Digital Twins in Earthmoving: A Practical Shift in Site Management

According to the European Centre for the Development of Vocational Training (Cedefop), Europe will need to fill 4.2 million construction job openings between 2022 and 2035 to meet projected demand. As the workforce ages and project complexity increases, the sector faces a critical shortage of skilled labour. To remain competitive and resilient, investment in workforce training and digital technologies will be essential.

One of the technologies driving change in the construction sector is the digital twin. By providing a continuously updated virtual model of the job site, it enables real-time monitoring, more effective resource allocation, and safer working conditions. Data collected from machines and sensors is processed by AI systems to simulate different operational scenarios, such as fleet composition or task sequencing, allowing project managers to plan more efficiently and reduce downtime.

Beyond planning, digital twins also support workforce development. They improve progress tracking and enable digital logging of completed work, which can later serve as a reference for maintenance or future modifications. By automating data analysis and reporting, these systems reduce the administrative burden on site teams, allowing them to focus on high-value tasks. The same real-time insight that improves coordination also helps identify potential safety risks in advance, making it possible to test procedures virtually before implementing them on the ground.

The integration of digital tools into earthmoving is gradually changing how contractors manage complex sites. Komatsu’s Smart Construction Dashboard is one example of this shift, combining 3D design files with aerial mapping and machine-generated data to deliver a continuously updated digital twin of the jobsite. Rather than relying on manual checks or fragmented reports, project managers can access a centralised platform that reflects real-time conditions and progress.

At a HEITKAMP Corporate Group site, site manager Sina Motsch turned to this system to bring order to a fast-moving operation. As machines carried out grading and excavation, the dashboard automatically gathered high-density as-built data, creating an evolving virtual model of the terrain. This allowed her to monitor changes, detect delays, and address issues early, often without needing to be on-site.

Beyond visibility, the tool supported more informed decisions. By consolidating information from various sources, it helped improve coordination across teams and reduce inefficiencies.

While still not widespread, the use of such platforms is growing as project demands become more complex and workforce challenges persist. Digital twins and real-time dashboards are becoming essential tools for companies looking to maintain control, limit delays, and adapt more quickly on the ground.