From Levers to Touchscreens

Once upon a time, the clunk of levers and the rumble of heavy machinery was the soundtrack to construction sites, but step into a modern excavator or crane today and you’re likely to find sleek touchscreens, integrated sensors and augmented reality displays taking center stage.

Equipment controls have come a long way from their basic mechanical roots and the pace of innovation isn’t slowing down. As contractors and operators adapt to cutting-edge technologies, they’re not just controlling machines, they’re shaping the future of an industry poised for a technological revolution.

Where We’ve Been

In the industrial era of the 1920s and ’30s, pneumatic controls and compressed air powered and operated actuators and tools. This was a good fit for smaller and lighter machinery, like jackhammers and forklifts, but they produced less force and weren’t useful for heavy-duty equipment.

But by the 1960s, the rise of hydraulic systems powered heavy machinery from bulldozers to cranes that relied on basic levers, pedals and physical linkages. Operators manually controlled these hydraulic systems, which required significant force and precise coordination, and could fatigue operators. Hydraulic-assisted levers reduced the physical effort operators needed to pilot systems, but they suffered from wear and leakage, and they required a lot of maintenance.

In the 1980s, electro-hydraulic systems were the answer to these problems. Many featured electronic joysticks that replaced old-style levers; these more comfortable, ergonomic controls let operators be more precise and offered multi-functional capabilities. Varying operational modes and single-system controls streamlined operator tasks. Some equipment had CAN (Controller Area Network) bus systems, which let machine components communicate electronically with each other and improved equipment diagnostics and performance monitoring. However, as systems became more complex, operators needed more training, and the systems demanded more maintenance.

Where We Are

With the new century came the rise of digital displays and touchscreens. Now, modern construction equipment, such as excavators, graders and loaders, have touchscreen controls that combine with joysticks. Operators can control nearly every function of their machines with a central digital display.

Customizations such as sensitivity and operational modes, machine learning and artificial intelligence (AI) can automate certain functions like digging depth or speed over specific surfaces. Telematics and remote monitoring give operators and fleet managers the ability to supervise equipment from offsite locations, and GPS integration lets machines operate with extreme precision as they’re guided by predefined coordinates. These features require less manual operation and increase efficiency, and built-in ergonomics keep workers more comfortable, reduce fatigue and minimize repetitive stress injuries.

Beyond that, on-board diagnostics collect vital operational data to predict maintenance needs and reduce downtime by identifying potential issues before they become big problems. Cloud-based programs provide fleet-wide analytics that help companies make data-driven decisions about equipment use, fuel consumption and maintenance schedules. However, touchscreens and other sensitive electronics are susceptible to damage from harsh weather conditions and screen malfunctions.

Where We’re Going

It’s impossible to say just how equipment controls will change in the decades to come, but it’s likely we’ll see more extended reality, augmented reality (AR), virtual reality (VR), machine learning, AI and autonomous machines in construction spaces.

Companies are already using VR technology for training purposes to help operators safely practice using machinery like excavators, cranes and bulldozers in realistic scenarios. Benefits, such as reduced risk, cost savings and better retention of skills, mean more companies are likely to embrace this type of tech solution. We may even see AR glasses become as common as hard hats, providing real-time visualizations for operators and supervisors.

Similarly, AR can merge real-time data and visual cues with an operator’s view. AR glasses and heads up displays can show machine data like load weights, fuel levels and maintenance requirements in a location and way that keeps the operator informed yet focused on the worksite. AR overlays can project blueprints directly onto jobsites during grading, excavation work and material placement for exact locations without additional mapping or marking, and it may provide teams in different locations with visuals of the project through shared AR experiences for better collaboration across miles.

Eventually, semi-autonomous and autonomous machines will take operators out of the driver’s seat. Instead of actively controlling equipment, they’ll supervise. They may be onsite or operating remotely from work headquarters or even home offices. Some companies, including Caterpillar and Komatsu, have developed semi- or fully autonomous versions of equipment; other companies are currently working on grading, digging and material-handling machinery that uses AI to make real-time decisions and requires minimal human intervention.

How to Prepare for the Future

With all of these changes on the horizon, companies and workers in the construction industry need to be proactive to keep up. Training, technology adoption and business strategies focused on tools of the future are the only way to be sure you can compete.

Training and upskilling workers will help current and future employees learn to operate autonomous systems and touchscreen controls, integrate AR and VR into daily tasks and get them comfortable with AI and computerized intelligence. Hands-on training is the best way to do this and taking advantage of specialized training from equipment manufacturers and fostering a culture of lifelong learning are key.

While embracing change is hard for any industry, it’s important for companies to gradually adapt through phased approaches rather than sudden changes. Starting with semi-autonomous features and basic touchscreen interfaces will help operators adjust with less disruption than massive technology overhauls. It can also help employees overcome initial reluctance or fear of technology replacing their jobs, and positive engagement and upskilling or reskilling can lead to better job satisfaction, reduced stress and more buy-in.

Staying adaptable is important for employees and companies. Job titles will begin to shift from hands-on operator roles to overseeing performance, diagnosing problems and ensuring smooth operation. These are generally higher-skilled roles, so companies may need to provide training, education and incentives to encourage and attract tech-savvy talent. They’ll also need to implement cybersecurity protocols, data encryption and software updates to prevent hacking and cyberattacks of sensitive equipment.

It's also necessary for companies and shareholders to embrace tech investments in their budgeting strategies. High-tech equipment comes with larger upfront costs and potential sticker shock, but long-term benefits in efficiency, reduced downtime, lower operating costs, fewer mistakes and environmental protection can balance out that bigger initial investment. Technology and automation also have the potential to increase productivity, but only if businesses scale operations in the right way by improving internal processes, emphasizing coordination across departments and setting realistic budgets and goals.

As the construction industry stands on the cusp of technological transformation, the road ahead offers opportunities and challenges. Companies that invest in innovation and training will be better equipped to capitalize on the efficiency, safety and precision that advanced equipment controls can bring. However, technology alone won’t solve every problem — success depends on the people behind the machines and their willingness and ability to embrace change.