The Wirtgen Group's modular concept is built on a platform of interchangeable drive system solutions. The real innovation lies in an end-to-end construction system that provides road construction and maintenance contractors with everything they need to complete new construction or rehabilitation projects.

This includes: cold milling machines, pavers, tandem roller compactors, asphalt mixing plants, crushing equipment and a complete set of specially customized digital solutions. The combined result is lower CO2 and noise emissions and, when electric drive systems are used, lower energy costs.

As a result, construction projects become more sustainable while also achieving higher returns. The Wirtgen Group's "construction system for zero-emission construction" was successfully shortlisted for the 2025 Bauma innovation award in the "Climate Protection" category.

Challenges faced by urban construction projects: achieving zero-emission construction

Urban road construction projects mainly involve repairing and maintaining existing infrastructure on small sites. For this, classic cold milling machines first remove the damaged asphalt pavement, pavers then lay new asphalt concrete, and finally rollers compact the newly paved surface.

With the Wirtgen W 50 Re cold milling machine, the Vögele SUPER 1300-5e road paver and the Hamm HX 70e tandem roller, the Wirtgen Group has developed a construction system that consistently uses battery-electric drive systems.

Vögele presents a fully electric paver at Bauma

Advantages of the platform solution: higher returns, lower costs, a more comfortable working environment

The major challenge for battery drive systems across various machines is that power requirements, available installation space and drivetrain functional requirements all differ. Experts from the parent company and from battery manufacturer Kreisel Electric (with John Deere as major shareholder) therefore worked closely together to develop the high-voltage drive system.

The holistic approach of the platform solution not only enables users to reduce emissions but also to increase their returns. All construction equipment in the system uses standardized components, enabling interchangeability of service components, high availability of drive system components and simple, standardized operation.

In addition, the lower noise levels during machine operation create a more comfortable environment for operators and local residents. To fully exploit the advantages of the platform solution, an on-site power supply infrastructure is also essential. Customized mobile charging systems can reliably supply sufficient power to multiple battery-electric machines used on a project.

A drive system solution tailored to crushing equipment

Because crushing equipment has very high power demands that far exceed common battery capacities, we developed other solutions. Thanks to the E-DRIVE fully electric drive concept using external mains power, the Kleemann MR 100i NEOe mobile impact crusher can also achieve zero-emission construction, processing milled material sustainably so that it can be reused in the production of new asphalt concrete.

If on-site power supply is insufficient, the machine can also use a diesel-electric drive system, which can also run on renewable HVO100 biodiesel, thus ensuring lower carbon emissions. 

An asphalt mixing plant burner that can run entirely on green hydrogen completes the solution

Thanks to our innovative first mixing plant burner that can run entirely on green hydrogen, asphalt concrete production can also significantly reduce carbon emissions. To maximize production efficiency, the new-generation Benninghoven burner includes not only the burner itself but also the burner control and drying system.

Asphalt concrete production holds considerable potential for advancing sustainability in future road construction. This means that both hydrogen fuel systems and electric drive solutions play a particularly key role.

Transparent site documentation with the John Deere Operations Center™

All the machines and electric drive system components described above can transmit performance data to the John Deere Operations Center™ via telematics solutions. This central platform manages the fleet and the entire construction project, keeping users informed of each machine's charging status and functions at all times.

Technological innovation drives low-carbon construction

Added value for contractors and the industry

The Wirtgen Group's modular concept is the first to offer road construction contractors an end-to-end construction system that enables zero-emission construction. The one-stop solution ensures high operational reliability and better compatibility between machines and telematics solutions. As a result, construction projects become more sustainable while also achieving higher returns.  

In addition, users of this construction system gain a clear competitive advantage in tenders for municipal construction projects, because the system enables them to meet increasingly stringent specification standards.

The holistic solution also meets the requirements of potential investors, as today's investors place growing importance on project sustainability and increasingly make it a condition of financing. Contractors can likewise use it to achieve their own sustainability goals.

In summary, the "construction system for zero-emission construction" plays a decisive role in advancing sustainability in road construction.

The Wirtgen Group's "construction system for zero-emission construction" was successfully shortlisted for the 2025 Bauma innovation award in the "Climate Protection" category.