The road construction industry in India is undergoing a significant transformation, driven by the need for enhanced infrastructure and the adoption of advanced technologies. Despite the promising outlook, the industry faces execution challenges that threaten to slow down progress. According to a recent CareEdge Ratings forecast, the daily road construction rate is expected to drop to 31 km per day in 2024, down from 34 km per day in 2023. This projected slowdown puts the spotlight on best practices and technologies that can maintain the momentum in road construction while ensuring quality outcomes.

One of the key factors in overcoming the challenges in road construction is the adoption of advanced equipment and technologies. These innovations not only enhance efficiency but also improve the quality of the roads being constructed. Several industry experts have shared insights on how these technologies can be leveraged to pave faster and better without compromising on quality.

Said Sunil Talreja, Vice President – Road Construction Equipment, Road Construction Equipment Division, Action Construction Equipment, “The vigorous growth in highway construction during 2023-24 has positively impacted the demand and sales of road equipment such as compactors, graders, and pavers. There was a visible surge in demand for efficient, dependable, and cutting-edge machinery amid the government’s push for timely project completion. The construction sector, particularly in road building, exhibited a greater reliance on equipment that could handle large-scale projects with accuracy and speed.”

He added, “Sales of these machines went up substantially as contractors and developers sought to optimise their operations and meet rigorous project deadlines. Additionally, the drift towards mechanisation and automation in construction has further strengthened the demand for modern road equipment, as it provides more control over quality and efficiency. On the whole, the demand for road construction machinery remained robust, propelled by the sector’s expansion and the imperative of keeping up with the rising pace of infrastructure creation.”

The sustained expansion of road construction activities affords considerable opportunities for manufacturers and suppliers of road equipment such as compactors, graders, and pavers. The government’s efforts on boosting infrastructure, particularly in rural and remote areas, will likely drive continuing demand for high-grade, reliable machinery. There is a need for more advanced and versatile equipment due to the growing intricacies of road construction projects, which frequently involve tough geographical terrain and tight deadlines. To exploit these opportunities, we aim to expand our product line by introducing machines that feature the latest technologies, such as GPS-enabled grading systems and automated compaction monitoring.

In the Indian market, skid-steer loaders have garnered significant demand compared to other types of construction equipment, owing to their versatility and adaptability. Said Shalabh Chaturvedi, Managing Director, CASE Construction Equipment – India & SAARC region, “Skid-steer loaders offer a range of functionalities crucial for construction activities, including digging, lifting, and material handling, making them highly sought after for various tasks on construction sites. The adaptability of skid-steer loaders to diverse building sites is a key factor driving their demand. Their ability to navigate and operate effectively in confined spaces or areas where manoeuvrability is essential makes them indispensable in many construction projects across India.”

In India, the skid steer loader market reported a gain of 11.94 per cent in value shipments in 2022 compared to 2021, along with a 23.54 per cent increase in CAGR in 2022 over the period of 2017. This indicates a sustained upward trend in the adoption of skid-steer loaders within the construction industry.

Shrinath Rao, Senior Vice President & Head of Transportation Infrastructure at L&T Construction, emphasises the importance of conducting mock-ups before starting construction. Mock-ups help synchronise material, machinery, methods, and crew, ensuring that all elements work together seamlessly.

Similarly, Atasi Das, Assistant Vice President at GR Infraprojects, highlights the need for preplanning the next day’s material requirements. This approach eliminates lags between different site teams, such as the QA-QC team, highway team, planning team, mechanical team, and store department, thereby enhancing overall efficiency.

Weather conditions play a crucial role in the quality of the final pavement. Das stresses the importance of studying weather conditions such as rain, temperature, wind speed, and humidity before paving operations. These factors can significantly impact the paving process and the quality of the laid pavement. To address this, GR Infraprojects has developed an innovative Mobile Construction Quality Monitoring Van. This low-cost solution provides real-time readings of wind direction, wind velocity, humidity, temperature, and more, allowing for immediate adjustments to be made on-site to avoid issues such as rapid evaporation and shrinkage cracks.

The use of state-of-the-art equipment is another critical factor in improving road construction outcomes. Das advocates for the use of slipform pavers equipped with automatic texturing and curing capabilities, capable of paving up to 16 m in width in a single go. Continuous operations with these advanced pavers help eliminate unnecessary joint formations, leading to smoother, more durable pavements.

Moreover, Rao shares that L&T Construction uses concrete batching and mixing plants with capacities 25 per cent greater than planned production to ensure timely completion. These plants are supported by chilling plants and insulated storage tanks to maintain the water temperature below 6 degree Celsius, ensuring optimal conditions for concrete setting. The combination of flatbed tippers, wheel loaders, and fog sprayers further enhances the paving process, allowing for consistent and high-quality results.

Intelligent compaction technology is another innovation that is gaining traction in the road construction industry. Compaction plays a vital role in almost every major construction project, including those in irrigation. Said Dimitrov Krishnan, Managing Director, Volvo Construction Equipment India, “Our products are integral to achieving desired soil compaction levels, contributing significantly to project success. Through increased localisation and value addition, we ensure our products meet the diverse needs of such projects, providing features like forward and reverse compaction options for optimal asphalt rolling performance. When it comes to irrigation jobs, we have soil compactors with both axle drive and drum drive options. The standard machine comes as a axle drive machine which is suitable for all soil compaction applications while the drum drive option improves the gradeability of the compactor upwards of 35 deg Gradient.  “

This technology, which incorporates non-nuclear density gauges, allows for precise monitoring of compaction levels, ensuring that roads are not over-compacted, which can lead to material wastage and increased costs. Arppan B Ghosh, President – Engineering at Cube Highways Technologies, explains that intelligent compaction helps optimise the use of time and fuel, making the construction process more efficient.

However, the widespread adoption of intelligent compaction technology in India has been limited, primarily due to the lack of government specifications and guidelines. Ghosh suggests that the government should mandate the use of this technology in road projects to ensure consistent quality across the board.

Material transfer vehicles (MTVs) are another piece of equipment that can significantly improve road construction quality. These vehicles help prevent thermal segregation, which can lead to weak spots and premature pavement failure. By allowing for continuous paving without stopping, MTVs ensure a consistent and smooth pavement surface. Ghosh notes that MTVs, such as those from Wirtgen available in India, are essential for projects where maintaining temperature consistency in the asphalt mix is critical.

Riding on technological innovations and the growing emphasis on sustainability, the road equipment sector is projected to witness key trends over the next two to three years. One of the key trends will be the increased uptake of automation and artificial intelligence in equipment like compactors, graders, and pavers. These technologies will allow machines to execute tasks with superior precision and efficiency, reducing the need for human oversight and minimising errors. 

Another important trend will be a move towards green machinery, with manufacturers developing electric and hybrid-powered equipment that mitigates carbon emissions and fuel consumption, as industries gravitate towards sustainable construction practices. Said Talreja, “There will also be a rising appetite for equipment with advanced telematics and remote monitoring capabilities, allowing operators and project managers to monitor performance, identify and resolve issues, and make data-driven decisions in real-time. As these developments influence the future of road construction, we are investing resources in research and development to create groundbreaking, eco-friendly, and technologically advanced products as we endeavour to be at the vanguard of the industry.”

The road construction industry in India is also witnessing a shift towards more sustainable practices. Technologies such as cold-mix and warm-mix asphalt are being increasingly adopted to reduce carbon emissions and energy consumption. Satyanarayan Purohit, Vice President at Dilip Buildcon, mentions that cold-mix technology, which uses emulsions instead of traditional hot asphalt, is now being used in various projects across India. This technology not only minimises carbon emissions but also reduces the energy required for paving.

Similarly, warm-mix asphalt, which can be compacted at lower temperatures, is gaining popularity for its energy efficiency. By combining these eco-friendly methods with high-capacity rollers and thin layers of emulsion, construction companies can achieve precise and efficient paving, further reducing the environmental impact of road construction.

Stone mastic asphalt (SMA) is another innovative material being used in the construction of high-traffic roads and expressways in India. SMA delivers a rougher surface with higher moisture resistance and flexibility compared to traditional bituminous concrete. SMA is particularly well-suited for projects such as the Delhi-Katra Expressway and the Delhi Vadodara Expressway, where the longevity of the pavement is a priority.

The use of polymer-modified bitumen in SMA further enhances its durability, making it an ideal choice for expressways that experience heavy traffic. As the road construction industry in India moves towards the implementation of the perpetual pavement concept, SMA is expected to be specified for more projects, ensuring longer-lasting and more resilient road surfaces.

While the adoption of advanced technologies and sustainable practices is essential for the growth of the road construction industry in India, there are challenges that need to be addressed. One of the primary challenges is the lack of government specifications and guidelines for the use of these technologies. Ghosh and Purohit emphasise the need for the government to take a proactive approach in mandating the use of intelligent compaction, MTVs, and sustainable paving methods in road contracts.

Moreover, the high cost of advanced equipment and materials can be a barrier for smaller construction companies. The government can play a crucial role in providing incentives or subsidies to encourage the adoption of these technologies, ensuring that all road construction projects in India meet high-quality standards.

The road construction industry in India is at a critical juncture. With the increasing demand for better infrastructure and the challenges posed by execution delays, there is a pressing need to embrace innovation and advanced technologies. By adopting best practices such as mock-ups, preplanning, weather monitoring, and the use of state-of-the-art equipment, construction companies can improve efficiency and ensure the timely completion of projects.

Furthermore, the shift towards sustainable practices, such as cold-mix and warm-mix asphalt, and the use of durable materials like stone mastic asphalt, will help reduce the environmental impact of road construction while enhancing the longevity of the roads.

The government's role in supporting the industry through specifications, guidelines, and incentives cannot be overstated. By mandating the use of advanced technologies and providing the necessary support, the government can help the road construction industry in India achieve its full potential.

The road equipment market in India is poised for growth, driven by the need for better infrastructure and the adoption of advanced technologies. However, the industry faces significant challenges, including execution delays and the high cost of equipment and materials. By leveraging innovations such as intelligent compaction, material transfer vehicles, and sustainable paving methods, the industry can overcome these challenges and pave the way for a brighter future.

As the road construction industry continues to evolve, it is crucial for all stakeholders, including the government, construction companies, and equipment manufacturers, to work together to drive innovation and ensure the successful completion of projects. With the right approach, India can achieve its infrastructure goals and build a road network that meets the needs of its growing population.