ForBat@Bau - Holistic planning and execution of construction projects using battery-powered machinery

Contact: Simon Mailhammer, M.Sc., Markus Pointner, M.Sc.

Problem

The construction industry contributes significantly to global CO₂ emissions, particularly through the use of internal combustion engine-powered construction machinery. To reduce these emissions, various alternative propulsion concepts are being discussed in industry and research, including battery-electric, hydrogen-based, and synthetic fuel-based solutions. Due to their high overall efficiency, zero local emissions, and potential for low operating costs, battery-electric construction machines are increasingly emerging as the preferred option.

Despite these advantages, their market penetration has been low so far. Key barriers include the limited availability of electrical power on construction sites, long charging times, inadequately designed grid connections, and the lack of a systemic approach to integrating machines, energy storage systems, and construction processes. Particularly in complex construction projects and for high-performance machine classes, it is evident that simply replacing diesel machines with electric ones is not effective. Rather, the successful use of battery-electric machines requires a holistic view of construction site operations as well as the underlying energy and process structures.

Project goals

The goal of the ForBat@Bau research consortium is to enable fully electrified construction sites in a cost-effective and reliable way through a holistic, software-supported approach. Instead of viewing individual machines in isolation, construction processes, machinery, energy storage systems, charging infrastructure, and grid connections are to be planned and operated in an integrated manner. Through standardized processes and energy data, intelligent energy management, and close collaboration among all relevant stakeholders, the goal is to implement practical, zero-emission construction sites and unlock economic potential.

Project overview

Four key areas have been identified and will be addressed in subprojects (SP):

SP 1: Drive and auxiliary power concepts optimally tailored to the load profiles encountered
SP 2: The development and deployment of intelligent, modular, and multifunctional battery systems
SP 3: The integrated, software-supported planning and control of construction processes and energy flows
SP 4: Dynamic flexibility enhancement of grid connections, which are often limiting

The results will be incorporated into an integrated planning and operations tool for complex, zero-emission construction sites. Through networking events, real-world demonstrations, and other forms of dissemination, the results will be made available to a broad audience of interested parties.

Procedure

The entire project is coordinated by the Chair of Automotive Engineering, which is also responsible for Subproject 2.

Subproject 2 aims to

design modular, divisible, and dynamically deployable battery storage systems for stationary and mobile applications and demonstrate their use cases using prototypes,
use simulations to assess the techno-economic potential of combining all application scenarios for modular battery storage systems and “machine-to-machine” charging, taking into account the potential of all other subprojects and using real-world data to conduct simulations,
to develop software with user-friendly interfaces for planning and scheduling dynamic energy distribution in construction site operations for common application scenarios and to integrate it into the research consortium’s overall tool.