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Electric heavy equipment

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Elektrischer Raupenbagger PC4000-11E auf der Bauma 2022
Electric crawler excavator PC4000-11E of Komatsu

Electric heavy equipment, electric heavy machinery, electric construction vehicles, or electric construction equipment, refers to a subcategory of heavy equipment propelled by electric motors. The majority of electric heavy equipment uses electrical energy stored in an onboard battery which makes them battery electric vehicles. For construction machines that are rarely moved, such as stationary excavators, a cable connection can also supply power. Electrified heavy machinery is considered a key development in the decarbonisation of the construction sector.

The introduction of electric heavy equipment follows the introduction of other heavy electric vehicles such as electric trucks. The requirements for construction machinery are highly diverse and pose a number of challenges for electrification. For example, mobile charging infrastructure is often required because most construction machinery cannot be relocated for charging. The required power and battery sizes can far exceed those of electric trucks and extreme temperatures, for example in road construction, challenge the temperature management of the batteries.

Development

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In 2012, Caterpillar presented the Cat 336E H, a hybrid crawler excavator weighing 37 tonnes. It saves up to 25% fuel through recuperation when braking the bucket. This was an important early milestone in the electrification of heavy equipment.[1]

A 2017 study by IDTechEx Research analysed the potential of electric vehicles in construction, agriculture, and mining over the next 10 years up to 2027. The study found that the major manufacturers were still focusing on machines with hybrid drives, while other companies already offer small, fully-electric construction equipment. The sector was forecast to grow to 165,000 vehicles or USD 81 billion by 2027.[2]

In 2017, Volvo and Skanska conducted a 10-week test of an electric quarry. Autonomous HX2 transporters and an EX1 wired excavator based on the EC750 model were used.[3]

Also in 2017, the eDumper, an electric dump truck from Komatsu in cooperation with Kuhn Switzerland and Lithium Storage was presented. It has a 600 kWh battery and can transport loads of 55 tonnes. At the mining site where it operates, it even has a positive energy balance, as it travels uphill empty and can recuperate more energy on the way back than it needs due to the weight of the transported material.[4]

In 2018, Cummins and Hyundai joined forces to enter the development of electric construction machinery. The first target was a 3.5-tonne compact excavator with a 35.2 kWh battery that could be used for a full eight-hour shift.[5] A prototype of the R35E was unveiled in 2019.[6]

In 2019, a report by McKinsey & Company found that in certain areas, the total cost of operating electric construction machinery was already 30% lower than comparable diesel models. The acquisition costs were calculated to be 30 to 90% higher, but the operating costs over 60% lower.[7]

Since 2019, the company Pon Equipment has been offering converted 323F crawler excavators from Caterpillar as the so-called Z-Line. These machines have been converted with 300-kWh, 3.4-tonne batteries and are designed to work for up to seven hours.[8]

Elektrischer Raupenbagger Hitachi ZE135 auf der Bauma 2022
Electric crawler excavator Hitachi ZE135

In 2022, the Bauma trade fair chose "The Road to Zero Emissions" as one of its leitmotifs. Several electric construction machines were announced and presented, including tandem rollers, concrete mixing trucks, and the world's first all-electric T7X skid steer loader from Bobcat.[9]

The "Electric Worksite" study conducted 2024 in Gothenburg with the participation of Volvo, investigated the feasibility of fully-electric construction sites using real examples in the city. Electrically-powered mobile and crawler excavators, wheel loaders and load carriers weighing between 3.5 and 30 tonnes were used, which were supplied with power either by battery or via cable connections.[10]

A study by IDTechEx Research from 2024 states that the market for electric vehicles in construction was previously held back by high investment costs and customer reluctance due to limited battery capacities and small model selection. However, it was also observed that the entry phase of many manufacturers with small construction machinery and battery sizes comparable to electric cars is coming to an end and the trend is moving towards larger machines that can cover the full range of the construction machinery market.[11]

In 2025, climate neutrality and alternative drives were the central themes of the Bauma trade fair.[12]

Advantages and disadvantages

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Advantages

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Electric heavy equipment can be operated in a climate-neutral way. They produce no local emissions, such as CO2 or nitrogen oxides, and are significantly quieter in operation than comparable heavy equipment with internal combustion engines. Electric motors require little maintenance and have high energy efficiency, which leads to lower operating and energy costs.[13]

The low-noise operation makes them particularly suitable for use in noise-sensitive locations such as residential areas or allows for use during sensitive times, for example at night. The absence of exhaust fumes makes electric construction machinery ideal for poorly-ventilated environments such as tunnels and indoor areas. Both also reduce the strain on operators and other workers on construction sites and comply with increasing environmental regulations.[9]

Electrification of the drive system is accelerating the introduction of electronic systems in construction machinery and is also making automation easier.[14]

Using the example of a 10-tonne standard excavator, a study by IDTechEx calculated annual costs for diesel of USD 6,500 in 2024, while the electricity for the electric model would cost USD 3,350.[11]

Disadvantages

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At present,[when?] electric heavy equipment is still significantly more expensive to purchase and may also require additional investment in charging infrastructure. The price premium compared to comparable models with combustion engines is between 50% and 100%.[11]

The possible working time without charging breaks is limited by the battery capacity. While larger batteries increase the purchase price, smaller batteries require good integration of the charging process into the operation. The high weight of the batteries is often not a disadvantage, which enables the use of cheaper variants such as LFP batteries and, if necessary, replaces some of the counterweights required for excavators and cranes.[11]

Charging infrastructure

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Various concepts are being developed for the charging infrastructure of heavy machinery, which are optimised for different types of construction sites. For stationary excavators or machines that are only slightly mobile, a local power supply via cable is a good option, if possible. Construction machinery that is only used for short periods on small construction sites and is easy to move can be charged at the construction company's depot or at public charging stations. For other construction sites, it may be necessary to set up mobile fast charging stations that either use an existing power grid or are supplied via mobile power storage units that have to be brought to depots for charging.[15]

Distribution

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According to an estimate by Custom Market Insights, the global market for electric construction equipment was valued at USD 14.5 billion in 2024 and is expected to grow to USD 37.4 billion by 2033.[16]

So far, the main drivers of the spread are initiatives and guidelines from governments and municipalities, but also the low long-term maintenance costs.

Public funding

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Municipal initiatives are incentivising companies to use electric machines. Berlin has pilot projects with fully electric construction machinery. Initiatives in Oslo, Copenhagen, and London are aiming for climate-neutral operations by 2030.[17] Helsinki is part of a Finnish Green Deal initiative for emission-free construction sites and is already demanding electric excavators for selected construction sites.[18]

Categories

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Excavators

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Large excavators

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Model Brand Weight Power Battery capacity Operation time Characteristics
PC4000-11E[19] Komatsu 409 t 1400 kW N/A unlimited Used in mines with power connection
ZE135[20] Hitachi 14.6 t 300 kWh 6 h
DX300LC Electric[21] Doosan 32.3 t 145 kW 390 kWh 8 h exchangeable batteries
145 X-Tier[22] John Deere unknown unknown unknown unknown
PC210E-11[23] Komatsu 24 t 123 kW 451 kWh 8 h
EC230 Electric[24] Volvo 21 t 160 kW 450 kWh 4–5 h
Elektro-Kompaktbagger KX38-4e von Kubota auf der Bauma 2022
Electric compact excavator KX38-4e from Kubota

Mini and compact excavators

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Mini and compact excavators are hydraulic excavators that are used in light earthworks, gardening and landscaping and generally weigh a maximum of 8.5 tonnes.

Model Brand Weight Power Battery capacity Operation time
ZE19-T[20] Hitachi 2 t unknown 26,4 kWh 4 h
ZX55U-6EB[25] Hitachi 5.3 t 33 kW 40 kWh 2 h
ZEX85-6EB[26] Hitachi 8.8 t 40 kW 133 kWh 5.5 h
DX19 Electric[21] Doosan 2.1 t 15 kW 32 kWh 8 h
PC138E-11[27] Komatsu 15.3 t 72,5 kW 225.6 kWh 8 h
PC33E-6[28] Komatsu 3.6 t 17,4 kW 35 kWh 3 h
9C-1E[29] JCB 1.9 t 20 kW 19.8 kWh 4 h
KX38-4e[30] Kubota 4 t 17.8 kW 49.2 kWh 5 h
ECR25 Electric[31] Volvo 2.6 t 18 kW 40 kWh 4 h
ECR18 Electric[32] Volvo 1.8 t 18 kW 16 kWh 5 h
Elektrischer Radlader RT220-2e von Kubota auf der Bauma 2022
Electric wheel loader RT220-2e from Kubota at Bauma 2022

Loaders

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Model Brand Weight Power Battery capacity Operation time
L25 Electric[33] Volvo 4.9 t 22 kW 40 kWh 8 h
L90 Electric[34] Volvo 15 t 140 kW 180 kWh 4–6 h
L120 Electric[35] Volvo 20 t 228 kW 282 kWh 5–9 h
5065e[36] Kramer 3.9 t 23.2 kW 37.5 kWh 4 h
T7X[37] Bobcat 5.7 t 75 kW 72.6 kWh 6 h
580EV[38] CASE 9 t 80 kW 72.7 kWh unknown
RT220-2e[39] Kubota 2.2 t 6.5 kW 25 kWh unknown

Bulldozers

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Model Brand Weight Power Battery capacity Operation time Characteristics
"All-electric underwater bulldozer"[40] Komatsu unknown unknown 500 kWh 6 h Bulldozer for underwater
ML 6 Moonlander[41] Lumina 32 t 552 kW 414 kWh unknown can be used autonomously
Elektrischer Straßengrader HBM NOBAS BG 120 TA-E auf der Bauma 2022
HBM-NOBAS BG 120 TA-E electric road grader at Bauma 2022

Graders

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model brand weight power battery capacity operation time
BG 120 TA-E[42] HBM-NOBAS 15.5 t 110 kW 325 kWh 8 h

Transporters

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Trucks with road licences are often used to transport construction materials. Specialised vehicle types for construction sites such as dump trucks are listed here.

Dump trucks

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Model Brand Weight Power Battery capacity Operation time Characteristics
A30 Electric[43] Volvo 29 t 265 kW 245 kWh unknown
A40 Electric[44] Volvo 39 t 350 kW 350 kWh unknown
eDumper[4] Komatsu 45 t 588 kW 600 kWh unknown recuperates more energy than it consumes

Material handlers

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Mobile cranes

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Model Brand Weight Power Battery capacity Operation time Characteristics
MK5150XLe Plug-in-Hybrid[45] Manitowoc 60 t unknown 180 kWh 5 h Fully-electric use in crane operation
LR 1250.1 unplugged[46] Liebherr 212 t 255 kW unknown 8 h
LR 1300.2 SX unplugged[47] Liebherr 293 t 438 kW 392 kWh 13 h
653 E[48] Sennebogen unknown 130 kW 210 kWh 14 h

Telehandlers

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Model Brand Weight Power Battery capacity Operation time Characteristics
525-60E[49] JCB 5.1 t 39 kW 24 kWh unknown
17.45[50] Faresin 12.1 t 51 kW 45 kWh unknown
Elektrischer Asphaltfertiger MINI 500e von Vögele auf der Bauma 2022
Electric asphalt paver MINI 500e from Vögele at Bauma 2022

Highway engineering

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Some heavy equipment is specialised for highway engineering.

Pavers

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Model Brand Weight Power Battery capacity Operation time
MINI 500e[51] Vögele 1.5 t unknown 21.5 kWh unknown
SUPER 1300-5e[52] Vögele 11 t unknown 126 kWh unknown
SD1800W e[53] Dynapac 10.3 t 55 kW 98 kWh unknown

Road rollers

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Model Brand Weight Power Battery capacity Operation time
DD25 Electric[54] Volvo 2.7 t 96 kW 20 kWh 4 h

Concrete handling

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Concrete pumps

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Model Brand Weight Power Battery capacity Operation time
CP 2800 BE[55] Schwing Stetter 13.5 t 112 kW 112 kWh 8 h
prototype[56] Volvo 32 t 330 kW 360 kWh unknown

Concrete mixing trucks

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Model Brand Weight Power Battery capacity Operation time
ETM 1005/1205[57] Liebherr unknown 500 kW 340 kWh unknown
FMX electric concrete mixer[58] Volvo unknown 330 kW 360 kWh unknown

Compactors

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Rollers

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Model Brand Weight Power Battery capacity Operation time
BW 177 DH e[59] BOMAG 7 t unknown 78 kWh unknown

Drilling rigs

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Model Brand Weight Power Battery capacity Operation time
LB 16 unplugged[60] Liebherr 59.4 t 265 kW none 10 h

See also

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References

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  1. ↑ David Herron (2012-10-17). "Caterpillar announces hybrid electric earth moving machine, Cat663E H | Torque News". Retrieved 2025-06-08.
  2. ↑ Electric Vehicles for Construction, Agriculture and Mining 2017-2027. 2017.
  3. ↑ "Volvo rolls electric heavy machinery into emission-free quarry test site". 2018-09-05. Retrieved 2025-06-08.
  4. 1 2 Rob Stumpf (2017-10-10). "The e-Dumper is the World's Largest and Most Efficient Electric Truck". Retrieved 2025-06-08.
  5. ↑ Lambert, Fred (2018-10-30). Cummins and Hyundai made an all-electric excavator as heavy machinery goes electric. {{cite book}}: |work= ignored (help)
  6. ↑ "Hyundai, Cummins unveil prototype of fully electric compact excavator - On-Site MagazineOn-Site Magazine". 2019-10-09. Retrieved 2025-06-07.
  7. ↑ "Electromobility Gaining Ground in Heavy Machinery and Equipment". McKinsey & Company. 2019-04-19. Retrieved 2025-06-08.
  8. ↑ Stephen Edelstein (2019-01-30). "This Electric Caterpillar Excavator Is the Tesla of Heavy Construction Equipment". Retrieved 2025-06-08.
  9. 1 2 "bauma 2022: Baumaschinen erhalten elektrische Antriebe - bauma, Elektromobilität (E-Mobilität), Umwelt-, Klimaschutz und Nachhaltigkeit | News | Logistik Heute - Das deutsche Logistikmagazin" (in German). Retrieved 2025-06-05.
  10. ↑ "Study proves viability of urban electric construction – with big benefits for society". Retrieved 2025-06-07.
  11. 1 2 3 4 Electric Vehicles in Construction 2024-2044: Technologies, Players, Forecasts. 2024. ISBN 978-1-83570-049-5.
  12. ↑ "Unsere Leitthemen" (in German). Retrieved 2025-06-05.
  13. ↑ Electric construction equipment: Construction beyond diesel.
  14. ↑ Sara Jensen (2025-06-02). "Electrification a Key Enabler for Automation in Mobile Machinery". Retrieved 2025-06-07.
  15. ↑ "Construction Equipment Goes Electric, But Hurdles Remain | 2019-06-05 | Engineering News-Record". Retrieved 2025-06-08.
  16. ↑ "Global Electric Construction Equipment Market Size 2033". Retrieved 2025-06-07.
  17. ↑ "Entwicklungen, Perspektiven und aktive Bestrebungen in der Elektrifizierung von Baumaschinen" (in German). 2025-03-10. Retrieved 2025-06-07.
  18. ↑ "Städte und Gemeinden profitieren von der Energiewende | Volvo CE" (in German). Retrieved 2025-06-07.
  19. ↑ "Komatsu Bagger PC4000-11 mit elektrischem Antrieb" (in German). Retrieved 2025-06-09.
  20. 1 2 "Elektrobagger und Zero Emission | KTEG" (in German). Retrieved 2025-06-09.
  21. 1 2 "Doosan Netherlands Dealer Develops Electric Excavators". Retrieved 2025-06-09.
  22. ↑ "Deere Expands Options with New E-Drive and E-Power Machines". Retrieved 2025-06-09.
  23. ↑ "Komatsu Ready to Launch New 20 tonnes Class Electric Excavators". Retrieved 2025-06-09.
  24. ↑ "EC230 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  25. ↑ "ZX55U-6EB Mini Excavators". Retrieved 2025-06-09.
  26. ↑ "ZX85-6EB Medium". Retrieved 2025-06-09.
  27. ↑ "Komatsu ready to launch new 13 ton class PC138E-11 electric excavator with lithium-ion battery". Retrieved 2025-06-09.
  28. ↑ "Komatsu Mini Excavator PC33E-6". Retrieved 2025-06-09.
  29. ↑ "19C-1E | Minibagger | JCB.com" (in German). Retrieved 2025-06-09.
  30. ↑ "Elektrischer Kompaktbagger KX38-4e von Kubota" (in German). Retrieved 2025-06-09.
  31. ↑ "ECR25 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  32. ↑ "ECR18 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  33. ↑ "L25 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  34. ↑ "L90 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  35. ↑ "L120 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  36. ↑ "Radlader 5065e" (in German). Retrieved 2025-06-09.
  37. ↑ "T7X All-Electric Compact Track Loader (Specs, Pricing & More) - Bobcat Company". Retrieved 2025-06-09.
  38. ↑ "CASE 580EV Electrified Backhoe Loader | CASE". Retrieved 2025-06-09.
  39. ↑ "RT220-2e". Construction Machinery. Retrieved 2025-06-09.
  40. ↑ "The Coolest EV at CES Is Komatsu's New Electric Underwater Bulldozer". Komatsu. 2025-01-13. Retrieved 2025-06-10.
  41. ↑ "ML 6 Moonlander: Autonomer 32-Tonnen-Bulldozer fährt vollelektrisch" (in German). 2025-06-04. Retrieved 2025-06-10.
  42. ↑ "HBM NOBAS BG 120 TA-E - HBM NOBAS - TERRA Group". Retrieved 2025-06-10.
  43. ↑ "A30 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  44. ↑ "A40 Electric | Elektrische Maschinen | Überblick" (in German). Retrieved 2025-06-09.
  45. ↑ "New Grove Plug-in Hybrid all-terrain cranes to star at bauma 2025 | Manitowoc". Retrieved 2025-06-10.
  46. ↑ "LR 1250.1 unplugged Crawler crane - Liebherr". Retrieved 2025-06-10.
  47. ↑ "LR 1300.2 SX unplugged Crawler crane - Liebherr". www.liebherr.com. Retrieved 2025-06-23.
  48. ↑ "Sennebogen 653 Electro Battery - telescopic crawler crane | Sennebogen". Retrieved 2025-06-10.
  49. ↑ "JCB 525-60E | Electric Telehandler". T.C. Harrison JCB. Retrieved 2025-06-10.
  50. ↑ "Big Range Full Electric | Faresin Industries". Retrieved 2025-06-10.
  51. ↑ "MINI 500e | Straßenfertiger | Vögele" (in German). Retrieved 2025-06-10.
  52. ↑ "SUPER 1300-5e | Straßenfertiger | Vögele" (in German). Retrieved 2025-06-10.
  53. ↑ "Dynapac SD1800W e" (in Basque). Retrieved 2025-06-10.
  54. ↑ "DD25 Electric | Electric Machines | Overview". Retrieved 2025-06-10.
  55. ↑ "Stationäre Betonpumpen". Retrieved 2025-06-10.
  56. ↑ "Volvo and Putzmeister showcase unique battery-electric pump truck at Bauma". Retrieved 2025-06-10.
  57. ↑ "Liebherr presents all-electric truck mixers - electrive.com". 2020-03-29. Retrieved 2025-06-10.
  58. ↑ Peter Johnson (2023-02-10). "First electric concrete mixer truck unveiled by Volvo Trucks paves way for sustainable construction". electrek. Retrieved 2025-06-10.
  59. ↑ "BOMAG Walzenzug | SUNCAR". Retrieved 2025-06-10.
  60. ↑ "LB 16 unplugged Drehbohrgerät - Liebherr" (in German). Retrieved 2025-06-09.
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