China has successfully resurfaced a 158-kilometer stretch of the Beijing-Hong Kong-Macao Expressway using drones and autonomous robots. This project highlights the transformative potential of AI and autonomous machinery in the field of road construction.
The project employed drones equipped with high-resolution cameras to survey the highway and identify repair needs. These drones provided precise data, which autonomous robots used to execute the resurfacing with remarkable accuracy. This method not only significantly reduced the time required for completion but also minimized traffic disruptions, ensuring a smoother flow for motorists.
The Sany drone swarm, utilized for the resurfacing, showcased remarkable technological advancements. These drones used high-precision path tracking algorithms and a self-developed fusion high-precision self-sensing positioning system. This allowed them to accurately identify and position curbstones, achieving a “zero edge-to-edge” operation. This innovation eliminated the need for small rollers typically used for edge trimming, enabling the road surface to be formed in a single step. As a result, both work efficiency and quality were significantly enhanced.
Safety was a top priority in this project. The drones were equipped with multiple redundant safety protection strategies, including collaborative safety measures, electronic fences, emergency stop systems, and perception and obstacle avoidance systems. Depending on the risk level, the equipment could decelerate, pause, or execute an emergency stop in real time, ensuring safe operations throughout the project.
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The expressway, often referred to as the “Golden Channel,” is a vital north-south traffic artery in China, connecting economically developed regions. It gained notoriety in October 2015 when one of the world’s worst traffic jams occurred, affecting an estimated 750 million people during National Day celebrations. The incident was triggered by a newly installed checkpoint that forced traffic to merge from 50 lanes to just 20. This recent project marks a significant advancement in intelligent infrastructure and sets new standards for efficiency, quality, and safety in the industry.
This large-scale undertaking was an impressive fleet of autonomous road equipment supplied by Sany, a major Chinese manufacturer of heavy machinery. The equipment lineup included a 20-meter-wide unmanned paver, six 13-tonne double-drum rollers, and three 30-tonne rubber-wheel rollers, operating in a synchronized formation.
The machines were orchestrated using advanced algorithms, the Beidou satellite positioning system offering centimetre-level precision and a low-latency communication network that enabled real-time path planning and precise operational control. This system ensured “close following and slow rolling,” a method which minimized under-compaction and avoided missed sections, ultimately guaranteeing the road’s quality and longevity.
The highlight of the project was the SAP200C-10 paver, a groundbreaking piece of technology that achieved a world-first by laying a 19.25-meter-wide stretch of asphalt in a single pass. This capability not only accelerated the construction process but also reduced the number of joints, enhancing the road’s smoothness and structural integrity.
Each piece of autonomous equipment was equipped with multiple layers of safety features, including electronic fences, emergency stop functions, and real-time obstacle detection systems. These features allowed the machinery to dynamically respond to potential hazards, such as obstacles on the construction site or environmental changes, ensuring safe operations.
Additionally, the equipment could perform edge rolling with high accuracy, eliminating the need for smaller rollers and achieving “zero” edge trimming errors, thanks to advanced tracking algorithms.
By adopting fully unmanned operations, the project greatly reduced the need for human presence in potentially hazardous environments, thus enhancing worker safety and lowering labour costs. The success of deploying these technologies on a large-scale project underscores a substantial advancement in autonomous construction capabilities.
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This unmanned paving project serves as a model for future advancements in road construction worldwide. The integration of AI and autonomous machinery can revolutionize the industry by significantly reducing costs, shortening project timelines, and improving construction quality. As these technologies gain wider adoption, human workers may transition to supervisory roles, overseeing automated operations rather than performing labour-intensive tasks.
The challenge for other countries lies in scaling up existing trials and transitioning to fully autonomous road construction projects. This would involve considerable investment in infrastructure, communication networks, and regulatory frameworks to support AI-driven construction activities. However, the success of China’s pioneering project offers a compelling case for other nations to explore similar technologies, potentially ushering in a new era of intelligent infrastructure development that prioritizes safety, sustainability, and operational efficiency.
China’s accomplishment in resurfacing the Beijing-Hong Kong-Macao Expressway using drones and autonomous robots marks a significant milestone in road construction. This innovative approach not only showcases the potential of advanced technology in infrastructure projects but also sets a new standard for efficiency and safety in the industry. As countries worldwide look to enhance their infrastructure, the lessons learned from this project could pave the way for a future where intelligent, autonomous systems play a central role in construction.
