The Wirtgen Group is presenting for the first time a complete line of 100% electric road construction machinery. A paver from Vögele and a compactor from Hamm now operate without a thermal engine. The German group, based in Windhagen and Ludwigshafen, is targeting the European urban market where emission restrictions are tightening.
Why road construction sites are going electric
Road construction sites concentrate multiple machines in a confined space. A standard asphalt project mobilizes 3 to 5 machines simultaneously: paver, tandem and pneumatic compactors, milling machine upstream. Each machine runs continuously for 8 to 12 hours. Noise and particle emissions accumulate, especially in urban areas. Paris, Berlin, Amsterdam and Milan already ban Stage III machines in their low-emission zones. By 2025, around twenty European cities will follow.
Compaction is the step that consumes the most fuel per square meter laid. A 10-ton tandem compactor burns 12 to 18 liters of diesel per hour depending on compaction intensity. On a 5,000 m² asphalt site, this represents 150 to 200 liters for compaction alone. Electrifying this phase directly reduces operating costs and environmental impact. The Wirtgen Group therefore chose to start with these two critical machines.
Vögele paver: actual capacity and range
The electric Vögele paver is based on the proven platform of thermal models of 6 to 8 tons. The laying width reaches 3 to 9 meters with an extendable hydraulic table. The hopper capacity remains at 10 tons of asphalt. The electric power unit develops equivalent power of 130 kW, comparable to the 4-cylinder diesel it replaces. The announced range is 6 hours of continuous laying at standard speeds of 2 to 4 m/min.
The paver integrates a 300 kWh battery pack cooled by liquid. Fast charging on 400 V three-phase is accomplished in 2 hours via CCS industrial connector. On site, a backup generator or standard grid connection is sufficient. Vögele also offers a mobile charging solution on a trailer for remote sites. Total weight increases by 800 kg compared to the diesel version, but remains within road transport limits without exceptional convoy.
The paver retains all assistance systems: 3D leveling, automatic thickness control, adjustable pre-compaction. The hydraulic table operates with electric pumps, eliminating pressure drop losses from the diesel circuit. The table heating temperature reaches 180°C in 20 minutes, compared to 25 to 30 minutes on a thermal paver. This reduces waiting times at the start of the shift.
Hamm compactor: electric vibration and traction
The electric Hamm tandem compactor follows the architecture of 10 to 12-ton models. Two cylinders 1.50 m wide each ensure compaction over 3 m wide. The adjustable vibration frequency ranges from 30 to 60 Hz, with adjustable amplitude of 0.4 to 1.8 mm. The centrifugal force reaches 110 kN, sufficient to compact up to 30 cm thickness per pass on hot asphalt.
The 250 kWh battery pack powers the electric traction motors and vibration exciters. The announced range is 8 hours in continuous vibration mode. The thermal management system cools the batteries and motors in a closed loop. Full recharge at 400 V takes 90 minutes. Hamm offers fast charging in 45 minutes via 600 V system, available as an option.
The electric compactor weighs 950 kg more than its diesel equivalent. The extra weight is concentrated in the rear cylinder, improving distribution and compaction effect. Maximum speed remains at 12 km/h in transport mode. The lowered center of gravity by 8 cm improves stability on slopes. Noise level drops to 72 dB(A) during operation, or 15 dB less than a thermal compactor. This allows night work in residential areas without special authorization.
TCO: calculation over 7 years of operation
The electric Vögele paver will be marketed approximately 30% more expensive than its diesel equivalent. A thermal model in this category costs between 220,000 and 250,000 €. The electric version is therefore positioned around 290,000 to 320,000 €. The electric Hamm compactor shows a 25% surcharge, or 140,000 to 160,000 € compared to 110,000 to 130,000 € in diesel.
Operating costs shift quickly in favor of electric. A diesel paver consumes 15 to 20 liters per hour, or 120 to 160 liters per construction day. At 1.60 €/liter, this represents 190 to 250 € per day. The electric paver consumes 50 kWh per laying day, or 10 to 15 € at the professional rate of 0.20 to 0.30 €/kWh. The savings reach 180 to 240 € per day, or 45,000 to 60,000 € over 250 construction days annually.
Maintenance drops by 40 to 50%: no more oil changes, no particle filters, no SCR catalyst replacement. Regenerative braking reduces brake pad wear. Over 7 years, the maintenance difference represents 25,000 to 35,000 € depending on usage intensity. The purchase surcharge is therefore amortized in 18 to 24 months for a company operating at full capacity. For a rental company with intermittent use, return on investment stretches over 3 to 4 years.
Urban regulation: the true driver of electrification
European low-emission zones (LEZs) already exclude Stage III machines since 2023 in 12 cities. Paris, Lyon, Marseille, Barcelona, Milan ban machines over 10 years old. By 2025, Brussels, Amsterdam, Berlin and Copenhagen will require Stage V minimum for any public contract. Penalties range from 500 to 2,000 € per machine per day of non-compliance.
Public tender calls now include binding environmental criteria. The City of Paris awards 20% of points on emissions and noise. Some urban resurfacing projects require zero emissions on at least 50% of machines. An electric paver and compactor allow meeting this quota without touching supply trucks. This combination provides a decisive advantage against fully thermal competitors.
Night work sites become profitable. The 72 dB(A) noise level for the compactor and 68 dB(A) for the paver allows work between 10 p.m. and 6 a.m. without special authorization in most municipalities. Night-time rates increase 30 to 40% compared to daytime due to lack of traffic. The productivity gain far exceeds the higher hourly labor cost. On a 10,000 m² urban site, switching to night work shortens the timeline from 12 to 7 working days.
Commercial deployment and prospects
The Wirtgen Group will launch both machines in limited series in the second half of 2025. First deliveries target large French, German and Dutch road groups already equipped with thermal Vögele and Hamm fleets. Standard series production is planned for 2026, with capacity of 150 to 200 annual units for each model.
The group is developing in parallel an electric cold milling machine 2 m wide. This third link will allow offering a 100% electric road line by 2027. The goal is to cover 80% of a standard urban site's needs without any thermal machines. What remains are asphalt supply trucks, where electrification still faces range and payload constraints.
For companies investing now, the risk of obsolescence is low. Batteries guaranteed for 5,000 cycles retain 80% capacity after 7 years of intensive use. Pack replacement costs 25,000 to 35,000 €, less than a diesel engine overhaul. Hydraulic and mechanical systems remain interchangeable with thermal models, facilitating spare parts management. The Wirtgen Group electric platform follows a logic of progressive transition, not a sudden break. Automation will come next, once the electric base is stabilized.
