Wirtgen Group is actively developing automated road construction vehicles as stepping stones for full autonomy using some of the same technology stack as parent company John Deere.

During a recent demonstration of its roadbuilding machinery at the company’s North American headquarters in the US state of Tennessee, company executives outlined the benefits of its specialised heavy machinery for road building.

Demand for roads and infrastructure keeps rising while contractors juggle labour shortages, climbing material costs, tighter project timelines and shorter paving seasons.

In the US alone, the construction industry is expected to need nearly 700,000 additional workers by 2031 just to keep pace with demand.

About 40% of the four million miles of roadways across the US are currently rated in poor or mediocre condition.

“As we talked with our customers, we learned a few things about some of their business challenges, which is simply to do more with less,” said Craig Lamarque, VP and head of digital products at Wirtgen America. “Every day our customers are responsible to ensure the safety of every person on absolutely every job site”.

“And they have to do that with increasingly less skilled and less experienced personnel.”

Lamarque explained customers must complete a greater number of projects on tighter timelines to stay profitable while coping with issues with materials, sustainability pressures, labour shortages, and the need to stay on budget and on schedule.

Wirtgen Group responded by introducing digital tools to help address those challenges.

He said Wirtgen’s digital strategy centres on three pillars: connected support to maximize uptime, job site intelligence to expose inefficiencies and improve decision-making, and smart automation to boost machine performance.

Those capabilities are embedded across its road construction equipment lineup and are supported by hardware and software in collaboration with John Deere.

A legacy built on family names

The Wirtgen Group was a privately held German company before it was acquired by John Deere in 2017.

Earlier in its history, the Wirtgen Group bought asphalt paving company Vogele (in 1996) ahead of purchasing soil and asphalt compaction company Hamm three years later. Vogele was established in 1836, one year prior to John Deere.

Kleemann was acquired in 2006, which expanded Wirtgen’s reach into mineral processing with mobile crushing and screening plants.

The Wirtgen Group bought a 70% stake in Benninghoven in 2014, adding asphalt mixing plants to the ecosystem and enabling Wirtgen to offer the entire cycle of road construction equipment from mixing and paving to milling and recycling.

Wirtgen America was established in 1984 and now includes 300 employees across the Tennessee campus.

“Every one of those names of the brands is a family name, much the same as Deere,” said Wirtgen America president and CEO Jim McEvoy. “From that standpoint, we have a long legacy of being early in these markets, being leaders in these markets and being very innovative in these product spaces.”

Here’s a look at three of the roadbuilding machines and technologies showcased in Tennessee across asphalt milling, paving and compaction.

Wirtgen milling machine
The milling machine removes old asphalt or concrete surfaces while using automation and digital guidance technologies to improve precision, efficiency and performance tracking. It is designed for high-output work on freeways, highways, airports and other major infrastructure projects.

The W210XF is equipped with a 2.5 metre-wide cutter drum which removes asphalt and concrete prior to loading the material into a truck. It uses automation and digital guidance technologies across eight cameras to improve precision, efficiency and machine performance tracking.

“Simple diagnostics, intuitive instructions on the display and backup components built into the machine make it easy to keep going,” Lamarque said.

WPT Milling documents job and machine data for billing and emissions tracking. Smart Level Pro is a fully integrated differential milling system which scans the surface about to be milled.

The process begins with a high-speed survey scan of the existing road surface, either by the customer or a third-party surveyor, without closing the road. The resulting digital model is then georeferenced and logged using GNSS.

After scanning, the road profile is refined to meet specifications, then uploaded to the John Deere Operations Centre and Work Planner, where cutting depths can be checked in advance which saves time compared with milling first and verifying later.

Utilising two John Deere StarFire receivers connected by cellular service, Lamarque said the mill goes to work, “precisely milling the design depth and slope, leaving the best possible surface”.

StarFire GNSS Guidance is Deere’s satellite technology which helps machines maintain highly accurate positioning, alignment and paving guidance throughout the roadbuilding process.

Mill Assist is an automated system on the milling machine that uses real-time machine data to optimise performance, improve efficiency, and reduce fuel consumption and emissions.

Vogele asphalt paver
The asphalt pavers are packed with highly specialised automation, levelling and material handling technologies.

Smart Pave is an advanced digital control and automation system developed by Vogele for its asphalt road pavers. AutoTrac technology helps the paver hold its direction of travel and paving width with precision.  

RoadScan is Vogele’s proprietary, non-contact thermal imaging and temperature measurement system mounted directly to the asphalt paver.

Hamm asphalt roller
The double-drum asphalt roller machine compacts fresh asphalt to the target density required for long term durability, using real-time density monitoring and intelligent compaction technology to hit the mark.

It focuses on preventing over-compaction, maximising operator efficiency and providing proof of compaction quality to contractors, state and federal authorities.

The roller uses a combination of vibration and oscillation to compact material to the desired density. Smart Compact Pro and Track Assist help road crews compact more efficiently, cost-effectively and safely while also meeting intelligent compaction specifications.

Intelligent compaction is data collection of the roller using GPS compact mapping, temperature sensors which map and report asphalt surface temperature and an accelerometer sensor that reports stiffness.

From automation to autonomy
Jason Ambroson, VP and managing director of Wirtgen International, explained running the same technologies, connectivity and data sensors across the various roadbuilding machines enables customers to be more productive using fewer employees and fewer resources.

“We are moving from automation to autonomy,” he said.

That trajectory of connecting machines, data and operators into a single intelligent system was what the Tennessee demonstration was ultimately built to show.

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