remain incomplete. The work in North Carolina is being managed by the North Carolina Department of Transportation (NCDOT). The

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repair work to I-40 in Tennessee is being handled by the Tennessee Department of Transportation (TnDOT). Assistance to NCDOT and TnDOT is being provided by the Federal Highway Administration (FHWA). Meanwhile, plans for toll lanes along a 25.6km stretch of I-40 in North Carolina are being considered. Costing $700 million, the work would widen the highway between Exit 27 and Exit 44. The majority of the cost of the work would be covered by revenue from tolling.

GLOBAL HIGHWAYS 2025 VOL. 6

Repairs to I-40 in North Carolina and Tennessee will take until 2028 to complete – Extended features & latest digital content globalhighways.com

I-40 HIGHWAY REPAIRS DELAYED

NORTH AMERICA

NEWS

Proposals are being considered for the new bridge spanning the Delaware River and linking Pennsylvania and New Jersey

NEW DELAWARE RIVER BRIDGE PROJECT Options are being considered for the project to build a new bridge over the Delaware River in the US. Two options are being considered, having been proposed by the Pennsylvania Turnpike Commission and New Jersey Turnpike Authority. A new bridge is required as traffic volumes are increasing and the existing link is no longer able to cope with demand. With just two lanes in either direction, there is heavy congestion on the bridge at peak periods that can lead to long delays for drivers. Built around 70 years ago, the bridge is ageing rapidly and a crack in one of the approach trusses highlighted concerns over its structural condition. Before an interchange with I-965 opened in 2018, the bridge was handling around 42,000 vehicles/day. It now has to cope with around 67,000 vehicles/day, with traffic volumes expected to grow to around

90,000 vehicles/day by 2050. Given the age of the bridge, the fact that it only has two lanes in either direction and is already struggling to cope with the vehicle traffic it has to carry, it is clear a replacement is required. The new bridge will be a result of a joint project between the Pennsylvania Turnpike Commission and the New Jersey Turnpike Authority. A total of nine options have been considered, with two now being put forward for further review. One proposal is for the construction of a bridge around 23m to the north of the existing structure over a four-year period. This design would feature three lanes of traffic in either direction, separated around 4.6m apart. Once complete, traffic would be rerouted onto the new structure, with the old bridge then being demolished and removed.

The other proposal is for the construction of a bridge 12m to the north of the existing link over an eight-year period. This would be built in two stages. The first half of the span would be built and when ready, it would carry four (narrow) lanes of traffic on a temporary basis. The old bridge would then be demolished and removed, with work then being carried out for the second parallel span. As with the other proposal, the final design would be for three traffic lanes in either direction. Replacement of the existing bridge was first considered 30 years ago, with design proposals having originally been put forward in 2003. Plans then included upgrading the existing bridge but concerns over its structural condition now mean it will have to be demolished. As a result, the proposals and original environmental study will now have to be reviewed to meet the latest requirements.

NORTH AMERICAN EDITION

Digital editions and eNewsletters will include dedicated North American content in addition to all of the Global Highways regular content Global Highways Magazine for industry-related discussion

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CEMENT PRICES COULD SOAR The World Cement Association (WCA) has expressed concern that cement prices could triple or quadruple under current European policies

peaking at the recent two-day European Cement Decarbonisation Summit 2025 in Frankfurt, WCA’s director Emir Adiguzel highlighted key challenges facing the industry, such as rising energy costs, growing global overcapacity and the effects of carbon pricing. "Cement prices will triple, if not quadruple, with these policies in Europe,” Adiguzel warned, noting the significant costs that decarbonisation measures will place on the construction sector and end consumers. Most carbon-related costs will be passed to consumers, with carbon pricing becoming a "selling imperative" for price increases across the industry. The WCA's latest analysis was presented, indicating that the cement sector will require US$200 billion in investment by 2050 to fully decarbonise. Between 2019 and 2023, leading global firms reduced carbon intensity from an average of 700kg CO2/tonne to 640kg CO2/tonne, demonstrating that progress is achievable with the right support mechanisms. While acknowledging that carboncapture projects “must continue if applied correctly”, he emphasised that these technologies will have a limited effect on global industry decarbonisation. Adiguzel’s presentation highlighted that current carbon-capture technology requires investment exceeding the

Construction of the new E10 route in North Norway will improve transport to and from the important port of Narvik

capital cost of an entire cement plant, with significant development still needed for scalability. There are four key levers for decarbonisation that remain largely underused by the sector, including better energy efficiency. This can include wasteheat recovery, advanced process control and AI optimisation. Using alternative fuels is another, such as increased use of biogenic fuels and higher thermal substitution rates. A greater use of natural pozzolans is possible. Pozzolans are a broad class of siliceous and aluminous materials which, in themselves, possess little or no cementitious value. However, they will, in finely divided form and in the presence of water, react chemically with calcium hydroxide at ordinary temperature to form compounds possessing cementitious properties.

New technologies for carbon capture and storage, electrification and heatstorage solutions is another area where their use could make cement production more sustainable. Adiguzel also raised concerns about the effectiveness of the European Union's Carbon Border Adjustment Mechanism to incentivise non-scheme exporters to reduce their carbon footprint, particularly given the expensive investments required. Adiguzel emphasised that the cement industry must engage actively with governments to promote policies that incentivise a healthy transition to a lowcarbon, low-clinker future. "Cement is an irreplaceable material, vital for the infrastructure that underpins a green economy," Adiguzel concluded. "This journey will require more than just plans, it demands collaborative action across the entire value chain.”

Fiskefjord tunnelling complete

Drilling work for Norway’s Fiskefjord tunnel finished around six months ahead of schedule. When it opens in 2028, the 9.7km tunnel will link Kanstadbotn in Lødingen municipality with Fiskefjorden in Tjeldsund municipality. The work forms part of the OPS Hålogalandsvegen project for the E10 route. Work is being carried out under the PPP model jointly by Skanska Norge and Hæhre. The client for the project is the Norwegian Public Roads

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Administration, Statens Vegvesen. The project E10/rv 85 runs from Tjeldsund through to Gullesfjordbotn and ends at Langvassbukt. Work includes building 82km of road, of which 27km are in seven tunnels, with the Fiskefjord tunnel being the longest. The new E10 will shorten the distance from Tjeldsund Bridge to Gullesfjordbotn by around 30km and cut the travel time on the entire section by 39 minutes.

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NEWS

Transport in Italy’s Calabria region will be improved once the Ionian State Road project, SS 106, is complete

Construction work for the Third Mega Lot of Italy’s Ionian State Road (SS 106) project is 76% complete

ocated in Calabria, this strategic infrastructure project is being developed by Webuild on behalf of ANAS (FS Italiane Group). Preparations for the raising of the deck for the Annunziata viaduct are complete. Meanwhile, other works are being carried out on the major project along the Calabrian section of the SS 106 that will transform it into a modern dual carriageway. Among the most complex and iconic works of the Third Mega Lot, the Annunziata viaduct spans over 900m with a single carriageway and features a distinctive two-level, steel-concrete composite deck, one for each direction. In recent weeks, the Ferro viaduct reached its own milestone: standing 20m tall and stretching over 500m, it features a mixed steel-concrete structure with 11 spans. Its construction required 2,800tonnes of steel and more than 23,000m³ of concrete, showcasing the engineering commitment behind the entire Mega Lot. Construction continues in parallel on four other viaducts - Straface, Monaco, Forno and Stellitano - as well as

on the iconic Avena viaduct, the most architecturally significant overpass of the entire infrastructure, featuring distinctive V-shaped steel piers. Asphalt laying also continues between the Sibari and Trebisacce junctions along the first 18km. Once the auxiliary works being carried out by ANAS are completed, they will allow for early traffic opening ahead of the final completion. In the coming weeks, the second diaphragm of the Trebisacce Tunnel, around 3.3km-long and twin-tubed, is scheduled to be broken through, while excavation and lining works continue on the other ten artificial tunnels along the route. The construction site spans 38km, currently involving around 1,200 workers and activating a supply chain of over 880 companies, with a strong local component: 45% of the companies are based in Calabria. Once completed, the Mega Lot will enhance connections between the Ionian coasts of Calabria, Basilicata and Puglia, improving access to coastal towns and linking the A14 and A2 highway corridors.

Global Highways Magazine for industry-related discussion

The UK government has called a halt to the controversial Stonehenge Bypass. The A303 Amesbury to Berwick Down Development Consent Order 2023 has now been revoked. The plan to build the £2.3 road tunnel close to the famous historical site of Stonehenge was approved by the previous UK government but was suspended by the new administration following the election in June 2024. The project was cancelled due to exceptional circumstances by the Department for Transport. The move will be welcomed by the Save Stonehenge World Heritage Site and the Stonehenge Alliance, which have been against the project on both environmental and historical grounds. Archaeologists and environmentalists alike were against the project, as well as UNESCO, over concern at possible damage to the historic World Heritage Site.

Improving the A303 at this stretch was intended to cut congestion and prevent traffic delays, while also improving safety for drivers and local residents alike. The existing road along this section features a single lane in either direction and is not sufficient to cope with the heavy traffic demand. The A303 carries a high percentage of heavy, large trucks while traffic volumes on the route peaks during holiday periods as the route is favoured by tourists. Most of the rest of the A303 features dual carriageway. The project was originally awarded in 2022 to a consortium comprising FCC, BeMoTunnelling and Webuild. The project had called for the construction of a new 12.km stretch of dual carriageway. The most controversial portion of the project was for the 3.2km dual-tube tunnel passing within 200m of the Stonehenge standing stones.

PROGRESS IN CALABRIA

Stonehenge canned

The UK’s controversial Stonehenge Bypass project has been cancelled, again

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A CENTURY FOR GEIGER + SCHÜLE In the German town of Erbach-Ringingen, Geiger + Schüle is developing a new area and building key infrastructure, including access roads and a roundabout. Precision and versatility are ensured by three Liebherr machines: A 918 Compact, A 920 wheeled excavators and the L 507 Stereo wheeled loader. The machines are part of a much larger 100-unit contingent operated by Geiger + Schüle, explains Rolf Mezger, managing director of the company. “Today, we have more than 50 wheel loaders, over 50 wheeled excavators and around ten rail-road excavators. The Liebherr machines have proven to be reliable, powerful and durable." The A 918 Compact stands out for its compact design and exceptional flexibility - ideal for confined spaces without sacrificing performance. Its 1.85m tail swing radius and stability enable precise roundabout construction, while the powerful hydraulic system supports a wide range of attachments.

ABOVE The machines are among the 100 or more Liebherr units operated by Geiger + Schüle in Germany

For heavy-duty tasks, the A 920 delivers. With an operating weight of around 20tonnes and 129kW engine power, it ensures efficient material loading. High digging performance, impressive payloads, and fast cycles guarantee productivity - critical for meeting tight road-construction schedules. The machine ensemble is completed by the L 507 Stereo wheeled loader, renowned for its exceptional manoeuvrability. Its stereo steering dramatically reduces the turning circle, while its versatility makes it ideal for tasks such as levelling and material transport, ensuring superb flexibility. The Liebherr Group, one of the largest construction equipment manufacturers in the world, is a family-run technology company with a highly diversified product programme. It was founded by Hans Liebherr in 1949 in the southern German town of Kirchdorf an der Iller and achieved combined revenues of over €14 billion in 2024. www.liebherr.com

Quiet times for Atlas A new water pipe needs to be laid in the quiet Schwennau district of Glücksburg, Germany. A perfect jobsite for the Atlas 185 W ‘quiet excavator’ with its sophisticated sound insulation. The external noise level is 98 dB(A). The cabin is as quiet as a living room thanks to a noise level of 69 dB(A). What's more, thanks to the new design of the upper- and undercarriage and the excellent interaction of all components, there is hardly any working noise. This results in further positive effects. The 185 W offers more precision, more direct handling and greater cost-effectiveness. The 6-cylinder Deutz engine generates 129kW with EU

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Stage V, which is 24kW more than its predecessor model. The environmentally friendly operating foundation for the AWE

The Atlas 185 W works with extreme precision and the tiltrotator makes it highly flexible

GLOBAL HIGHWAYS 2025 VOL. 6

5 hydraulic system operates with a delivery rate of 340 l/min - 80 l/ min more than its predecessor - at a maximum operating

pressure of 350 bar. This means fast and quiet working movements in practice. Most importantly, extremely precise movements of the excavator and boom with attached equipment. This can be seen in the 185 W when it excavates or digs with millimetre precision at narrow access points to the work site. In doing so, the uppercarriage can move very quickly at 9 rpm. The lifting cylinder has a larger dimension with a diameter of 110mm. This, in combination with the heavier counterweight, increases the lifting capacity. The Atlas 185 W is designed to be used for many tasks.

https://atlasgmbh.com

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EQUIPMENT

SMART QUARRYING WITH SQSITE

As modern quarry sites face mounting pressures, Wouter Boon, smart quarry site product manager at Komatsu, explains the benefits of Komatsu Smart Quarry Site (SQSite) solution

quipment productivity directly impacts revenue - meaning streamlined efficiency to ensure profitability is critical for all quarry sites. Site managers must do more than just keep machines running - every process must be managed and optimised. But what is the most cost-effective approach? The answer is to implement digital tools that reduce downtime, measure material movement and production, monitor vehicle health, on-site safety, fuel consumption and flag potential bottlenecks. By creating live insights into equipment performance and site activity, technology can pinpoint inefficiencies, prevent costly machine downtime and streamline operations. This can also lead to much less time spent on site to follow up alerts and mechanical issues. This saved time can then be spent on businesscritical tasks such as efficiency improvement projects. Instead of waiting for a machinery problem to arise, digital solutions can enable teams to detect potential issues before they escalate. Alerts ahead of time mean maintenance can be scheduled to take place during pre-planned downtime, avoiding disruptions to production, keeping operations consistent and avoiding financial losses. Global Highways Magazine for industry-related discussion

Komatsu Smart Quarry Site (SQSite) provides real-time monitoring of machine movement, loads, material flow, fuel consumption and machine health. It gives managers the data they need to reduce idle time, prevent bottlenecks and improve efficiency. With SQSite, operators receive immediate feedback on optimal load levels and machine usage. This ensures trucks are consistently loaded to capacity - still further reducing fuel consumption, lowering potential equipment wear and keeping production on schedule. Operators also receive overload and overspread alerts, increasing on-site safety across quarry operations. Access to live, real-time data facilitates smarter machine deployment and strict resource and material management. By empowering managers to make proactive, data-driven decisions, technology solutions can help optimise efficiency and on-site productivity. Real-time tracking of assets such as trucks, loads and dozers allows managers to allocate resources, effectively avoiding bottlenecks or waiting periods to load machines. Beyond operational efficiency, digital transformation is also shaping sustainability in quarrying by reducing fuel consumption, optimising resource use and minimising environmental impact through CO2. SQSite provides a comprehensive, real-time overview of the entire quarry. This includes

"By empowering managers to make proactive, datadriven decisions, technology solutions can help optimise efficiency and on-site productivity"

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material flow, allowing managers to make data-driven decisions, deploy resources more accurately and allocate equipment where it’s needed most. By replacing manual tracking and reporting with automated data collection, SQS technology can reduce errors, save time and ensure operational decisions are based on accurate, up-to-date information. Quarries are complex, high-output operations where machine usage directly impacts productivity, revenue and operational efficiency. MHI Gruppe, a quarry operator with multiple sites across Germany, recognised some challenges and sought a solution to optimise performance, reduce bottlenecks and improve resource use. Previous manual tracking of fleet movements and material flow meant that operators had to record journeys on paper. This approach falls short in terms of

the provision of in-depth or real-time data, resulting in the potential for errors and necessitating further effort from administrative teams to process. Unlike other fleet-tracking systems, SQSite, a solution for a mixed fleet, is integrated with the machines' canBUS to monitor movement, load, error codes, fuel consumption and idling in real time. The digital solution provides operators with immediate feedback on optimal load levels and machine usage. This helps to minimise idle time and improve efficiency. Smart Quarry also provides managers with a real-time overview of the quarry, including material flow, enabling them to make more informed decisions without relying on manual reporting. End www.smartconstruction.io www.komatsu.eu/en

"SQS technology can reduce errors, save time and ensure operational decisions are based on accurate, up-to-date information"

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EMERGENT

NEWS

REUNION COASTAL ROAD FINAL STAGE

Completion of the long-running and much delayed New Coastal Road project for Reunion Island is entering its final stage

rough weather. Work will be carried out to remove the overpass at La Possession, with the new interchange then being built. The project is costing some €846 million more than was originally

planned. The work has been beset with delays and complexities. However, the project is much needed as the old coastal road route suffered from frequent issues with rockfalls and was not considered safe.

$68.5 million Bahrain Airport road link

PARAGUAY PROJECT PROGRESSING

New road connections to Bahrain Airport will improve traffic flow. Construction work worth $68.5 million is being carried out, which will speed journeys to and from the airport. This forms part of the Phase 3A development project for the airport. The construction

work is being carried out by a consortium that comprises local firm Nas Contracting and Nassir Hazza and Brothers from Saudi Arabia. A portion of funding is being supplied by the Saudi Fund for Development. The road improvement work will boost capacity to 16,000 vehicles/hour and cut

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Construction is underway in Paraguay for the Route of Progress project. The work is being managed by Paraguay’s Ministry of Public Works and Communications (MOPC). The route lies in South Paraguay and is around 75% complete at present. The 44km stretch linking Ybyraty and San Juan Bautista is benefiting from major improvement work that will boost safety and capacity. The road structure is being upgraded, while paving will deliver an improved surface.

congestion on the Arad and Khalifa Al Kabeer highways. A new free left-turn bridge will be built on the Khalifa Al Kabeer highway at the junction with Arad highway. The work is needed as the population in the area is growing, with increasing numbers of registered vehicles using the roads. GLOBAL HIGHWAYS 2025 VOL. 6

project. This will connect La Possession with La Grande Chaloupe. The 9.6km section of the route linking Saint-Deni with La Grande is in operation already. It is raised sufficiently to allow vehicle traffic in

onstruction work will recommence in November 2025, with the work then due for completion in 2030. The last stretch is for the 3.1km maritime viaduct, the most complex portion of the

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EMERGENT

NEWS

Triple-nation Asian highway for India, Myanmar, Thailand

KENYA-UGANDA EXPRESSWAY PROJECT A new 200km expressway is being discussed that will connect Kenya and Uganda

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for the Kimaeti to Lwakhakha stretch of road. The border posts at Busia and Malaba will be improved to speed procedures and reduce delays. The project will be carried out under the PPP model, with the Kenya National Highways Authority (KENHA) managing the Kenyan side of the project. The work is intended to improve transport links between Kenya and Uganda, as well as boosting transport with other neighbouring nations. It is one of a series of projects intended to improve international transport connections for East Africa nations. Meanwhile, a consortium comprising National Social Security Fund (NSSF) and China Road and Bridge Corporation (CRBC) has won the tender process for Kenya’s Mau Summit Highway project. The consortium has a 30-year concession package to construct, operate and maintain the upgraded highway link.

GLOBAL HIGHWAYS 2025 VOL. 6

serious political issues facing Myanmar at present. Construction work is being carried out on the 121km stretch linking Kalewa and Yagyi, as well as for 69 bridges on the 150km stretch connecting Tamu, Kyigone and Kalewa. The Indian portion of the project is being overseen by the Indian Ministry of Development of the North Eastern Region (DoNER).

$778 MILLION NEW BRIDGE FOR HO CHI MINH CITY LINK

four lanes in either direction and have a total length of 11.6km, linking Dai Phuoc Commune in Dong Nai with Nguyen Thi Dinh Street in HCMC. Costing some $622.5 million, the 15km Phu My 2 Bridge will link Nguyen Huu Tho Street in HCMC with Road 25C in Dong Nai. The Long Hung (Dong Nai 2) Bridge will cost $448 million and provide a link between National Highway 51 in Dong Nai and HCMC’s Ring Road 3. The three remaining bridges to be built in the future are the Thanh Hoi 2 Bridge, the Tan An Bridge and the Tan Hien Bridge.

A new bridge costing $778 million is one of six planned to improve transport links between Dong Nai Province and Ho Chi Minh City (HCMC) in Vietnam. The first three of the bridges will be major capital projects carried out under the PPP model, with approval having been given for the work by the People's Council of Dong Nai Province and are due for completion in 2028. Construction of the Cat Lai Bridge will cost an estimated $778 million. This will feature

inancial backing for the project looks likely to be provided by the African Development Bank (AfDB). The link will cut congestion on the existing network and speed journey times between the two capitals, Kampala in Uganda and Nairobi in Kenya. The feasibility study for the project has been approved by the Kenyan Government and the Ugandan Government. Discussions will be held between the two nations over the remaining portions of financing required. Much of the expressway project involves upgrading existing roads but there will be an all-new section measuring around 60km in Uganda between Jinja and Busesa. The stretches between Busesa and Malaba, as well as Busitema and Busia, will be upgraded to dual carriageway status. The Kenyan portion of the project meanwhile involves upgrading the Kisumu Bypass to dual carriageway status and providing a new asphalt surface

A major highway project is due for completion within three years, linking India, Myanmar and Thailand. The project will boost trade and transport, forming part of India’s Act East programme and also helping to deliver the ASEAN-India Free Trade Agreement. Called the India-MyanmarThailand (IMT) Trilateral Highway, the project is being built in spite of the

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$2 billion bridge repair

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How recycled plastic-based modified asphalt mixtures perform at low temperatures

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ASPHALT PAVING

INNOVATIVE ASPHALT DEVELOPMENT Holcim UK has laid an innovative asphalt surface on a major road link, as part of a trial of this new material

W BELOW: Holcim UK has carried out a trial of a new low-carbon SMA grade material on the UK’s busy M5 motorway

orking in partnership with National Highways, the firm has completed work on a demonstration scheme for the new E21 Stone Mastic Asphalt (SMA) specification. According to the firm, this sets a precedent for the next generation of low-carbon, high-performance road- surface materials. The project, carried out on the busy M5 motorway between Junction 28 and Junction 30, marks a significant step ahead in the UK’s transition to more durable, lower-emission road infrastructure. Developed through National Highways’ Low Carbon Demonstration Fund, the scheme shows how collaboration between Holcim UK and its supplychain partners can accelerate innovation from concept to carriageway. The resurfacing demo uses Holcim’s ProLay Ultra asphalt, a product that is being developed continuously as a next-generation road-surface solution. ProLay Ultra already meets the new National Highways E21 SMA specification, which places greater emphasis on durability, whole-life carbon, and ride quality.

GLOBAL HIGHWAYS 2025 VOL. 6

Designed with a carefully balanced aggregates matrix, increased bitumen content, and polymer modified bitumen (PMB), ProLay Ultra achieves a low in-situ void content for enhanced resilience and long-term performance. As part of this trial, a section of the E21 Stone Mastic Asphalt incorporated graphene, further enhancing the mechanical strength, fatigue resistance, and long-term durability of the surface.

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ASPHALT PAVING

REDUCTION OF PRODUCTION AND LAYING TEMPERATURES

ABOVE: Paving hot-to-hot has also helped ensure that the road surface will last longer

ENERGY SAVINGS

iterwarm rap RECOVERY AND REUSE OF RAP

REJUVENATION OF OLD ASPHALT

REDUCTION OF ATMOSPHERIC EMISSIONS

PRESERVING THE ENVIRONMENT

produzionepropria.com illustrazione benedetta fasson 2025

The M5 project saw Topcon’s sophisticated Smooth Ride technology being utilised to control surface levels with high precision and optimised ride quality, boosting both performance and driver comfort whilst reducing future maintenance needs. The LiDAR mapping and 3D road modelling developed by Driven International and MK Surveys guided precision milling using Wirtgen machines, operated by Tripod Crest. This advanced process leaves a smooth surface that is milled to grade for the paving operation. Echelon

paving was also used, with pavers working hot-to-hot, ensuring effective bonding of the asphalt surface and eliminating weak joints. This prevents future joint failure caused by moisture penetration as a result of the freeze/thaw process which, typically, results in potholes. With the echelon paving carried out to grade, a smooth and durable surface is achieved, without the uneven areas that would be subject to wear. Paving onto a surface that is milled to grade helps to reduce material wastage and lowers material costs because the paving operation no longer has to fill uneven areas. Neil Leake, national technical manager for Contracting at Holcim UK, said: “The M5 has provided the perfect opportunity to showcase the next generation of surface performance - a scheme that brings together low-carbon materials, advanced paving technology and all within the new National Highways specification. It’s a demonstration of how technical excellence and collaboration can deliver real change across the UK’s strategic road network.” Holcim UK’s extensive laboratory trials, including rutting and ageing tests, confirm that ProLay Ultra meets the performance requirements of the new E21 SMA specification. The product will be approved under CC 202 E/21, reinforcing Holcim’s confidence in its readiness for future contract submissions and National Highways adoption. End www.holcim.co.uk www.topconpositioning.com www.wirtgen-group.com

PRODUCTS FOR WARM MIXES AND REJUVENATORS FOR MIXTURES CONTAINING RAP A new and innovative sustainable product line that combines the function of products for Warm Mixes with the action of rejuvenators. This product line lowers the temperature of asphalt production, laying and compaction with significant savings in energy and atmospheric emissions. It allows to reclaim old asphalt pavements (RAP) even at high percentages, ensuring adequate workability and avoiding consumption of raw materials.

COST SAVINGS SAVINGS OF RAW MATERIALS

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GLOBAL HIGHWAYS 2025 VOL. 6

roads towards sustainability

17/11/25 16:26

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ASPHALT PAVING

Paving at a historic castle

Paving equipment from Vögele has been used to resurface the access road at Germany’s historic Neuschwanstein Castle by contractor Geiger Hoch- und Tiefbau. The work could only be carried out at night to avoid halting tourist access, so the contractor opted for the SUPER 1800-5 X paver with the integrated Light Package Plus. Neuschwanstein Castle is a UNESCO World Heritage Site and one of the most famous tourist

attractions in Germany. Many of the 1.4 million visitors/year make the climb to the castle by horse-drawn carriage. Apart from emergency and maintenance vehicles, these carriages are the only vehicles allowed to drive on the steep road. However, over many years iron-shod hooves have worn the asphalt, so the Bavarian Palace Administration decided to resurface the 1.3km road. The conditions for rehabilitating the pavement on the access road

were difficult. So, the contractor opted for a SUPER 1800-5 X road paver offering a high-power output, high traction, compact dimensions and integrated lighting. The team milled around 7,000m2 of asphalt surface with a Wirtgen W 100 CFi cold milling machine. Then the Vögele Universal Class paver laid approximately 800tonnes of surface course material over three nights in a width varying from

5-6m and a thickness of around 40mm. Given the curves, the new SmartWheel steering system, with its rotary control on the ErgoPlus 5 operator console, provided accurate control. In combination with the SmartWheel on the screed-control console, the paving team achieved a high-quality result, even in the curves. For night-time paving, the new Plus lighting package was helpful. This includes various lighting elements: lighting integrated into the canopy and the crossbar of the control panel, LEDs on the levelling cylinders, three headlights and powerful, permanently integrated LEDs in a canopy extension. They ensure optimum illumination across a pave width of up to 10m and up to 4m behind the screed. The light output is comparable to that of lighting balloons but they do not need to be transported or assembled separately. “This saved us a lot of setup time here on the jobsite,” said the contractor’s senior site manager, Stefan Keller. “With Light Package Plus, we were able to illuminate all relevant paver and work areas in a targeted manner.”

www.wirtgen-group.com

First outing for Dynapac paver model Dynapac’s latest XD25 110C asphalt-paver model has had its first site use on a road project in Germany. The machine was used at a highway construction site in northern Germany by contractor KEMNA. The XD25 110C has been developed as the flagship of the Dynapac highway-class paver series and the firm claims it represents Dynapac’s vision for the future of road construction. The KEMNA management team is convinced by the concept and features, with the machine having been developed in close cooperation with the contractor. Onsite, the contractor’s paving crew found the new interface clear and easy to use. “You get used to it quickly,” one operator commented. “The machine is quiet, visibility is excellent, and operator comfort is high.” Initial feedback from the KEMNA paving crew has been positive, reporting that the machine offers intuitive handling, quick adaptability, high build quality, and a smooth working experience. The operating concept, with controls integrated directly into the swivelling seat, was also well received.

Dynapac says that its new-generation XD25 110C highway-class paver is proving popular with contractor KEMNA

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ASPHALT PLANTS

A FIRST FOR LATIN AMERICA

Contractor Usicity, a subsidiary of CITYS and construction and infrastructure giant Turita Holding Group, is breaking barriers for asphalt production

he company is the first in the Southern Hemisphere to commission an RPP 4000 HG from Benninghoven. The facility benefits from Benninghoven’s advanced technology that can utilise a high ratio of reclaimed asphalt pavement (RAP) in asphalt mixes. The plant is located in the district of Jaraguá, around 30km from the centre of São Paulo. Greater São Paulo is a mega city with more than 20 million inhabitants, around 17,000km of roads and 1,059km of motorways. This offers a huge potential for asphalt, while providing a steady supply of RAP. Part of the Turita Holding Group, CITYS has its headquarters in São Paulo and has the brands Concrecity for concrete supply, Intercity for precast concrete, Servcity for project management and consulting and asphalt producer Usicity, with five production sites. The use of RAP is still new to the Brazilian market. RAP is often classified as hazardous waste and is not usually returned to the production cycle. Even though the market is demanding sustainable

GLOBAL HIGHWAYS 2025 VOL. 6

ABOVE: A customer in Brazil is breaking boundaries with its new Benninghoven RPP asphalt plant

solutions, there is still resistance from clients to using mixes with high percentages of RAP. Usicity is using international best practice to boost confidence in RAP. The new Benninghoven stationary batch plant can use up to 100% RAP and deliver high production capacities. It can also produce highly specialised mixtures for complex applications such as motorways and airports, but also for conventional roads. The new plant will allow the company to achieve its targets. Up to 1 million tonnes of high-quality asphalt is set to be produced for the roads and motorways in Greater São Paulo, six times the annual production volume of a plant in Germany. Sister firm Riuma operates a quarry next to the plant, while there are also facilities for RAP storage. Already standard in Europe, new-generation batch plants are gaining ground in Brazil; these plants can dose and mix batches with high precision, adapting recipes to suit the needs of specific sites. The Turita Holding Group has been a customer of Ciber for many years, leading to the contact with Benninghoven. The Brazilian firm looked at the Benninghoven range and opted for the RPP plant. Once the decision to purchase was made, everything went smoothly and quickly, with the customer’s employees receiving in-depth training that focused on the BLS 4 control system, including the recipe generator. Installation and commissioning were managed by Benninghoven, with the local team. Technical issues relating to the control system, such as the burner and automation, have been handled by Ciber for first-level support or remotely by Benninghoven in Germany. Usicity was also provided with an extensive spare-parts package. Usicity can now deliver the required high capacity, while using RAP and reducing emissions, due to the advanced hot-gas generator technology. The company now wants to go one investment step further and is planning to use hydrogen as fuel. And Benninghoven will be able to supply its innovative hydrogen burner. The RPP 4000 HG in São Paulo offers a mixing capacity of 320tonnes/hour and 4,000-5,000tonnes/day. The plant features the new hot-gas generator and can use up to 100% of RAP in the mix, while also having a dual-fuel burner that can run on heating oil or liquefied gas. End www.wirtgen-group.com Extended features & latest digital content globalhighways.com

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ASPHALT PLANTS

REFURBISHING A PLANT

Ermont has completed the retrofitting of an asphalt plant for client SEMAROUTE in Louvigny, France

he work replaced the 2007 Ermont TSM17 facility with a sophisticated and modern RF200 NEO2 plant. The upgraded plant, commissioned earlier this year, has already produced its first mixes using 50% recycled asphalt aggregates. This marks a significant step forward in sustainable road construction for SEMAROUTE, part of the Lingenheld Group. The project was to modernise the production facility to meet current performance, environmental, and recycling standards. The RF200 NEO2, based on Ermont’s RETROFLUX counter-flow technology, allows for higher recycling rates while maintaining superior asphalt quality. Compared with the older TSM17 plant, which could only recycle up to 35% of RAP, the new RF200 NEO2 can achieve recycling rates of up to 50% RAP, with full remobilisation of the binder. This represents a substantial reduction in the carbon footprint of the asphalt-production process, while also improving energy efficiency. The RF200 NEO2’s high-efficiency, counter-flow dryer-mixer features four distinct zones: drying and heating of aggregates, generation of hot air, drying and heating of recycled aggregates, and binder

GLOBAL HIGHWAYS 2025 VOL. 6

BELOW: Ermont has upgraded an existing continuous-flow asphalt plant for its client SEMAROUTE in France, allowing greater use of recycled materials

mixing. Any bitumen vapours released during production are safely incinerated in the burner flame, minimising emissions. The indirect heating process ensures that recycled aggregates are never exposed directly to the flame or high-temperature gases, protecting both the material quality and the environment. In addition, the plant integrates a foam bitumen kit, enabling the production of warm-mix asphalt, further reducing energy consumption and emissions. With a natural gas burner, a 30°C reduction in asphalt temperature saves approximately 2 kg of CO2 emissions per tonne of asphalt. Five new aggregate feeders and a dedicated recycled asphalt (RAP) feeder optimise material handling, ensuring consistency and efficiency in every mix. By combining advanced technology with practical sustainability measures, the project supports SEMAROUTE and the Lingenheld Group in delivering high-quality, environmentally responsible paving materials. The new plant is boosting the firm’s recycling rates, while also reducing emissions from the facility, improving its overall carbon profile. End www.ermont.fayat.com

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ASPHALT PLANTS

Fast asphalt-plant installation Lintec has managed to install one of its CSM3000 containerised asphalt-mixing plants in just 15 days for a client in China. The plant was installed at the Hubei Dangyang Highway Maintenance Centre under a complete turnkey model. According to Lintec & Linnhoff, the containerised design of the plant allowed for the quick installation. This modern plant can also deliver high production efficiency, providing 240tonnes/hour. The customer selected this type of plant due to its high productivity, as well as its ability to meet strict

BELOW: Lintec continues to lead the way in delivering high-efficiency, eco-conscious solutions across China and globally

environmental requirements. The Lintec CSM3000 is now fully operational, supporting a range of government-backed infrastructure projects, rural road construction, and municipal works. Delivered as a complete turnkey project, the Lintec & Linnhoff team oversaw every stage of the process, from plant transportation and installation to commissioning and operator training. All equipment components arrived on site on 1 April, and installation was completed efficiently and systematically by the company’s experienced engineering team. With commissioning finalised, asphalt production was able to commence the following day. The containerised design, a signature feature of Lintec asphalt plants, played a key role in enabling a swift and efficient setup, helping to minimise installation time while maximising safety and on-site efficiency. Mr Liu, plant manager of Dangyang Yuyang Highway Maintenance Limited Liability Company, commented: “Due to stricter environmental requirements, our previous plant was no longer suitable, so we sought a modern, eco-friendly asphalt-mixing solution. After evaluating several brands, we selected the Lintec CSM3000. From installation and commissioning to training, the professionalism of the Lintec & Linnhoff team left a deep impression on us. Their engineers demonstrated not only technical ability, but also a dedicated work ethic.”

www.lintec-linnhoff.com

NORTH AMERICAN EDITION

NEW FOR 202 ! 5

Digital editions and eNewsletters will now include dedicated North American content in addition to all of the Global Highways regular content Global Highways Magazine for industry-related discussion

GLOBAL HIGHWAYS 2025 VOL. 6

RECYCLING

RECYCLING MATERIAL ONSITE

Demolition waste is playing a key role in an urban regeneration project in Southern Italy

he contractor is utilising a crusher bucket on an excavator to ensure that rubble can become a reusable aggregate ready for the next pour or fill. In Matera, Italy, this approach has been put to the test on a large-scale urban regeneration project linking the city’s historic centre with its modern district, redesigning an area of 3.8ha. A new park is being built in the centre of Matera, but the need for transport

GLOBAL HIGHWAYS 2025 VOL. 6

ABOVE Crushing and recycling material onsite is providing major cost benefit for a project in Matera in Southern Italy

is not being overlooked as an underground parking area forms a key part of the work. New drainage with improved rainwater control and adaptive LED lighting also form part of the work. The project is being carried out under the guidance of engineer Carla La Torre from Trezza. The team behind the project chose to crush and recycle onsite. The firm’s Doosan excavator was fitted with an MB

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RECYCLING

Crusher BF90.3 which transformed demolition and excavation debris into valuable material used immediately for landscaping, base layers, and subgrade fills. On a large construction site, the MB Crusher jaw crusher allows materials to be crushed directly at the working area, without the need for trucks for internal transport. According to BM Crusher, users of the units can crush material where demolition occurs and reuse it immediately, such as sub-base for new roads, saving significantly on logistics, material costs, and time. As the crusher bucket is mounted on the excavator, it goes wherever the machine is moved at the working site. This reduces construction site traffic, waiting times, and pollution By cutting out landfill trips and reducing truck traffic, the site has seen faster progress, cleaner operations, and significant cost savings. Removing the cost of landfill charges by reusing the material instead has made a major benefit for the overall pricetag for the project, while also helping reduce the carbon profile for the contractor. The recycling work is also efficient and productive and the integrated 24V magnetic separator ensures that steel is removed safely without interrupting the crushing flow, which is important for optimising efficiency and safety. The device is controlled from the excavator cab, ensuring complete safety for both the operator and the construction site. End www.mbcrusher.com

ART

ASPHALT REPAIR TECHNOLOGY ART 1000

Efficient screening Simex is introducing its new VSE TORNADO screening buckets. The units are designed for onsite material separation, even in wet or damp soil conditions. Featuring either two- or three-shaft configuration with star elements, the VSE TORNADO is said to deliver better material swirling, improved performance, and increased operational profitability. The range is available in six different models, suiting use with mini and midi excavators from 1.5-10tonnes. The units are compact and versatile and can be used for duties ranging from soil cleaning and removal of debris, stones, and gravel, to compost aeration, as well as for beddinglayer preparation and backfilling of underground utilities and pipelines. The VSE TORNADO buckets are equipped with a Simex-patented

system that allows for the quick replacement of the entire shaft or individual screening elements. This mechanism enables easy adjustment of the output particle size, drastically reducing machine downtime and ensuring optimal performance across a wide range of materials. Depending on operational requirements, the bucket can be fitted with polyurethane or steel tools, for use in different working conditions.

www.simex.it

patent

FOR COLD ON-SITE RECYCLING OF SURFACE ASPHALT LAYERS QUICK AND LONGL A S T I N G R E S TO R AT I O N O F R O A D S U R FA C E DISTRESS WITHOUT REMOVING MILLED M AT E R I A L O R A D D I N G OT H E R A G G R E G AT E S

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GLOBAL HIGHWAYS 2025 VOL. 6

Digitalisation as lever to success Everything Wirtgen Group does, it does for its global customers. Wirtgen makes sure they have the world’s best machinery and latest technology to perform at the top of their game within their chosen field

nnovation is at the heart of everything Wirtgen Group does. It is the foundation upon which rests the performance excellence of its machines and systems that, in turn, ensure its customers’ remain in the forefront of their profession. Wirtgen ensures customer success and competitiveness with its systems in the area of jobsite intelligence (collection, documentation and provision of data including for example all WPT solutions) as well as with its assistance and automation systems. This makes Wirtgen machines extremely productive. Operating systems, such as Spective, also make machine operation very easy. With the AutoTrac steering and width control system, width and direction can be controlled automatically using various sensors and physical references. In addition to the Steering Control steering automation, the fixed screed width and the Edge Control wire follower, the new Edge Detection edge follower is also part of the AutoTrac solutions. Smart Pave automatically controls the paver’s working width and direction based on virtual references. It uses paving geometries stored in the digital platform - the John Deere Operations Center. With the AutoTrac steering and width control, the Smart Pave digital control system, the Wirtgen Group

GLOBAL HIGHWAYS 2025 VOL. 6

"Material deliveries can be quickly and easily recorded, along with other relevant data such as CO2 emissions and fuel consumption"

Performance Tracker Paving and the RoadScan temperature measurement system, paving can be carried out quickly, safely and digitally documented. The John Deere Operations Center is the Wirtgen Group’s central digital platform for construction site management. The intelligent systems of the individual brands provide the data for it. With new Wirtgen Group Performance Tracker (WPT) solutions, various systems not only document the work carried out by a machine - for example, the milled, asphalted or compacted surface or the processed material - but also simplify everyday site operations directly on location. Vögele also enables precise paving and site documentation. Based on basic paving data such as route length, layer width, layer thickness and material density, the system calculates the amount of material already installed. Material deliveries can be quickly and easily recorded, along with other relevant data such as CO2 emissions and fuel consumption. To document paving temperatures even more comprehensively and accurately, Vögele has also redesigned the RoadScan temperature measurement system specifically for the ‘Dash 5’ generation. The infrared camera’s measurement width has been increased by 3m - up to 13m - while improving resolution compared with the previous model.

www.wirtgen-group.com

Digitally optimising processing In Kleemann’s digital application Spective Connect, new configuration and optimisation tools help operators set the correct machine parameters and monitor processes on the job site. Functions such as crusher gap adjustment and belt scale calibration can, in future, be conveniently controlled directly via the app. The system is now also available for Kleemann’s mobile screening and coarse screening plants. Operators receive all relevant data - such as speed, consumption values, and fill levels - directly on their smartphones. A particularly useful function for screening plants is ‘stockpile monitoring’. With the new Performance Assistant, crushing processes are no longer just displayed - the system also actively provides recommendations for improvement based on the collected data. It works closely with the Smart Job Configurator. For example, operators are notified if the current production output does not match the values calculated by the Smart Job Configurator and are then given suggestions on how to optimise performance. New in the John Deere Operations Center is the WPT Crushing. This enables the retrieval of performance data from Kleemann crushing plants. It also allows target quantities to be set for construction sites and enables live remote monitoring of machine productivity. As a result, project progress can be recorded more easily and new jobs can be scheduled in good time.

www.wirtgen-group.com

New app for compaction control and documentation

"What began with WPT Milling is now also available in the production steps of paving, compacting, crushing"

The free Track Assist app from Hamm is an evolution of the Smart Doc app. It provides roller operators with key parameters such as number of passes, temperature limits and degree of compaction. In the next development stage, it will be possible to compare compaction targets with actual on-site results. When connected to the paver, valuable data from the paving process can also be used. Another useful feature is the display of recommended reversing points in cold or hot asphalt zones. In combination with WPT Compacting, the John Deere Operations Center enables monitoring, documentation, analysis and reporting of a construction site. Another new feature will be machine-to-machine communication. This will allow data exchange between multiple rollers - and in the future, also between paver and roller.

Automatic milling performance measurement With WPT Milling, Wirtgen has developed a solution that allows actual milling work to be recorded precisely and reliably. The system uses a laser scanner to determine the cross-sectional profile to be milled. Using GPS positioning and additional sensors, the milling area performance and milling volume are calculated with high accuracy. The machine operator receives all key information in real time on the display of the control panel, while remote workers can access the data in near real time in the John Deere Operations Center.. In addition to providing transparent and quick billing of milling jobs, the WPT also enables precise determination of construction site costs. • Produced in association with Wirtgen Group

GLOBAL HIGHWAYS 2025 VOL. 6

Automatic milling performance measurement with Wirtgen With WPT Milling, Wirtgen provides a solution that makes it possible to accurately and reliably document actual milling work completed. It is not uncommon for milling contractors to have to mill more than is specified in the RFP when carrying out a rehabilitation project. But how can the contractor bill the client on the basis of a transparent calculation when this occurs? What often resulted in additional costs and delays in completing the project can nowadays be avoided easily. The Wirtgen Group Performance Tracker ensures seamless documentation and also offers other valuable benefits.

GLOBAL HIGHWAYS 2025 VOL. 6

Reliable Documentation of Performance and Consumption data The Wirtgen Group Performance Tracker uses a laser scanner to measure the cross-sectional profile to be milled. Surface milling performance and milling volume are then precisely measured using GPS positioning and other sensors. The machine operator can continuously track the most important information in real time on the control panel’s display. The John Deere Operations Center provides a central and location-independent access to the data.

BELOW In addition to the new F series, all Wirtgen large milling machines built in 2010 or later can be retrofitted with the Wirtgen Group Performance Tracker

www.wirtgen-group.com

In addition to general equipment data such as the machines’ position and fuel level, machines equipped with WPT Milling transmit all data related to milling operations in near real time to the Wirtgen Group’s central telematics platform, the John Deere Operations Center. Here, the data can be accessed at any time, whether from a desktop or mobile device, enabling site managers to intervene even during milling work and manage projects effectively. Data from other work steps, such as asphalt paving or asphalt compaction, is also consolidated in the Operations Center, providing a holistic view of the construction site.

WPT with Numerous Additional Benefits In addition to the documentation feature, which allows milling jobs to be billed quickly and on the basis of transparent information, the Wirtgen Group Performance Tracker can also be used to precisely determine site costs. For example, the accurately measured performance and consumption data not only makes it easier to evaluate the efficiency of current and future construction sites. In addition, the data can be used to easily compare the machines with other cold milling machines in the machine fleet. This provides a valuable basis for the machine operator to decide which milling machine is the most efficient solution for which job.

WPT Milling Available as add-on kit In addition to the new F series, Wirtgen large milling machines built from 2010 onwards and already in operation can also be equipped with WPT Milling. Thanks to intelligent hardware and software solutions, it is possible to retrofit these machines at Wirtgen Group locations within a single day. • Produced in association with Wirtgen Group

ABOVE The Wirtgen Group Performance Tracker uses a laser scanner to measure the cross-sectional profile to be milled

"The Wirtgen Group Performance Tracker complements the Wirtgen Group’s WITOS telematics solution and makes milling performance transparent"

www.wirtgen-group.com

GLOBAL HIGHWAYS 2025 VOL. 6

Compaction control and documentation for the future with Hamm Hamm is now offering the further development of the previous Smart Doc app in the form of the free-of-charge Track Assist app. At the same time, it is presenting Wirtgen Group Performance Tracker (WPT) Compacting, a web-based solution in the John Deere Operations Center for documenting and reporting on compaction in asphalt construction and earthworks.

Track Assist – display unit for the driver Track Assist, the free-of-charge Android app, is the next phase in the development of the Smart Doc app and offers drivers an improved driving experience in the cab. Using a smartphone or tablet, Track Assist informs the operator about key parameters such as the number of double passes, temperature limits and the degree of compaction. In the next stage of development, Track Assist will become a sophisticated assistance system that allows the operator to compare compaction targets with the actual results. The connection to the paver also allows valuable data from the paving process to be used. Another useful function is the display of recommended reversing points in the cold or hot asphalt area.

These functions actively support the operator in their daily work and contribute to more homogeneous compaction results while simultaneously reducing the number of double passes, consumption and emissions.

Data exchange between the machine and the cloud application is also facilitated via WPT Compacting.

WPT Compacting - View jobsite performance in real time via the John Deere Operations Center

While Track Assist offers advantages for the operator during compaction itself, the integration of construction site data and compaction parameters into the John Deere Operations Center opens up new possibilities for the site management team in particular. The centralised data management allows users to access the relevant information anytime, anywhere. With the real-time display of the machine status, site managers can also respond proactively to potential challenges and optimise operations. Due to powerful analysis tools, the John Deere Operations Center provides precise insights into the machine performance of the rollers used. The integration of various Wirtgen Group machines and technologies ensures a seamless flow of information, which increases overall productivity in the construction site process. Thereby, WPT Compacting helps to increase efficiency and reduce the use of resources in road construction and earthworks. • Produced in association with Wirtgen Group

In combination with Track Assist, the roller manufacturer presents the Wirtgen Group Performance Tracker (WPT) Compacting. Rollers equipped with the WPT option collect data such as the number of passes, compaction values, and asphalt temperatures. In real time, these so-called performance data are available in the cloud-based jobsite management solution, the John Deere Operations Center, and can be used for monitoring, documentation, analysis, and reporting of a construction site. Interfaces such as the VETA export are also available, which is particularly important for the North American market. Another new feature will be machine-tomachine communication. This enables data exchange between multiple rollers and, in the future, also between paver and roller.

Greater efficiency, better planning and improved resource conservation

The new Track Assist app from Hamm provides drivers with a precise overview of compaction parameters and relevant construction site data

GLOBAL HIGHWAYS 2025 VOL. 6

www.wirtgen-group.com

Digitisation portfolio extended The digital application SPECTIVE CONNECT supports users with jobsite digitisation. New configuration and optimisation tools help a user set the correct machine parameters and monitor processes on the work site. Innovations are also available on the telematics platform John Deere Operations Center for Kleemann operators.

SPECTIVE CONNECT CONTROL – machine operation on smartphones With its innovative, bi-directional control system SPECTIVE CONNECT CONTROL, Kleemann raises machine operation to a new level. It is now possible to move the control point closer to the operator in the excavator. Functions such as crushing gap adjustment and belt scale calibration can be controlled in future conveniently directly via the app. These functions mean increased productivity, safety and comfort for the work routine.

ABOVE With Wirtgen Group Performance Tracker Crushing, performance data from Kleemann crushing plants can be called in the John Deere Operation Center BELOW New configuration and optimisation tools in SPECTIVE CONNECT from Kleemann help operators set the correct machine parameters and monitor processes on the work site

Optimised plant performance thanks to Performance Assistant The Performance Assistant means procedures in the crushing process are no longer simply depicted; suggestions for improvement are also actively made on the basis of the values determined. The Performance Assistant works closely together with the Smart Job Configurator. For example, operators are informed if the current plant performance does not correspond to the values calculated from the Smart Job Configurator. They are also given suggestions on how they can optimise production.

SPECTIVE CONNECT now also available for Kleemann screening plants Simple work site digitisation with SPECTIVE CONNECT is also available with the mobile classifying and scalping screens from Kleemann. Operators receive all relevant data such as speed, consumption values and fill levels directly on their smartphone. The “stockpile monitoring” function is particularly useful for screening plants. It displays the current status of material stockpiles. When a certain predefined value is reached, operators receive a message that the stockpile should be cleared as soon as possible. This facilitates internal logistics and increases productivity.

WPT Crushing – performance data in the John Deere Operations Center The John Deere Operations Center is the central and user-friendly telematics platform of the Wirtgen Group. It enables the professional management of complete work sites and is the interface between operators, machines, site managers and dispatchers. Crushers equipped with an belt scale and the WPT Crushing option also transmit performance data like the quantity of the crushed material live to the Operations Center. Target quantities can be created for work sites and the productivity of the machines can be viewed live from a safe distance. Work site progress is easier to record and new orders can be scheduled in good time. • Produced in association with Wirtgen Group

www.wirtgen-group.com

GLOBAL HIGHWAYS 2025 VOL. 6

New automatic functions and digital construction site monitoring from Vögele Vögele has introduced new systems delivering sophisticated asphalt paver control functionality. These are the AutoTrac and Smart Pave as well as the jobsite intelligence solutions, Wirtgen Group Performance Tracker (WPT) Paving, and the RoadScan 2.0 temperature measurement system.

AutoTrac: Control based on physical references To make life easier for users, increase work safety, and boost efficiency, Vögele has automated numerous control functions for the Dash 5 generation. The AutoTrac system offers automatic steering and width control. Using various sensors and physical references, users can automatically control width and direction. In addition to the Steering Control automated steering control, the fixed screed width and the Edge Control stringline follower, the new Edge Detection edge follower is also one of the AutoTrac solutions. It automatically controls the screed width based on an edge. Among other things, the associated laser sensor recognises kerbs, gutters or cut edges with a profile of at least 2m and uses them as a reference. This delivers a precise edge that saves material. It also reduces the workload of screed operators.

BELOW Vögele is now offering the new AutoTrac automatic steering and width control system, providing control based on physical references

Smart Pave: Control using virtual references With the new Smart Pave system, Vögele is introducing the next level of automation: The integrated system controls the pave width, position and direction of the paver fully automatically using virtual references. Smart Pave uses installation geometries that have been stored in the digital platform, John Deere Operations Center. After an automatic plausibility check, the data can be easily transferred to the road paver.

LEFT The integrated Smart Pave system from Vögele controls the pave width, position and direction of the paver fully automatically using virtual references

GLOBAL HIGHWAYS 2025 VOL. 6

www.wirtgen-group.com

The StarFiredual antenna system from John Deere is permanently installed on the canopy, determines the exact position of the paver and ensures high-precision control. "Smart Pave is an extremely user-friendly solution with a big impact," says Bastian Fleischer, Head of Product Management at Vögele. "All hardware components are integrated into the road paver, so users don't have to do any assembly work. Data handling is simple, transparent and leads to the desired result thanks to automatic error analysis." The automated control system saves time-consuming marking work, reduces the workload for users, increases the safety of screed operators and process safety during paving. Smart Pave is particularly suitable for the construction of rural and national roads and motorways.

Digital construction site documentation with WPT Paving

New temperature measuring system RoadScan

With the new solution Wirtgen Group Performance Tracker (WPT) Paving, Vögele also enables precise paving and construction site documentation. The system uses basic paving data such as section length, layer width, layer thickness and material density to calculate the amount of material already laid. Material deliveries can be recorded quickly and easily and additional relevant data such as CO₂ emissions and fuel consumption can be mapped. As with Smart Pave and all digital solutions from Wirtgen Group, the central platform is John Deere Operations Center: Installers and operators can call up the data there and efficiently network, coordinate, and analyse work steps. In combination with WPT Milling and WPT Compacting, a user can document and view the entire milling, paving and compacting process.

In order to document installation temperatures more comprehensively and precisely, Vögele has also developed the new RoadScan 2.0 temperature measurement system especially for the Dash 5 generation. The measuring width of the temperature sensor has been increased by 3m to up to 13m compared to the previous model, with better resolution. As the new RoadScan 2.0 uses the StarFire antenna system from WPT Paving, an additional GPS receiver is no longer required. For this reason, the housing accommodates only the sensor and is significantly smaller, lighter, and easier to mount. The data collected with RoadScan 2.0 will also be available to users of WPT Paving Pro in the Operations Center. • Produced in association with Wirtgen Group

www.wirtgen-group.com

TOP Vögele says the new RoadScan can be used for smaller housing or larger measuring width, offering advanced technology in combination with the new Dash 5 generation and the digital documentation tool WPT Paving ABOVE Vögele says its new Wirtgen Group Performance Tracker for asphalt paving, WPT Paving, enables precise paving and construction site documentation

GLOBAL HIGHWAYS 2025 VOL. 6

ENGINES

ENGINE TRAINING Volvo Penta has opened a new training facility, intended to give technicians the knowledge and skills they need to maximise customer uptime ABOVE Volvo Penta has opened a new training facility for engine technicians in Nuremberg, Germany

RIGHT The new Volvo Penta training facility will serve clients in Germany as well as Central Europe

“It’s providing a dedicated space where professionals can learn and get to grips with Volvo Penta technology directly”

ocated in Nuremberg, Germany, Volvo Penta’s new training centre will operate as a hub and important resource for key markets in Central Europe. The facility is on an industrial site in the heart of the city and is designed to educate and deliver immersive, hands-on training with Volvo Penta engines and systems, ensuring participants gain expertise they can apply in the field. The facility has dedicated spaces for both theoretical and practical courses and will host a wide range of programmes, from core service skills to advanced engineering and diagnostics, and emerging technologies. Dealer training events will also remain a key part of the schedule, with tailored sessions available to meet the specific needs of partners and customers. The facility is headed by Volvo Penta technical trainer Michael Schubert, who joined the company in 2024 and has more than 15 years’ experience in the industry. “I’m excited to welcome our partners and technicians to the new facility,” said Schubert. “With this centre, we are bringing training to life and getting enthusiastic people to work with real Volvo Penta engines and systems, share best practices, and ultimately bolster the Volvo Penta service network.” The new centre also provides practical knowledge on how to correctly install engines, integrate connected solutions, and better serve customers. By combining this education with hands-on skills, participants learn how to improve efficiency, predict maintenance needs, and help customers maximise uptime. “This centre is about more than technical training,” Schubert added. “It’s about building the confidence,

GLOBAL HIGHWAYS 2025 VOL. 6

skills, and strong connections across our service community. It’s providing a dedicated space where professionals can learn and get to grips with Volvo Penta technology directly.” Currently, competence training can involve getting hands-on with 5-13litre engines, with near-future plans to accommodate Volvo Penta’s full engine range up to the D17. Future initiatives should include electromobility and commercial training. Nuremberg offers a strategic location, offering accessibility for Germany and the neighbouring markets of Switzerland, Austria, Poland, and Czechia, and is easily accessible by public transport and major highways. End www.volvopenta.com

Extended features & latest digital content globalhighways.com

ENGINES

NEW GENERATOR ENGINE FROM HYUNDAI HD Hyundai Infracore is now offering the new DX15 generator engine which is said to offer performance and efficiency. The DX15 is the fifth model in the company’s DX Series electronic-generator engine line-up. Built on a 15.1 litre V8 configuration, the DX15 delivers an impressive 457–662 kWm of output and meets Tier 2 and Tier 3 emission regulations, making it suitable for a wide range of global markets. Compared to mechanical engines of the same class, output has increased by 16%. The engine features high-efficiency combustion technology and electronically controlled fuel injection, further boosting performance. Despite a compact design, the DX15 delivers highpower density and performance. Electronic control ensures speed stability and reliability, while its robust design enables consistent output even under extended operation.

ABOVE HD Hyundai Infracore is offering its new DX15 engine for additional markets

The engine is also compatible with eco-friendly fuels such as HVO and GTL and can operate for up to 500 hours without oil refills, reducing maintenance intervals and costs. End www.hd-hyundaiengine.com/en/engine/ generator/diesel-generator

New venture in China The Rolls-Royce Power Systems division is now producing the new mtu Series 2000 G06 engine in China. The new product is manufactured at MTU Yuchai Power (MYP), a joint venture between Rolls-Royce and Chinese engine manufacturer Guangxi Yuchai Machinery Co. (Yuchai Diesel), in its Suzhou facility. The new mtu Series 2000 G06 engine is said to offer high power density, fuel efficiency, and reliability. The launch of this model in China will boost options for Chinese customers and strengthen

Rolls-Royce’s service capabilities in key industries such as power generation. Rolls-Royce Power Systems and Yuchai signed a cooperation agreement in 2014 to establish the joint venture. In April 2018, the first mtu Series 4000 engine was made at Yuchai. In 2024, the two parties announced an expansion of the joint venture and have now achieved the production of 4000 Series S83 engines and the new 2000 Series engine. Meanwhile, Rolls-Royce Power Systems has also seen healthy half-year results for 2025. The

firm is benefiting from record investment, with new engine platforms and plant expansions worldwide, with manufacturing plant utilisation said to be at a record high. Rolls-Royce's Power Systems division, with its mtu product and solutions brand, continued its rapid profitable growth in the first half of 2025. Adjusted for the sale of the lower power engine business last year, revenue rose by 20% to €2.4billion, while adjusted operating profit increased by 89% to €371 million. The order backlog for new business now stands at a record level with OE

order coverage of 100% for the remainder of 2025 and 43% for 2026. Rolls-Royce is currently investing in a new mtu engine platform, which will offer higher power density, lower emissions and improved fuel consumption, and will be available from 2028. In mid2026, part of the large-scale modernisation of the production facilities in Friedrichshafen will be completed with the commissioning of a new assembly line for the mtu Series 4000.

www.rolls-royce.com

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CONCRETE PAVING

POWER CURBERS HAS PLANS FOR MILLER FORMLESS Power Curbers has significant plans for the recently acquired Miller Formless business – company president Stephen Bullock spoke with Mike Woof, editor of Global Highways Q: What are the plans for the business following the Miller acquisition? A: We will continue manufacturing Miller Formless machines in McHenry, Illinois. We will focus on core products, the M 1000, 8100, and 8800. Q: How will Miller be incorporated into Power Curbers? A: Miller Formless will continue to stand alone in manufacturing. Our sales teams and product-support teams will be crosstrained to provide sales and service to all products. You will see the Miller Formless name included with Power Curbers and Power Pavers, all under the Power Curbers Companies umbrella. Q: What are the plans for the Miller facility? What are its strengths? A: We will continue operating in McHenry, in Illinois. We have a great team of dedicated, long-time Miller employees who are excited about the new opportunity in partnership with Power Curbers Companies.

GLOBAL HIGHWAYS 2025 VOL. 6

Q: How will production of Power Curbers/ Power Pavers and Miller machines be changing following the purchase? Will certain models or components be made at one plant or another? A: Other than fully supplying Miller Formless with all the parts stock and materials needed, we will not make major production changes. As we’ve done for decades with Power Curbers and Power Pavers, we’ll have opportunities to supply each other with components, depending upon capacity at each location. Q: How will the Miller machines be adapted to standardise with models from Power Curbers? A: We will continue to build the 1000, 8100, 8800 to the specifications that Miller Formless owners have valued for decades. Q: What features of the Miller technology will be of benefit to the Power Curbers range, looking ahead? A: We have respected Miller Formless machines for decades. The core of Power Curbers products and Miller Formless products will not change. We, of course, will look to add features from one machine to another if it can improve the machine and make the customer more productive.

Q: Which Miller models offer the best opportunity for sales outside of the US? A: The M-8800 is already an extremely popular barrier wall machine in Europe. We expect to double 8800 sales within two years, and in select markets where compact size is important for curbing, the M-1000 will be a great fit. Q: How is the relationship between Power Curbers and Miller now? A: Power Curbers and Miller Formless were friendly competitors for five decades. We’ve always had great respect for the machines and for Miller’s outstanding service to customers. The culture fit could not have been better and has made for a smooth integration. Our teams are excited to work together as one company to better provide solutions to contractors. With the addition of the Miller Formless products, Power Curbers Companies can now offer machines from our small 150 extruder to our Power Pavers 3404 DBI mainline paver and everything in between. That makes for a line-up that no other slipform manufacturer can match. End www.powercurbers.com

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CONCRETE PAVING

PAVING IN THAILAND

In Thailand, two important road projects are being carried out using the latest Wirtgen SP 64 slipformers

he machines are working quickly, reliably and efficiently, delivering high-quality paved surfaces. As no fixed moulds are required, the manual work required is reduced considerably. For the site in Surat Thani Province, paving work is being carried out by contractor Premium Concrete, with the machine delivering an extremely even, highquality concrete road surface. The 22.3km section is a part of the important AH2 trunk road to Maluan. Sirichot Phettong, project engineer at Premium Concrete, said: “With the Wirtgen slipform paver, we achieve a high working speed and can ensure high surface quality.” The road has a full width of 11m and features two lanes that are 3.5m-wide, as well as a lane 4m-wide. Reinforcement is with dowel bars 38mm in diameter and side tie bars that are 20mm in diameter, with the firm paving a thickness of 320mm. Wirtgen technology is also optimising the construction of roads for heavy-goods traffic. Contractor CC Machinery & Construction is upgrading a 17km section of the road linking Tha Sala and Nopphitam on the section from Thai Bun to Nopphitam. As traffic drives on the left in Thailand, the lefthand lane tends to be used by heavy-goods vehicles. It is being paved 30mm thicker than the adjacent lane to cope with the additional stresses. Thawat Arunsuwannakon, managing director of CC Machinery & Construction, said: “We decided to use the slipform

ABOVE Wirtgen concrete-paving technology is delivering efficient paving for contractors in Thailand

paver because Wirtgen offers outstanding customer care, comprehensive service and training courses. These are particularly important criteria for us.” This section of road is 14m-wide, with four lanes that are each 3.5m-wide. Reinforcement is with dowel bars that are 38mm in diameter and side tie bars that are 20mm in diameter. The traffic lanes are being paved 250mm-thick and 280mm-thick, accounting for the differing loads. End www.wirtgen-group.com

Tough paver from Latin America

Developed in Brazil, the JL900 from LOCKS suits use in RCC and base applications

GLOBAL HIGHWAYS 2025 VOL. 6

A new paver, developed in Latin America, is said to be able to cope with harsh operating conditions and materials. The new JL900 model from LOCKS has been designed specifically to handle aggressive RCC or base materials paving duties. Unlike conventional asphalt pavers, for which the bitumen acts as a lubricant, the JL900 is designed from the start to cope with these more aggressive applications. The screed features thicker and harder smoothing plates as well as a structure designed for the heavy-duty application. The screed benefits from a proprietary vibratory system which has a specific amplitude and frequency for compacting RCC or base materials. The tamper has a greater amplitude than on conventional asphalt pavers, which is said to ensure efficient pre-compaction. Instead of using a chain-type material transport system, the LOCKS paver

benefits from the fitting of a conveyor, said to deliver a constant and smooth flow. This is claimed to allow a more constant delivery of material than chain systems, while also reducing mechanical wear and boosting productivity. Material finish is said to be high due to the weight of the screed and its heavyduty construction. This is further assisted by the efficient vibration system and the high-amplitude tamper design. According to the firm, pre-compaction of up to 70% is claimed, varying according to particle size, moisture, and thickness. The JL900 weighs 19tonnes, has a hopper capacity of 16tonnes and is said to be able to deliver up to 900tonnes/ hour. Power comes from a Cummins QSB 4.5 diesel rated at 145kW and the machine also features Linde hydraulic components and electrics from Siemens.

www.locksindustrial.com

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Automated compaction to target value SMART COMPACT IN EARTHWORKS

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CLOSE TO OUR CUSTOMERS. Automated compaction until the desired target value is reached? Smart Compact makes it possible. How does it work? Based on highly precise compaction measurements, Smart Compact constantly adjusts the compaction force depending on the ground conditions. The result: high process reliability, no over-compaction, no jump operation, fewer passes, lower diesel consumption. www.hamm.eu HAMM AG · Hammstr. 1 · D-95643 Tirschenreuth · Tel +49 (0) 9631 80-0