The Wirtgen Group presents its latest developments for road construction and earthmoving at Bauma 2025 in Munich. The group, which includes the brands Wirtgen, Vögele, Hamm, Kleemann and Benninghoven, focuses on autonomous machine controls and emission-optimized drives. For construction companies, this means: less operator dependence, more precise results and simultaneous compliance with strict EU Stage V emission requirements.
3D machine control reduces material consumption by up to 15 percent
A central topic at the trade fair booth is 3D machine control, which is now available across all product groups. The systems link GPS positioning with digital terrain models and control the working hydraulics in real time. With pavers from Vögele, automatic leveling ensures that asphalt layers are installed to the millimeter. This reduces material consumption by up to 15 percent and saves rework.
For operators of cold milling machines, integrated control is particularly relevant: the machine recognizes the target profile and automatically adjusts milling depth and feed rate. This saves operating hours and increases precision, which is crucial for highway rehabilitation projects. If you equip a Wirtgen W 210 Fi with a 3D system today, you pay around 80,000 euros extra – but this amortizes itself within two years through lower material costs and higher productivity.
Stage V without additional consumption: new engine generation in practical testing
Compliance with the EU Stage V standard has been mandatory for all new machines since 2020. The Wirtgen Group relies on SCR catalytic converters and diesel particulate filters that drastically reduce nitrogen oxide and particle emissions. The key point is: according to the manufacturer, the latest engine generation operates without noticeable additional consumption. For Hamm rollers in the HD+ series, fuel consumption remains below 8 liters per operating hour despite Stage V – a value that older Stage IIIB models also achieved.
The HAMM compaction rollers also use intelligent engine management that adjusts performance to actual load. At idle, the engine automatically switches to minimum speed; during compaction operation, it switches to full load. This reduces consumption over a working day by up to 20 percent – with unchanged compaction performance.
Retrofit for older fleets: retrofitting exhaust treatment costs from 25,000 euros
For operators of older machines, the Wirtgen Group offers retrofit solutions to gradually upgrade existing fleets to Stage V. Retrofitting a cold milling machine with SCR catalyst and particulate filter costs from 25,000 euros – significantly cheaper than a new purchase. However, retrofitting only makes economic sense for machines from 2015 onwards, as older engines often lack the necessary control technology.
Kleemann crushers: mobile recycling units with electric drive as an option
The Kleemann brand presents mobile crushing plants at Bauma 2025 that can optionally be operated with diesel engines or electric drives. The jaw crusher Mobicat MC 120 Z Pro delivers up to 650 tons of throughput per hour and is designed for medium-sized recycling construction sites. In electric operation, energy consumption is reduced by about 40 percent compared to diesel operation – provided the construction site has a power connection with at least 400 volts and 125 amperes.
The price for the electric variant is about 15 percent higher than the diesel model. However, those working on inner-city demolition projects save in the long term: operating costs fall by up to 50 percent as diesel is replaced by cheaper electricity. In addition, emission regulations that severely restrict diesel operation in many German city centers no longer apply.
Autonomy in road construction: where do we really stand?
The Wirtgen Group is currently testing fully autonomous milling and paving systems on selected highway construction sites. The machines work completely driverless – controlled from a control station at the edge of the construction site. The operator monitors several machines simultaneously and only intervenes in case of malfunctions. This reduces personnel requirements by up to 30 percent and increases utilization, as machines can work continuously even at night without interruption.
However, series production readiness has not yet been achieved. Autonomous systems currently only function on closed highway sections with clear traffic management. More complex construction sites with changing obstacles and cross traffic overwhelm sensor technology. The Wirtgen Group expects market introduction from 2027 onwards – initially for large-scale projects with high investment budgets.
Telematics as a bridge to full autonomy
Until then, the group relies on telematics systems that capture machine data in real time and transmit it to fleet managers. The systems display operating hours, fuel consumption, maintenance intervals and locations of all machines on a central platform. For construction companies with more than 20 machines, this is a real efficiency gain: maintenance is planned proactively, downtime is reduced by up to 15 percent.
Telematics retrofitting costs between 1,500 and 5,000 euros depending on machine type. Ongoing data transmission costs are around 30 euros per machine per month. For larger fleets, the system amortizes itself within a year through reduced downtime and optimized deployment planning.
Conclusion: evolution instead of revolution – but with noticeable practical benefits
The Wirtgen Group shows no spectacular new inventions at Bauma 2025, but rather consistent further development of existing technologies. 3D control systems are mature and pay for themselves within a few years. Stage V engines meet legal requirements without performance losses. Electric drives are an economically viable alternative for certain applications – but not yet a universal solution.
For construction companies, this means: if you invest now, you get machines that will remain competitive over the next ten years. The combination of more precise control, lower emissions and digital networking reduces operating costs and increases utilization. Fully autonomous systems remain future music for now – but the foundations are laid.
For more information on the innovations of the Wirtgen Group, visit the manufacturer's official website. If you are interested in automated control systems for road construction, you should also read our article on Vögele's automation systems for pavers.
