Automated & Intelligent Machine-Aided Construction for NH Projects

The Ministry of Road Transport and Highways (MoRTH) is committed to working closely with stakeholders to ensure the smooth adoption of cutting-edge technologies and innovative solutions aimed at improving efficiency, quality, safety, and sustainability in road construction.

MoRTH recently released a draft policy for the adoption of Automated and Intelligent Machine-Aided Construction (AI-MC) in National Highway projects. The main agenda of the workshop, held on 30th January 2025 at The Ashok Hotel in New Delhi, was to brainstorm and provide suggestions to refine the proposed policy, explore potential improvements, and ensure alignment with industry needs and the future direction of road construction. Attendees included officials from MoRTH, NHAI, NHIDCL, technology providers, consultants, concessionaires, machinery manufacturers, and other stakeholders.

The National Highways Authority of India (NHAI) is successfully implementing a pilot project for AI-MC on the Lucknow-Kanpur Expressway. This project involves the use of automated and intelligent machines such as GPS-aided motor graders, intelligent compactors, and stringless pavers. Based on the evaluation of the AI-MC pilot project, along with feedback from stakeholders and international guidelines, NHAI plans to expand the use of AI-MC for the construction of additional greenfield expressways and access-controlled corridor projects.

Union Minister for Road Transport and Highways, Shri Nitin Gadkari, stated, “National Highways are our national assets, and we have taken steps to hold contractors responsible for improving construction quality and increasing transparency in our system. Technology is a great enabler, and the adoption of Automated & Intelligent Machine-Aided Construction is a step in the right direction. We have seen success in the Lucknow-Kanpur Expressway pilot project, and we plan to implement this technology in other projects soon.”

He also noted that India’s highway network is globally recognized and shared a recent conversation with the President of Singapore, who praised India’s rapid infrastructure progress. Reflecting on his previous work in Maharashtra, he highlighted the importance of technology in road construction, recalling the introduction of India’s first piling machine and the significant advancements that followed, including the use of concrete mixers from Germany in the late 1990s.

He outlined three main objectives for road construction: ensuring public safety, providing comfort for road users, and using technology to achieve these goals. He expressed satisfaction with the shift towards electric and hydrogen-powered machinery, which reduces pollution and offers significant cost savings. He emphasized that pollution is a major issue in India, with 40% of the country’s pollution stemming from transportation and construction. To address this, he pointed to eco-friendly materials, such as bricks made from biofuels and agricultural waste, which can significantly reduce both pollution and costs. He also mentioned the use of bamboo as an alternative to steel for crash barriers, due to its durability and corrosion resistance.

He stressed the importance of improving road construction quality, reducing maintenance costs, and preventing errors in project planning. “The focus should be on better design and construction quality from the start, along with robust monitoring systems to ensure accountability and prevent accidents. We need a transparent, results-oriented, and quality-driven system with minimal human errors,” he said.

He expressed appreciation for the work done by all stakeholders involved in the Lucknow-Kanpur projects, noting that the successful implementation of innovative technologies would set a global standard for road construction. He encouraged continued adoption of such technologies and expressed confidence that India would emerge as a global leader in infrastructure development.

Minister of State for Road Transport and Highways, Shri Ajay Tamta, in his address, stated, “India has made remarkable strides in developing world-class roads and highways, significantly enhancing our infrastructure. Every stakeholder plays a vital role in this transformation. As we move forward, leveraging advanced technology such as sensors, satellites, and real-time monitoring will be key to accelerating progress. With continuous technological advancements, we are committed to aligning India’s road infrastructure with Vision 2047 and elevating our National Highway network to world-class standards.”

Shri V. Umashankar, Secretary, MoRTH, said, “The roads and highways we construct today will serve our nation for many years to come. Therefore, time and quality of construction are critical parameters. Compaction is one of the most important aspects of road construction, and the technology available today allows us to address compaction-related challenges. I am confident that the discussions at this workshop will provide valuable insights that will help us adopt AI-MC technology to enhance National Highway construction.”

Shri Sudip Chaudhury, ADG of MoRTH, informed that the policy discussions began months ago to address challenges in road construction. He was tasked by the then Secretary of Road Transport to explore the broader contours of policy initiatives for fiscal year 2024-25. His responsibility was to develop specifications that would allow for experimental projects, which could later be scaled, based on lessons learned. He emphasized the importance of creating technology-agnostic specifications that encourage innovation and integration of new solutions. He urged stakeholders to work together to finalize specifications and move forward with the implementation process.

He also highlighted how integrating automated control systems in pilot projects has improved safety, reduced errors, and boosted productivity. Technologies like geospatial data, GPS positioning, and machine guidance systems have already enhanced construction quality, particularly in compaction, leveling, and temperature monitoring. “As these technologies continue to mature, further guidance will be provided for their application in future National Highway projects,” he said.

Shri Vishal Chauhan, Member-Administration of NHAI, highlighted the Ministry’s ongoing focus on improving safety, quality, and efficiency in road construction. “While safety remains a priority, quality control in construction has often been a challenge—an area where modern technology plays a crucial role,” he said.

He gave the example of the successful Lucknow-Kanpur pilot project, where automated technology for grading and compaction has led to greater accuracy and better quality control. He expressed confidence that, despite challenges such as initial investment costs and the need for behavioral change, these barriers would be overcome over time. He said that technology would improve quality, efficiency, and transparency across projects, and MoRTH is committed to working with all stakeholders to refine and implement these technologies.

Overview of Lucknow-Kanpur Expressway Pilot Project for AI-MC

Shri Vivek Jaiswal, Chief General Manager, NHAI, presented an overview of the adoption of Automated and Intelligent Machine Control (AI-MC) systems in highway construction. He explained that NHAI has initiated the integration of electronic control packages, transforming traditional commercial survey setups into automated systems for data transactions. This shift eliminates inefficiencies, enhances safety, boosts productivity, and ensures improved quality control in construction processes.

The core of this technology lies in the integration of geospatial data segmentation and machine positioning. By utilizing base stations and satellites, data is transmitted via radio signals to construction equipment, enabling the enforcement of Standard Operating Procedures (SOPs) and guidelines from the Indian Roads Congress (IRC). These guidelines, which focus on ensuring proper layer thickness, surface leveling, and temperature control, can be effectively managed through AI-MC systems.

He highlighted the use of machine guidance control systems for various tasks, including road leveling, drainage, and compaction, referring to the IRC guidelines that define compaction and leveling standards, such as tolerances for bituminous surfaces and specifications for rolling and laying temperatures.

A key feature of AI-MC technology is its ability to monitor relative compaction. GPS-equipped compactors track the number of passes required and the position of each pass, ensuring adherence to specifications. The system automatically documents this information, enabling operators to pinpoint areas that need additional compaction. Similarly, for graders and pavers, AI-MC systems ensure precise control over road leveling and layer thickness. These systems also monitor asphalt temperature during paving to ensure optimal bonding.

“NHAI has formalized the use of these technologies in its guidelines, with machine guidance control systems now included in Schedule D of NHAI documentation for motor graders, pavers, and compactors. NHAI is committed to continuing the integration of these technologies into the specifications for future national highway projects.

Looking ahead, NHAI plans to refine existing guidelines to incorporate these technologies, provide training for staff and contractors, and develop policies that support the use of machine guidance control systems. As these systems continue to evolve, NHAI will update policies to ensure quality control and compaction standards are met, based on the data provided by automated systems.”

He said that the integration of machine guidance control systems into highway construction offers substantial improvements in quality, safety, and efficiency. These systems enable precise monitoring and control of key construction activities, ensuring that projects meet the highest standards. “Technology providers are eager to collaborate with NHAI to further enhance and refine these systems, ultimately delivering better outcomes for highway construction projects,” he stated.

Presentation by Technology Solution Providers

Technology providers from leading companies such as Trimble, MOBA, Topcon, and Leica Geosystems shared their experiences and advancements in automated and intelligent machine-aided construction (AI-MC). They emphasized the benefits of the technologies in meeting quality control standards, such as the IRC specifications, while real-time tracking and data documentation have significantly improved transparency and accountability.

Shri Anand Sirohi, Business Area Director, and Shri Saurabh Trivedi, Sales Head at Sitech Trimble, highlighted significant advancements in automated and intelligent construction. They discussed the shift from traditional manual processes to a data-driven, connected construction model, addressing challenges such as the shortage of skilled manpower.

They emphasized how Trimble's 3D Automated Machine Guidance (AMG) and control technology integrates design software with construction equipment, guiding machinery precisely according to project specifications. This ensures accuracy in critical activities like grading, compaction, and surface leveling, minimizing human error and maximizing efficiency.

The AMG process enables real-time data capture from the field, which is transmitted to the office for instant adjustments, ensuring projects stay on track. It also tracks compaction and ensures design compliance in real-time, transforming project management.

“The benefits of Trimble's technology include up to twice the productivity, reduced fuel consumption, and enhanced on-site safety. Contractors have reported up to 2.5 times more productivity during nighttime operations,” said Sirohi.

3DMG is a process that connects the workforce, material requirements, machines, construction processes, and workflows. It links the site and the office, enabling real-time inspection, reporting, and control, while creating a living Digital Twin throughout the construction process. This facilitates operations and maintenance in infrastructure lifecycle management by integrating data from all machine types involved, including excavators, graders, compactors, pavers, piling machines, and more.

“Trimble's technology eliminates the need for rework by ensuring that everything is built exactly as designed, improving sustainability and reducing project costs. With over 200 systems deployed in major projects such as the Delhi-Mumbai Expressway and New Delhi International Airport, Trimble continues to support the Indian construction industry with robust technology solutions,” stated Trivedi.

Shri Alexander Wahlmann, Director - APAC, MOBA, a company with 50 years of expertise in road construction technologies, presented advancements in paving systems designed to enhance road quality and construction efficiency. MOBA’s innovations address primary challenges in road construction, such as consistent smooth leveling, cost reduction, and improving road durability.

One of the key technological innovations of MOBA is the Big sonic Ski (multiplexing averaging beam) an advanced ultrasonic sensor that ensures precision in road leveling by averaging surface levels. The Super Ski, with its Leading Leveling technology, provides exceptional accuracy in leveling, resulting in high-quality roads that meet International Roughness Index (IRI) standards. MOBA's Paver System also measures and visualizes the temperature profile of asphalt during application, ensuring material homogeneity and improving structural integrity.

“MOBA’s integrated systems covers full range of solutions beyond paving to machinery like graders, compactors, and excavators, ensuring high precision machine control throughout the entire construction process. The company’s long-term solutions, such as the Compaction Assistant (MCA) and the Grader & Excavator systems have been deployed in India for many years. MOBA has its subsidiary in India for over 20 years, demonstrating their effectiveness in improving road construction outcomes,” he informed.

Shri Pramod Kumar Mishra, Topcon Sokkia India, emphasized the critical role of technology in enhancing construction efficiency and productivity. As a leader in machine control systems, Topcon provides solutions that optimize construction machinery, including excavators, pavers, motor graders, and compactors. Topcon systems automate tasks like excavation, grading, and paving, significantly reducing time and labor requirements. By enabling construction equipment to follow design data automatically, Topcon's systems enhance precision and overall project efficiency.

Topcon’s paver solution reduces machine costs, improves accuracy, and eliminates the need for manual grade checking. The company’s compaction systems enhance both efficiency and consistency, leading to better road construction results. Topcon’s excavation and dozing solutions, both 2D and 3D, improve task accuracy, reduce errors, and boost productivity.

“These technologies address industry challenges like low productivity, rising material costs, and labor shortages. By reducing construction periods, cutting costs, and enhancing safety, Topcon’s solutions contribute to more sustainable and effective construction practices,” he said.

Shri Pankaj Gupta, Director Sales and Services, Hexagon India, (Leica Geosystems), a global leader in automation and sensor technologies, presented the company’s innovative solutions aimed at improving construction site management, enhancing precision, and streamlining workflows. One of their flagship offerings, the Leica ICON 3D system, integrates all machine functions into a single software platform, allowing operators to monitor real-time updates and control machinery with high precision.

Leica’s ICON Connex platform syncs data across all machines on-site, ensuring seamless operation and better coordination, while the advanced paving solutions, such as the ICON S-Wallpaper, offers significant improvements in grading and slope management of foundation layers for pavements. The 3D solution for asphalt pavers ensures accurate material placement, grading, and slope control, reducing waste and accelerating project timelines.

For motor graders, Leica’s ICON IGG4 system offers precise blade control, ensuring accuracy in complex grading tasks like creating ditches or grading side slopes, even for less experienced operators. Leica’s excavation and grading systems, like the Leica MC1 and ICON ICG-70T, provide real-time updates for accurate surface analysis and streamline workflows with automatic tool recognition.

He informed that Leica also integrates data across systems and offers remote management capabilities, enabling real-time monitoring of machine performance and project progress. These advancements enhance site management, reduce downtime, and increase efficiency - contributing to successful project execution.

The presentations by Trimble, MOBA, Topcon, and Leica Geosystems underscore the transformative impact of technology on India's road construction industry. The integration of advanced machine control systems, paving technologies, and data management tools is revolutionizing construction, making it more efficient, accurate, and cost-effective.

As India continues to expand its infrastructure, these technologies will play a critical role in improving road quality, reducing costs, and enhancing safety. Collaboration between technology providers, contractors, and government agencies will be key to driving this transformation and ensuring the successful implementation of smart and sustainable road construction practices.

Views of Equipment Users

Shri S.P. Rajan, VP & Head – Competency Center Roads, Bridges, & Formations Business, Transportation Infrastructure IC, discussed the evolution of construction technology in India, and the challenges of adopting and integrating the solutions. Significant progress was made by 2019, with technologies like motor graders, 3D excavation, paving, and intelligent compaction systems being embraced. He highlighted the growing role of technology in enhancing safety and productivity, predicting a future where machines would perform most tasks, and human interaction would be limited. This could lead to the need for permits for workers to physically engage with machines.

However, the real challenge wasn’t the technology itself but convincing the industry to accept the concept. He also discussed interoperability and equipment compatibility. While integration time has improved, equipment still faces compatibility issues, especially when working with machines from different manufacturers, and called for a more adaptable approach to ensure seamless connections between various machines, which would reduce delays and inefficiencies.

He raised concerns about warranties, especially when equipment attachments and technologies were swapped. A standardized approach to managing different input/output formats from various providers was suggested to avoid operational disruptions. Skill development was identified as another critical need. As new systems are adopted, operators and service providers must be equipped with the necessary skills. Data gaps, such as the transfer of moisture content into systems, and network dependency issues, particularly in remote areas, were also discussed. Data ownership and the need for clear regulations were highlighted, and the importance of securing and managing data generated from construction projects.

“Cost remains a barrier, as the high upfront investment in technology makes it challenging to achieve a quick return on investment. Hence, the need for more affordable, efficient solutions, since the cost of technology sometimes rivals that of the machines themselves,” he said.

In view of the fact that connectivity was also a key issue, he proposed radio frequency solutions to overcome network limitations and called for Ministry support in addressing regulatory restrictions around connectivity.

He stressed the need for a unified approach to technology integration, with standardized protocols and seamless data sharing between technology providers, and said that he envisioned a future where technology in road construction would be adopted as a collaborative, standardized culture, helping India become a global leader in construction technology.

Shri Anil Chaudhary, Member (Projects), NHAI, summarized the valuable insights gathered from stakeholders regarding the implementation of AI-MC technology in road construction. He emphasized the importance of adopting cutting-edge technologies like AI-MC to improve the precision and quality of road projects and highlighted NHAI's ongoing efforts to incorporate such technologies into the existing construction framework.

He explained how AI-MC utilizes machine tracking control systems to integrate equipment like compactors, graders, and pavers with onboard computers and sensors. These systems ensure precise grading and compaction, guaranteeing the desired quality of construction. For example, the technology allows operators to monitor compaction and grading in real-time, providing data on the number of passes made by compactors and the soil’s compaction quality. Similarly, for graders, the system adjusts the blade position to achieve the required profile, while for pavers, it monitors the temperature of material being laid to ensure quality is maintained.

He said that integration of equipment ensures that all the machines on-site are aware of the work being done by the other machines improves overall efficiency and quality. He shared the encouraging results from pilot projects such as the Lucknow-Kanpur Expressway, demonstrating the potential of AI-MC technology to enhance road construction by providing precise and accurate data for operators and supervisors.

He addressed the concerns raised by stakeholders regarding the interoperability of equipment from different vendors, emphasizing the need for ensuring compatibility across machines and systems to guarantee smooth operation. He said that a cultural shift was required to adopt such technologies, referencing Japan’s successful implementation of similar systems over a decade ago.

He highlighted the importance of creating a robust data management system to handle the large amount of data generated by these technologies and reassured the participants that NHAI is committed to addressing these concerns and is working toward incorporating AI-MC technology in a phased manner, ensuring smooth implementation.

Conclusion

The stakeholder consultation workshop successfully brought together a diverse group of participants to discuss the future of automated and intelligent machine-aided construction for National Highway projects, and highlighted the importance of collaboration between technology providers, government bodies, and other stakeholders to ensure the successful implementation of the technologies. As the industry moves toward more data-driven and automated construction processes, addressing challenges like skill gaps and providing adequate workforce training will be essential.

The feedback and discussions from the workshop will serve as the foundation for refining the policy framework and specifications for adopting these advancements. The next steps will involve refining the draft policy based on the insights received, with continued focus on capacity building and workforce training to support the transition to more automated and intelligent construction methods.

Feedback & Recommendations Based on Industry Stakeholder Discussions

Mechanization and Industry Roadmap

• The need for mechanization in construction is evident.
• A phased roadmap should be implemented, starting with a limited number of units and progressively scaling, making the technology a standard.

Clear Specifications and Technology Performance

• Clearer specifications are needed to define technology performance and reliability.
• Understanding how technology addresses problems and improves construction processes is crucial.

Data and Road Asset Management

• AI-MC technology data will lay the foundation for a road asset management system, offering a comparison with traditional methods and building confidence in machine-generated data.

Process-Driven vs. Manufacturer-Specific Systems

• Clarify whether the focus will be on process-driven solutions (e.g., temperature or paving density) or if proprietary manufacturer systems will continue.
• As automation evolves, the end result may become more important than the process itself.

Incentivizing Technology Adoption through Carbon Credits

• Incorporating AI-MC technology into a carbon trading system, which could incentivize adoption by concessionaires.

Skill Development

• Technology adoption requires skilled personnel, so training youth for the sector is essential.
• Technology can make the industry more attractive to younger workers, addressing talent attraction challenges.

Carbon Credits in Contracts

• Propose including carbon credits in RFPs or contracts to incentivize green practices, moving beyond circulars.

Phased Implementation and Modular Systems

• The Ministry plans to implement technology in phases, beginning with scalable, modular systems that evolve over time.

Standardization and Technology Flexibility

• Focus on setting the right standards to ensure safety, durability, and sustainability, reducing rework and material waste.

Data Management Standardization

• Standardizing data management, especially in linear projects, would improve collaboration and future project outcomes.

Technology Agnosticism and Flexibility

• Specifications should allow for flexibility and compatibility with all technology solutions, maintaining industry standards.

Cloud Platform Management and Data Integration

• The Ministry or contractors will gradually guide cloud platform management, evolving as the ecosystem develops.

Ensuring Data Accuracy and Quality

• Ensuring data accuracy, particularly for material placement and sensor performance, is essential, with traditional testing still required for compliance.

Seamless Integration Across Systems

• Technologies must integrate seamlessly across systems, ensuring compatibility between different manufacturers’ equipment.

Commitment to International Standards for Data Standardization

• Technology providers are committed to aligning with international standards (ISO) to ensure consistent data usage across technologies.

Improving Efficiency and Control

• Automation should enhance control over construction activities, improving efficiency and outcomes.

Investing in Automation and Machine Control Systems

• Adopting automation reduces labor costs, increases accuracy, and boosts productivity on-site.

Focus on Data Integration

• Real-time data sharing between machines and the central office ensures better project management and resource allocation.

Continued Collaboration:

• Government agencies, technology providers, and contractors must collaborate to align objectives and ensure effective technology implementation.