That UK productivity is lower than that of similar developed countries is not news. That the construction industry has lagged behind and shown lower productivity increases than other sectors, such as services and manufacturing, is also well documented.
What if there were technologies that, if implemented, would boost productivity, improve construction quality, enhance safety and wellbeing, and, whilst we’re at it, cut carbon emissions? Surely, if there were a return on investment, contractors would be falling over themselves to use it, wouldn’t they? Enter the curious case of connected and autonomous plant.
What is Connected and Autonomous Plant?
Put simply, it is an item of construction plant such as an excavator or bulldozer, fitted with sensors, cameras and lidar that allow it to ‘see’ its surroundings along with an interface on which 2D and 3D plans can be uploaded. Some manufacturers offer their own technology and interfaces, while others can be retrofitted with equipment from 3rd party suppliers. Case studies exist showing successful applications in the real world, and some companies use it routinely. However, its use is far from ‘business as usual’.
Depending on the system, machines can operate at different autonomy levels:
- Machine assistance
- In-cab task supervision
- Remote operation
- Fully autonomous operation with remote human oversight
Unlike driverless cars, where the objective is to remove the driver from the vehicle, in the case of CAP, whilst there are examples of fully autonomous plant, significant benefits can be gained from lower levels of autonomy, where the machine and operator work in tandem. Here are three real-world examples of CAP in action.
Compaction
Compacting asphalt relies on an operators making a set number of passes, a process prone to human error, especially as fatigue sets in, resulting in too few or too many passes or uneven compaction. With CAP, once the plan is loaded onto the machine, it will complete the correct number of passes, evenly across all areas of the site. Better still, with intelligent compaction technology, the compaction levels are set and the machine only passes as many times as is required. Very often, this will be fewer than is specified. The result? Less fuel, less time, lower carbon emissions and better construction quality.
Excavation and earthworks
This is possibly the area with the biggest opportunities for improved construction efficiency and site safety. Once a 3D plan of the site and requirements is loaded, the parameters for boom movements can be specified. This can prevent over digging or hitting above ground or buried utilities.
The potential to limit the depth of excavations potentially offers the greatest benefits. Machine assist technology will ensure every excavation is dug perfectly to specification, reducing costly rework and optimising power use for fuel efficiency. Not only is this more efficient, but there are safety benefits – if an operator doesn’t have to concentrate on ensuring the correct depth is achieved, it reduces fatigue, improving safety both on site and on the journey home. It also frees concentration to undertake more complex tasks that are best achieved by a skilled human operator.
Remote operation
An increasing area of interest is the remote operation of plant. This can be over short or long distances. An example of the former could be a machine doing work near a live carriageway and an operator controlling it with a pad at a safe distance. However, with good connectivity, there is the potential to operate from a significant distance. This author has witnessed a demonstration of an operator in Birmingham controlling a machine in Italy. For sites in remote locations, hazardous environments or extreme weather conditions, removing the operator from the machine has significant safety benefits. There are also welfare benefits to be had; often, work sites are a considerable distance from kitchen and washroom facilities, meaning a long trek for food and comfort breaks.
With high levels of connectivity, there could be a future where operators work in urban operation hubs, operating machines all over the country. Improved safety, improved welfare and reduced isolation. It might also encourage new entrants to the workforce, who cannot or don’t want to work on remote sites. With 43% of construction operators over 45, 18% over 55 and only 8% under 24 , this is needed more than ever.
There could be productivity benefits too. Excavator operators spend a lot of time waiting around for hauling units. Remote operation would allow efficiencies where operators could move from one site to another, minimising downtime.
Can it be used on anything?
Some machines are more suited to CAP operation than others. Compactors are now largely fitted with CAP as the benefits of intelligent compaction are being realised, with non-CAP equipment achieving levels of compaction exceeding those specified in the standards, risking over compaction and/or wasted effort. Single-use machines like dozers and graders also have high rates of adoption, estimated to be around 40-70% of units fitted with machine control in the factory.
Only around 10% of excavators are reported to have intelligent machine control fitted in the factory. Here, too, there is variation, with machines in the 13 to 20 tonne range being most suited for 2D or 3D technology adoption. Above this is haulage, and below this, there are mini-diggers and multi-use machines like JCB 3CX. Here, the smaller scale and variety of work make it harder to specify and justify the investment in technology.
The size of the prize
A 2024 market analysis for the Department for Transport (led by Costain, with Maple Consulting and ITEN involvement) interviewed stakeholders across industry and government (National Highways, Network Rail, HS2 and BEIS). The report is available here, and the results are striking – if CAP were rolled out fully, the cumulative benefits by 2050 could be:
- £61 billion to UK GVA through equipment orders (cumulative to 2050)
- £356 billion additional GVA for all construction sectors combined, made up from cost savings from productivity, fuel savings and lower injury costs, and £14 billion for the road and rail sector alone
And that’s not all. For road and rail alone, CAP could deliver:
- 28,000 injuries avoided and 31 lives saved
- £10 billion in fuel cost savings
- 19,300 kt CO₂e emissions reduction
- Net workforce growth of 29,000
- 12% average wage increase
The benefits are proven. So why isn’t adoption universal?
What’s holding back CAP adoption?
There’s no one answer, but they are cultural and structural rather than technological. They include:
- A lack of government support and regulation mandating the use of CAP.
- Limited awareness of CAP ROI
- High upfront cost, or higher hire costs (CAP-enabled machines are £60 – 80K more expensive than equivalent standard plant), where the benefits are not suitably defined.
- Lower levels of digital maturity in the construction process, and a lack of understanding as to how data can be harnessed to increase productivity.
- Procurement structures often disincentivise innovation – there are no requirements for CAP, and clients are known to question why the investment should be made.
Perhaps the last point is most relevant. Currently, contractors know how to cost a job using conventional plant. There is often little incentive to use technology that would complete the work more quickly and for less money, unless increased profit could be shown. Also, unlike in many other countries, around 70% of construction plant in the UK is hired, rather than being owner-operated. Whilst hire companies will add CAP technology if requested, in interviews, they reported that companies are generally unprepared to pay the extra hourly rental charge, and when machines have been rented with CAP features, most were not used. There is also the view from some that, as plant hire companies charge by the hour, there is little incentive to add technology that would complete work more quickly.
How do we accelerate adoption?
Again, there’s no single answer, but it includes:
- Mandating CAP on public projects
- Reforming procurement to incentivise innovation
- Sharing risk and reward between clients and contractors
- Publishing real-world case studies to build confidence
- Driving digital maturity across the supply chain
Costs will fall over time, but early adopters, especially those with their own fleets, can lead the way.
The future of construction is here
We know what needs to change; we just need to get on with it. Connected and autonomous plant is more than a technological upgrade— it’s a cultural shift towards smarter, safer, more sustainable construction that is more attractive for the next generation of the workforce. Every step we take now shortens the gap between promise and practice. The tools are ready; it’s time to put them to work.
