At the 111th Illinois Transportation and Highway Engineering (T.H.E.) Conference, Cotter’s Clark Fisher, P.E., and Jose Mendez explored how emerging technologies are reshaping the future of roadway safety, efficiency, and project delivery. Digital twins and sinusoidal rumble strips were two innovations already transforming project planning, design, construction, and delivery.

“Technology gives us a new level of control in unpredictable environments. We can spot risks before they become incidents, and work proactively instead of reactively. It’s about engineering safety into every step of the process—not just reacting to problems, but preventing them.”

— Jose Mendez, Cotter Consulting

By adopting these tools, the industry is moving toward a smarter, safer future where budgets and schedules are not the only things being protected.

Digital Twin: A dynamic, real-time digital replica of a physical space

A digital twin is a dynamic, real-time digital replica of a physical space or system, like a building, bridge, or roadway. More than just a 3D model, digital twins are interactive platforms that integrate data from multiple sources, allowing stakeholders to visualize, manipulate, and analyze complex infrastructure in ways traditional blueprints cannot. Applications for digital twins include:

• Detecting design and construction conflicts early
• Monitoring project progress and changes in real-time
• Improving coordination between design and construction teams and project stakeholders
• Anticipating and reducing costly delays or rework
• Quantitative decision-making across the project lifecycle

For transportation projects, digital twins allow engineers and contractors to optimize every aspect of a project before even breaking ground. Utilizing digital twins during the design phase can identify potential construction conflicts before they occur, preserving time and budget, especially on large-scale projects. With the implementation of digital twins, we can expect:

• Fewer design errors, change orders, and RFIs
• Shorter construction schedules and accelerated delivery timelines
• Lower long-term maintenance costs
• Improved client and community satisfaction
• Improved safety for both workers and the public
• Reduction in costly rework
• Resource management

Digital Twin Integration with AI and Drone Technology: Enhancing Safety and Performance

When integrated with artificial intelligence (AI) and drone technology, digital twins evolve into transformative safety, efficiency, and sustainability platforms. Integrating AI and drone technology into digital twin workflows doesn’t just streamline operations; it also creates measurable safety impact:

• Real-time safety management
• Real-time hazard detection and intervention
• Reduced worker and driver risk in and around active work zones
• Predictive maintenance planning
• Fewer emergency repairs

AI-enabled digital twins can process real-time inputs from drone imagery and IoT sensors, allowing engineers to monitor site conditions without stepping onto potentially hazardous job sites. This significantly reduces workers’ exposure to dangerous environments, particularly in high-traffic areas or during inclement weather. According to Applied Sciences (2025) research, these systems can detect and simulate accident scenarios, allowing for proactive risk mitigation​. For example, a drone equipped with high-resolution cameras can scan an active work zone and feed data into the digital twin. AI then compares the current layout to the work zone design and instantly flags deviations or unsafe conditions (like equipment placed too close to open traffic lanes) before an incident occurs. By layering drone-captured imagery with AI analysis, digital twins can also forecast where infrastructure degradation might occur, allowing teams to schedule maintenance proactively rather than responding to emergencies. That includes identifying:

• Cracks in bridge joints
• Pavement fatigue zones
• Areas with poor water drainage

Digital twins can also enhance traveler safety by enabling real-time updates from live data captured by drones to traffic control systems. For instance, if a drone detects a fallen sign or road debris, the system can automatically send alerts, trigger digital message boards, or reroute drivers without manual intervention. AI also supports adaptive traffic systems by collecting live traffic data that reduces congestion and accidents, especially in complex intersections or reduced-lane corridors. These functions contribute to safer, smoother travel experiences, even during construction or lane closures.

Several companies (AECOM, DPR Construction, Jacobs, and Gannett Fleming) have already begun utilizing digital twin technology. Their practical applications include:

• Integrating digital twins with BIM (Building Information Modeling) for planning and optimizing roadways and transit systems. (AECOM)
• Lifecycle asset management. (DPR)
• AI-enhanced digital twins to model and predict infrastructure performance, enabling smarter maintenance and energy efficiency. (Jacobs)
• Advanced bridge conditions and traffic system modeling to improve safety and operational planning. (Gannett Fleming)

As AI capabilities expand and improve, we can expect fully autonomous technology that continuously and accurately collects data from project sites. Imagine being able to detect design flaws or utility clashes before they become costly field issues without ever setting foot on the job site! The integration of AI and drone technology with digital twins is not just about flashy new tech – it’s about building infrastructure that works smarter and safer.

Sinusoidal Rumble Strips: A Quieter, Safer Driving Experience

Rumble strips are engineered indentations in the pavement that produce tactile vibrations and audible warnings when a vehicle crosses them. Their primary purpose is to alert inattentive or drowsy drivers, reducing the likelihood of run-off-road incidents and head-on collisions. Currently, there are three types of strips:

• Shoulder Rumble Strips: Located along the road shoulder to prevent vehicles from veering off the roadway
• Centerline Rumble Strips: Placed along the centerline to deter head-on collisions, alerting drivers drifting across lanes.​
• Transverse Rumble Strips (TRS): Installed perpendicular to the direction of travel, often before intersections or toll booths, to prompt drivers to slow down or stop. TRS are particularly effective in rural areas where intersection-related crashes are prevalent.

First introduced in the 1950s, rumble strips have been a cost-effective safety measure to combat driver inattention. Providing immediate sensory feedback they help prevent accidents caused by fatigue or distraction. The Federal Highway Administration (FHWA) notes that milled centerline rumble strips can reduce injury crashes by 38–50% on rural two-lane roads and 37–91% on urban two-lane roads.​ Safety benefits of Rumble Strips include:

• Prevention of Run-Off-Road and Head-On Crashes
• Increased Driver Reaction Time
• Enhanced Safety at Rural Intersections
• Lower Crash Severity
• Improved Nighttime and Adverse Weather Safety

While traditional rumble strips are effective, they can generate unwanted noise that disturbs nearby residents. Sinusoidal rumble strips (also known as “mumble strips) mitigate this disturbance because of their wave-like pattern that maintains the internal vehicle vibration necessary to alert drivers while significantly reducing external noise, thus offering a quieter, safer driving experience. Studies have shown that the sinusoidal design can decrease external noise up to 7.9 decibels compared to traditional rumble strips.​

The National Cooperative Highway Research Program (NCHRP) recommends sinusoidal rumble strips as an effective low-noise alternative, balancing safety benefits with community noise concerns. States like Michigan and Indiana have implemented sinusoidal rumble strips in various roadway projects, observing positive safety and community satisfaction outcomes. Additionally, transverse rumble strips have been utilized at rural intersections to reduce crashes resulting from drivers failing to stop at stop signs. Research indicates that TRS can be a valuable tool in enhancing intersection safety, especially in areas with limited visibility or high incidences of stop-sign violations. In Minnesota, transverse rumble strips have reduced severe crashes by up to 40% at rural stop-controlled intersections.

As transportation professionals and public agencies seek a balance between safety, quality of life, and infrastructure resilience, sinusoidal rumble strips emerge as a smart compromise. Combined with other smart technologies like digital twins, they’re part of a modern toolkit to reduce crashes, protect lives, and design roadways for everyone’s benefit. Such advancements exemplify how thoughtful engineering solutions contribute to safer and more livable communities. 

“Innovation is what keeps our teams and the public safe. Advancements in technology let us make informed decisions without stepping into danger zones.”

— Clark Fisher, P.E., Cotter Consulting

The Bigger Picture

​As we celebrate National Work Zone Awareness Week (NWZAW) (April 21 to 25, 2025), it serves as a timely reminder of technology’s critical role in protecting workers and travelers. This year’s theme, “Respect the zone so we all get home,” highlights our shared responsibility to prioritize safety in every aspect of infrastructure development. Let’s commit to supporting work zone safety and building a transportation network where everyone gets home safely. 

Sources

1. Wu, D., Zheng, A., Yu, W., et al. (2025). Digital Twin Technology in Transportation Infrastructure: A Comprehensive Survey of Current Applications, Challenges, and Future Directions. Appl. Sci., 15(1911). https://doi.org/10.3390/app15041911
2. Manandhar, B., Dunkel Vance, K., Rawat, D.B., Yilmaz, N. (2025). Leveraging Digital Twin Technology for Sustainable and Efficient Public Transportation. Appl. Sci., 15(2942). https://doi.org/10.3390/app15062942
3. Transverse Rumble Strips: Another Tool for Rural Road Safety
   https://mntransportationresearch.org/2020/04/29/transverse-rumble-strips-another-tool-for-rural-road-safety/
4. Rumble Strips vs. Mumble Strips: Noise Comparison
   https://mntransportationresearch.org/2014/06/10/rumble-strips-vs-mumble-strips-noise-comparison-video/
5. The Joint Solution (n.d)
   Discoveries on Low-Noise Rumble Strips
   https://thejointsolution.com/discoveries-on-low-noise-rumble-strips/