Wirtgen Group advances zero-emission road repairs with efficient, high-performance milling, paving, and compaction solutions. (Image source: Wirtgen Group)

Wirtgen Group, a leader in road construction technology, has introduced a groundbreaking production system designed to operate with zero emissions, combining electrically powered machines with green hydrogen technology.

Unveiled as a modular solution, the system integrates a cold milling machine, a road paver, a tandem roller, an asphalt mixing plant, and a crushing plant, all tailored for sustainable urban construction projects.

With growing pressure to reduce environmental impact, particularly in inner-city settings, this innovation addresses the need for lower CO₂ emissions, reduced noise pollution, and improved energy efficiency.

Green hydrogen focus 

The system’s standardised components streamline maintenance and reduce costs by using shared service parts and a universal operating interface. Beyond operational benefits, it offers a quieter working environment, benefiting both site workers and nearby residents. Contractors adopting this technology gain a competitive edge, meeting stringent municipal regulations and appealing to investors who prioritise sustainability in project funding.

Mohamed Amer, managing director of ICC MENA

Towering skyscrapers and large-scale infrastructure projects continue to redefine the GCC's landscape, but alongside this rapid expansion comes an urgent need for more sustainable and resilient building practices.

Governments across the region are setting ambitious environmental targets, and the industry is responding with groundbreaking innovations in materials, technology, and regulatory frameworks.

From concrete to carbon-conscious

For the GCC, achieving net-zero buildings is a growing priority that is key to reducing energy demand and ensuring long-term sustainability. With air conditioning accounting for a significant portion of energy use, the region is uniquely motivated to lead in passive cooling and renewable energy integration. The adoption of high-performance insulation, on-site renewable energy generation and smart building technologies can significantly reduce operational emissions. A key challenge remains in demonstrating that sustainability and premium development can coexist an approach that is increasingly gaining traction.

As an example, concrete, responsible for a significant amount of global CO₂ emissions, has long been the backbone of GCC construction. However, innovative alternatives like Low Carbon Alternative Cement are gaining traction, particularly in the standardisation processes of various SDOs. This type of cement not only reduces carbon emissions and energy consumption associated with cement production, but also opens the door for enhancing the curing process through concrete admixtures. These admixtures improve the strength and durability of concrete, making it viable and sustainable choice for construction projects in the GCC.

The GCC is emerging as a leader in 3D printing technology, with the UAE already home to several additively manufactured buildings. The UAE’s 3D-printed office in Dubai, the first of its kind, showcases how this technology can reduce waste while enabling the region's signature intricate designs. The ability to combine sustainability with custom, high-performance structures make 3D printing a key enabler for the next-generation construction.

The extreme climate of the GCC presents operational challenges for traditional construction. Off-site, factory-based manufacturing including modular and prefabricated solutions offers a viable alternative. By shifting production to climate-controlled environments, these approaches enhance worker safety, minimise material waste and improve overall build quality.

With cooling systems consuming up to 70% of energy in some GCC buildings, the shift to smart HVAC technologies isn’t just an environmental imperative - it’s a financial one. The transition to energy-efficient HVAC systems, integrated with renewable energy solutions, presents an opportunity to optimise energy use while maintaining indoor comfort standards. Advances in demand-driven cooling technologies play a crucial role in achieving broader decarbonisation targets.

Aligning ambitions with action

A decisive shift is now underway, driven by Saudi Vision 2030 and the UAE’s Net Zero 2050 strategy. These national commitments are more than aspirational - they are actionable blueprints for a sustainable future. By aligning industry capabilities with government ambitions, the GCC is setting a global benchmark for green construction.

In 2021, the UAE launched its "Net Zero by 2050 Strategic Initiative," making it the first nation in the Middle East to set a target of achieving net-zero emissions by 2050. Similarly, Saudi Arabia announced its commitment to achieving net-zero greenhouse gas emissions by 2060 during the first Saudi Green Initiative Forum in 2021. These initiatives are not just about reducing emissions: they are about transforming economies and securing a sustainable future for generations to come.

Technological progress must be matched by a skilled workforce capable of implementing high-performance construction practices. Training and credentialing programs, such as those offered by the International Code Council (ICC), have the potential to help professionals gain the necessary credentials. These programmes also equip them with the tools needed to effectively conduct their work on-site and apply codes, standards, and building safety regulations when designing structures and benchmarking to global practices. 

This piece was originally written by written by Mohamed Amer, managing director of ICC MENA, and has been edited for brevity. 

Wirtgen Group advances zero-emission road repairs with efficient, high-performance milling, paving, and compaction solutions. (Image source: Wirtgen Group)

Wirtgen Group is redefining small-scale road repairs with precision, efficiency, and sustainability. This report explores how its compact machines deliver seamless, zero-emission results

Small milling machines, MINI class pavers, and compact rollers work seamlessly together for small-scale repair projects, delivering high-quality results with zero operating emissions. These machines are ideal for working in confined spaces, ensuring long-term structural integrity in various applications.

On small project sites, whether dealing with minor repairs or addressing localised surface damage, maintaining top-tier quality remains essential. The Wirtgen Group provides a range of machines designed for application-specific efficiency and cost-effectiveness. Alongside Wirtgen’s small milling machines, this lineup includes Vögele’s MINI class pavers and Hamm’s compact rollers.

Permanent repair solutions

Common applications include small-scale maintenance in road construction, such as removing markings, working around road fixtures, milling gutters and slots, and repairing surfaces in active traffic areas. These machines also support the construction of cycleways, footpaths, farm tracks, car parks, and sports facilities. Their versatility extends to filling sewer trenches, paving industrial floors, and working in underground parking structures, as well as gardening and landscaping projects. Compact machines are particularly effective for time-sensitive repair and maintenance work, delivering durable results.

High-performance machines

Wirtgen’s small milling machines range from the compact W 35 Ri to the half-metre class W 50 Ri and the 1-metre class models. Despite their size, these machines offer impressive daily productivity, efficiently removing surface layers or milling multiple layers at once. The W 120 Ri rear loader, for instance, can remove complete asphalt packages up to 30 cm deep and 1.2 m wide.

Their efficiency is enhanced by single-handed operation, high travel speeds of up to 12 km/h, and the FCS quick-change system, which allows for rapid drum replacement with different widths and tool spacings. This enables both standard and fine-milling applications. Exceptional maneuverability allows precise milling around manhole covers and other tight spaces.

Compact paving solutions

For sites with restricted space or low headroom, Vögele’s smallest pavers—MINI 500, MINI 502, SUPER 700i, and SUPER 800i—provide paving widths from 0.25 m to 3.5 m, reducing manual labour while increasing efficiency. These machines enable contractors to execute small projects with greater convenience, precision, and cost-effectiveness.

Vögele’s Compact Class pavers are also suitable for small to medium-sized projects. Depending on the model, machines such as the SUPER 1000i, SUPER 1003i, SUPER 1300-3i, and SUPER 1303-3i can achieve paving widths ranging from 0.75 m to 5.00 m.

Versatile compaction machines

Hamm’s HD CompactLine tandem rollers, with operating weights between 1.5 t and 4.5 t, are highly adaptable for road and pathway construction, as well as landscaping. These rollers efficiently compact crushed stone, frost protection layers, base materials, and asphalt surfaces. Depending on the material and required compaction depth, contractors can select vibration, oscillation, or combination rollers for optimal results.

Hamm also offers electric rollers for zero-emission operation. The HD 10e and HD 12e models (drum widths: 1 m and 1.2 m, respectively, with operating weights of 2.5 t and 2.7 t) match the compaction performance of traditional combustion-engine models. Their operating system mirrors that of other HD CompactLine rollers, ensuring ease of use.

Innovative asphalt options

Using coloured asphalt enhances sustainability and aesthetics. Colourless bitumen, a mineral oil-based synthetic binder, allows for the integration of pigments. This approach enables urban planners, landscape designers, and construction firms to create unique paving effects for intersections, traffic guidance, and decorative landscaping. Small machines facilitate the efficient and precise application of colored asphalt.

Zero-emission construction

Municipal construction projects increasingly require sustainable solutions, and investors demand environmentally friendly execution. Contractors, too, are setting their own sustainability targets. The Wirtgen Group now offers a modular, end-to-end system that enables road construction projects to be completed with zero operating emissions. This fully integrated solution ensures operational reliability and seamless machine-to-machine coordination.

At the core of this system is a battery-electric drive concept, which can be expanded with additional modules. In road construction, this technology is exemplified by the Wirtgen W 50 Re milling machine, the Vögele SUPER 1300-5e paver, and the Hamm HX 70e tandem roller. These machines allow road rehabilitation projects to be completed with zero emissions.

This production system is designed for scalability. The Benninghoven MULTI JET burner, powered entirely by green hydrogen, is the first of its kind to achieve asphalt production without CO₂ emissions. Additionally, the Kleemann MR 100i NEOe mobile impact crusher enables the sustainable processing of milled material, allowing it to be reused in new asphalt mixes. The system can run exclusively on electric power from an external grid. If grid power is insufficient, it can also operate using a low-emission diesel-electric system powered by HVO100.

Also read: Doka to showcase over 40 innovations at bauma 2025 

Doka is introducing its fully digitised formwork process. (Image source: Doka)

Doka, alongside its parent company Umdasch Group, is set to transform the conversation around formwork and scaffolding at bauma 2025.

With more than 40 pioneering solutions on display, the company is bringing its vision for the future of construction to life.

From digital integration and automation to sustainable materials and enhanced safety systems, Doka is presenting a portfolio designed to modernise workflows, reduce inefficiencies, and drive progress in the industry.

"We cannot build the future with yesterday’s methods," said Robert Hauser, CEO of Doka. "The construction industry is facing enormous challenges – above all, it must overcome its productivity stagnation. While we are just one part of the bigger picture, we are committed to creating real value within our field. Through new technologies and, most importantly, the consistent digitalisation of the entire formwork process. Making this possible for our customers must be our ambition – nothing less.”

One of the most significant showcases at bauma 2025 will be Doka’s vision of a fully digitised formwork process.

The company is introducing a connected platform that integrates every stage of formwork and pouring, giving construction professionals complete transparency and control over their projects in real time.

The Smart Construction Area, an outdoor space dedicated to automation and robotics, will feature a range of cutting-edge advancements, including semi-automated formwork robots and digitally controlled construction tools. A key highlight is the DokaXbot Lift, which has been redesigned for greater ease of use. Now equipped with intuitive ground-level operation and automatic fine adjustments, the system makes positioning formwork elements up to 5.7 metres high safer and more precise.

Doka is also pushing automation forward with its FormDrive system. Designed for high-rise and infrastructure projects, FormDrive is a next-generation drive system that allows operators to lift climbing systems and manoeuvre wall formwork with minimal manual intervention. By reducing labour requirements and increasing precision, Doka is laying the foundation for a new era of formwork efficiency.

Advancing sustainable construction

At bauma 2025, the company is debuting an intelligent heated formwork prototype that accelerates the curing of CO₂-reduced concrete. By integrating digital sensors for real-time concrete monitoring, the system improves efficiency and ensures the successful adoption of low-carbon mixes on construction sites.

“As one of the largest GHG emitters worldwide, the construction industry must evolve,” said Hauser. “CO₂-reduced concrete is a key driver of change, and we are committed to supporting a lower carbon construction future, in line with our own ambitious goal of achieving net zero by 2040. We are excited to present our prototype at such an important show.”

^{Robert Hauser, CEO of Doka}

Doka is also incorporating circular economy principles into its product range. The Xlife top sheet, a high-durability formwork sheet made entirely from upcycled plastic, is designed for multiple reuse cycles, reducing both material consumption and maintenance costs. Once it reaches the end of its lifespan, it is returned to a closed-loop system, where it is processed into new sheet cores, demonstrating Doka’s commitment to sustainable resource management.

Doka is also bringing monolithic construction into the spotlight. Following its acquisition of MFE, a leading Malaysian manufacturer of aluminium formwork, the company is showcasing monolithic formwork technology at bauma 2025 for the first time. Designed for high-speed construction, this system is set to revolutionise large-scale building projects.

Together with AT-PAC, its dedicated scaffolding brand, Doka is expanding its range of scaffolding solutions to improve efficiency and safety in both construction and industrial applications. A newly developed 30-metre scaffolding tower with an integrated viewing platform will be a major attraction at the event, giving visitors a unique perspective of the bauma fairgrounds.

The company is also unveiling the DokaXshore system, a next-generation lightweight shoring solution engineered for high-speed assembly and maximum load capacity. Meanwhile, the UniKit heavy shoring system, already proven on complex infrastructure projects, is receiving key updates, including wall-mounted supports for up to 400 kN loads and full integration with Ringlock scaffolding to improve accessibility and safety at height.