On construction sites, arduous conditions and changing weather are unavoidable
Operating forklifts in the construction industry is a very different proposition to doing so in a warehouse.
“Equipment can be working in arduous conditions, often outside in changing weather and handling heavy or fragile products that have a high replacement cost if damaged,” says Neal Fowler, sales director at B&B Attachments.
For these reasons, visibility, load security and attachment durability are critical considerations. “Equipment must withstand demanding conditions over many years, while giving operators the confidence to move loads safely and accurately,” says Fowler.
Adding that reliability is another important requirement in this context, Fowler explains that customers look for suppliers who can offer responsive service, preventative maintenance programs and fast access to replacement parts.
“At B&B Attachments, we support customers throughout the entire lifecycle of their equipment with nationwide servicing, maintenance, repairs, thorough examinations and technical support to maximise uptime,” he says.
The BlockMaster from B&B Attachments is designed for handling concrete, clay and other building products
Developed specifically for the construction industry, the BlockMaster range remains one of B&B Attachments' flagship product families.
Designed for handling concrete, clay and other building products, the range ensures secure clamping, visibility and precise load control, to help users minimise damage while maintaining productivity.
B&B Attachments also offers PowerMount, a system that allows users to interchange attachments on a truck in under 60 seconds.
“This innovation ensures operators always have the correct attachment for the exact handling requirement, as well as increasing safety and reducing load damage,” says Fowler. “It ensures better equipment utilisation and can significantly reduce fleet size and operational costs for large users.”
In addition, as Fowler notes, the company is able to engineer bespoke solutions.
“Our in-house design and manufacturing capabilities enable us to develop attachments tailored to individual handling requirements,” he says.
Serving a growing market
As Julia Ye, sales director at Maxlion points out, construction forklifts are a niche segment within the material handling industry, and account for an estimated 20–25 per cent of the overall forklift market.
Maxlion Rough Terrain Forklifts are available in 2WD and 4WD configurations
“For Maxlion, this is a strategic product category,” explains Ye. “Our rough terrain forklifts and Compact Tele-Trucks represent an important part of our business, with growing demand from the construction, agriculture, mining, and infrastructure sectors.”
Available in capacities from 1.8t - 3.5t, with both 2WD and 4WD configurations, as well as diesel and lithium-ion battery models, the Rough Terrain series is one of Maxlion’s key product lines. According to Ye, it is designed for robust design and reliable performance and has been well received in Australia, New Zealand and Europe.
The company’s second key offering in this market is the Compact Tele-truck series, which is available in capacities from 1.5t - 3t and lift heights ranging from 4.5m – 7m.
Developed for the construction sector, it fills the gap between traditional rough terrain forklifts and telehandlers. It offers greater reach and flexibility than conventional forklifts, while providing a more compact and cost-effective alternative to telehandlers.
“We believe the market is in a growth phase. As infrastructure projects continue to increase worldwide, customers are looking for equipment that can operate reliably in demanding outdoor environments,” says Ye.
Asked about recent innovations and where the market is headed, Ye points to lithium-ion powered rough terrain forklifts, compact tele-trucks and intelligent telematics systems.
“These technologies help customers improve productivity, reduce operating costs and lower emissions, while providing greater flexibility on construction sites,” she says.
“Looking ahead, extending battery runtime, improving outdoor charging solutions and enhancing machine durability will remain key priorities for the industry.”
The rise of electrification
Nicola Tessaro, product manager material handling segment at Allison Off-Highway Drive & Motion Systems – a supplier of a range of drivetrain solutions, including front drive axles, rear steering axles, transmissions and electric drive systems – agrees with this assessment and says he has seen rapid expansion of electrification in the heavy-duty construction forklift market.
Allison Off-Highway Drive and Motion Systems offers of a range of drivetrain solutions, which are used in construction forklifts
According to Tessaro, the latest electric forklifts are focused on high-voltage technologies. Essentially, construction companies are looking for forklifts that combine the performance of internal combustion engines (ICE) with the environmental and operational requirements of modern fleets.
A key challenge in this context is ensuring electric options are able to handle the harsh outdoor conditions and demanding duty cycles of construction sites.
With products such as Front Dual Drive Axles for LV forklifts Class1, and the premium ICE Axle range (for heavy duty drivelines), the company is well-placed to assist original equipment manufacturers (OEMs) that are looking to address this challenge.
“What differentiates our solutions is their highly modular architecture,” says Tessaro. “Many of the core components of these products, including gears, brakes and the like, are shared across both electric and ICE platforms.”
In this way, they simplify the vehicle development process. Because they reduce complexity, they offer benefits to multiple applications.
“Another important differentiator is our customer-centric approach. Allison Off-Highway works closely with OEMs to understand their specific requirements and develop tailored solutions that meet their operational needs,” says Chris Menge, global sales lead for light material handling at Allison Off-Highway Drive and Motion Systems.
“The flexibility of our design allows customers to implement innovative features and configurations that may not be available in more standardised market offerings.”
In addition, because they are engineered with serviceability and maintenance in mind, the various products help reduce downtime and improve long-term operating efficiency. Combining modularity and customisation with durability and ease of service, they deliver real value in demanding material handling applications like those found in the construction sector.
“The challenge for manufacturers is to balance performance, durability, energy efficiency and cost – particularly in applications where equipment is subjected to intensive outdoor use.”
Performance, durability and energy efficiency
Beyond electrification, further developments in the construction forklift market include “intelligence” and connectivity. As is the case elsewhere, telematics, digital monitoring and intelligent control systems are becoming more prevalent.
UN Forklifts' NL Series 4.0T-mini 5.0T Li-ion Battery Forklift
“These technologies can provide information on equipment utilisation, operating conditions, maintenance requirements and fleet performance,” says Jack Yang, vice president of sales at UN Forklifts. “For fleet operators, the objective is to reduce unplanned downtime, improve utilisation and make maintenance more predictive.”
In addition – and in line with recent improvements in hydraulic systems, powertrain efficiency, cooling systems and structural design – customers are also seeking productivity improvements.
“The challenge for manufacturers is to balance performance, durability, energy efficiency and cost – particularly in applications where equipment is subjected to intensive outdoor use,” says Yang.
UN Forklifts offers three categories of product – namely, rough-terrain forklifts, heavy-duty internal combustion forklifts and heavy-duty lithium-ion forklifts – that are relevant to the construction market.
Available in 2WD and 4WD configurations, the Rough-Terrain range is designed to provide strong traction, stability and mobility on uneven or challenging surfaces.
“These forklifts are particularly suitable for construction sites, infrastructure projects, building-material handling, landscaping, agriculture and other outdoor applications where surfaces may include gravel, mud, slopes or unfinished roads,” says Yang.
Meanwhile, the Heavy-Duty Internal Combustion Forklift range is recommended for applications involving extreme weight and intensive operating cycles.
“These machines are designed for demanding applications such as steel, stone, concrete products, building materials, machinery manufacturing, timber, ports and other heavy industries,” says Yang.
And finally, the Heavy-Duty Lithium-Ion range includes forklifts with the high capacity and productivity expected from machinery of this type, while also delivering the benefits associated with electrification.
“This three-product strategy reflects the broader direction of UN Forklift's product development,” says Yang. “We do not believe there will be a single power solution for every application. Internal combustion, lithium-ion and specialised rough-terrain solutions will continue to coexist, depending on operating conditions and customer requirements.”
Optimised performance
Hou Guangyao, general manager of Hangcha Group Manufacturing (Thailand), ranks rough-terrain capability, high reach and outreach capacity, manoeuvrability, multi-functionality, and safety as the construction sector’s top five materials handling priorities.
The XH series High-Voltage Lithium Telescopic Handler from Hangcha
“Our latest XH series High-Voltage Lithium Telescopic Handlers and X series Diesel Rough-Terrain Forklifts are purpose-built for two distinct job-site realities – range anxiety in intermittent operations, and power/ground-clearance constraints in heavy-duty continuous use,” says Guangyao.
Featuring a high-voltage lithium battery and permanent-magnet motor with DC fast charging, the XH series delivers true one-hour fast replenishment and significantly cuts charging downtime.
Meanwhile, the X series is powered by a Cummins diesel engine, features full-time 4WD operation and extra ground clearance, and is engineered to handle heavy loads on the most punishing construction and port sites.
Both models share a quick-attach boom system, which not only facilitates fast attachment swaps but effectively means they are able to convert from forklift to loader or crane, and are therefore suitable for multiple tasks.
According to Guangyao, Hangcha’s key differentiator lies in its pursuit of class-leading performance across all key metrics.
“The XH series has leading battery capacity and motor power among electric equipment in its class, outperforming comparable electric products in driving speed, traction, and gradeability; its high-voltage fast charging greatly reduces downtime losses, and its throttle response approaches that of diesel models,” says Guangyao.
Meanwhile, the X series maximises engine power and ground clearance, and enables smooth passage, even through mud and gravel or up steep slopes.
Sustainability
Ken Kinsella, vice president industrial major accounts at Hyster, says many in the construction sector are emphasising the importance of carbon emission reductions and green initiatives.
“Transitioning from ICE to electric trucks is one way to reduce exhaust emissions throughout building and construction materials manufacturing sites,” says Kinsella.
In line with this, Hyster has recently expanded its lineup of electric forklifts. For example, the Hyster J4.0-7.0XTLG (J80-155XTLG) electric lift trucks deliver a robust, zero-emission solution for operations seeking reliable and affordable alternatives to ICE forklifts.
According to Hyster, electrification is one sure way to reduce exhaust emissions in the construction sector
Building on the popularity of the Hyster J2.0-3.5XTLG (J40-70XTLG) trucks, the more recent higher capacity models are well suited to both indoor and outdoor handling challenges.
“Operations moving or storing bricks, blocks, metals, and construction materials can expect to enhance productivity, reduce total cost of ownership (TCO), and eliminate tailpipe emissions,” says Kinsella.
Meanwhile, the Hyster J10-18XD series (J230-280XD) of high-capacity electric forklifts offer the configurability to match a range of heavy-duty applications.
With integrated lithium-ion battery power, these forklifts provide the performance and reliability required by demanding construction industry environments.
According to Kinsella these forklifts – which can be tailored to meet the needs of many applications, including construction operations – illustrate Hyster’s commitment to providing practical and affordable electric solutions.
“To help ease the transition for operations pursuing decarbonisation, they include a high level of commonality with equivalent diesel Hyster models, tools to help monitor and manage batteries, and compatibility with common charging infrastructure,” he says.
In this way, like the various other products mentioned above, they are well-equipped to be part of a future in which materials handling is about not just reliability and safety, but also efficiency, connectivity and sustainability.
Discover more of our contributors' solutions for forklifts in the construction and building industries by visiting this dedicated Virtual Expo Showroom.
For this report we interviewed the following industry specialists: