ForBat@Bau - Holistic Planning and Implementation of Complex Construction Projects Using Battery-Electric Machinery

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

Despite these advantages, its market penetration has been low so far. Key obstacles include the limited availability of electrical energy 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 power-intensive machine classes, it is evident that the isolated replacement of diesel machines with electric machines is not effective. Rather, the successful use of battery-electric machines requires a holistic view of construction site operations and the underlying energy and process structures.

The goal of the ForBat@Bau research project is to enable fully electrified construction sites in an economical and planning-friendly manner through a holistic, software-supported approach. Instead of considering individual machines in isolation, construction processes, machines, energy storage systems, charging infrastructure and grid connections shall be planned and operated in an integrated manner. Through standardised process and energy data, intelligent energy management and close cooperation between all relevant stakeholders, emission-free construction sites shall be implemented and their economic potential shall be unleashed.

The project follows an integrated, data- and software-based approach for planning, optimizing, and managing fully electrified construction sites, linking machines, energy storage, and grid connections.

Subproject 1 (HAW) develops a modular simulation framework for battery-electric drives, based on real operational and load data as well as detailed measurements of individual components. It models mechanical, electrical, and control aspects, compares drive concepts, and provides standardized data and interfaces for the other subprojects.

Subproject 2 (FTM) designs modular, dynamically deployable battery storage systems that can extend internal machine batteries, be used stationary, or be distributed between machines. Prototypes are tested and simulated, and the insights are integrated into a user-centered software solution for operational planning and deployment.

Subproject 3 (fml) develops a software-supported energy management system that systematically captures construction processes, standardizes them, and stores them in a construction process database. Integration with BIM enables practical planning of construction site energy logistics, complemented by an open-source IoT interface for monitoring machines, charge levels, and energy storage.

Subproject 4 (FENES) establishes a dynamic grid connection concept that ensures flexible, grid-supportive, and economically optimized power supply. Grid capacities are analyzed, forecasted, and managed through operational strategies. The concepts are tested in a demonstrator to dynamically adapt charging, minimize grid impacts, and realize both economic and ecological benefits.

This research project is funded by the Bavarian Research Foundation.