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Electric Vehicles

Electric trucks and the freight problem

Heavy freight is where battery mass, charging power and duty cycles all bite hardest, and where the answer differs sharply by route length.

Close-up view of a car dashboard featuring a ParkPilot parking assist display.
Close-up view of a car dashboard featuring a ParkPilot parking assist display. · Photo via Pexels

Road freight accounts for a large share of transport emissions and a disproportionate share of the difficulty, because the physics scales badly.

Why heavy vehicles are harder

Energy consumption scales with mass, so a forty-tonne vehicle consumes several times what a car does per kilometre.

Delivering long range therefore requires a very large battery, which is heavy, which reduces payload, which is the entire commercial purpose of the vehicle.

Several jurisdictions have granted weight allowances for zero-emission trucks specifically to offset battery mass, which helps and does not eliminate the trade.

Charging power is the other problem. Recharging a pack of that size in a legally mandated driver rest break requires power levels well beyond car fast charging — which is why megawatt charging standards have been developed and are beginning to be deployed.

The segments behave differently

Treating freight as one market is the main analytical error.

Urban delivery. Already commercially sensible in many cases.

Predictable daily routes, depot returns, moderate distances, and substantial stop-start operation where regenerative braking helps considerably.

Diesel is at its least efficient here and electric at its most. Fleet operators report favourable economics and, importantly, lower noise, which permits night deliveries in restricted areas.

Regional distribution. Routes of a few hundred kilometres returning to a depot. Feasible with current battery sizes and depot charging.

Long-haul. The hard case.

Long distances, drivers on tight schedules, unpredictable routes, and no depot at the far end. This is where the argument about batteries versus hydrogen versus catenary actually lives.

The competing approaches for long-haul

Battery with megawatt charging. Charge during the mandated rest break.

Driver hours regulations require breaks after a set driving period, which conveniently provides charging windows. If a truck can take enough energy in forty-five minutes to continue, the duty cycle works.

The obstacles are the charging infrastructure — very high power at truck stops requires substantial grid connections — and the battery mass.

Hydrogen fuel cell. Faster refuelling and lower vehicle mass for a given range.

The obstacles are the round-trip energy efficiency, which is poor relative to battery, and the near-total absence of refuelling infrastructure.

Several manufacturers that invested heavily have scaled back, and the segment has consolidated toward battery for most applications.

Overhead catenary. Electrified motorway lanes with pantographs on trucks, as trams and trains use.

Extremely efficient — no storage losses, small onboard battery for the last miles — and requires enormous infrastructure investment along specific corridors.

Trial installations exist in a few countries. It is the option with the best physics and the worst politics.

The infrastructure arithmetic

A truck stop serving several charging trucks simultaneously at megawatt power requires a grid connection comparable to a small town.

Which means the deployment problem is not building chargers but building the electrical supply to sites along freight corridors, in exactly the places where the network is weakest.

On-site battery buffering helps, and coordinated corridor planning between grid operators, hauliers and charging providers is what actually determines the pace.

Total cost of ownership for operators

Different from private buyers, and generally more favourable to electrification.

Hauliers operate on thin margins and high utilisation, which means fuel and maintenance dominate and purchase price is amortised across enormous mileage.

Electricity at commercial depot rates is substantially cheaper per kilometre than diesel in most markets, and maintenance savings on a high-mileage vehicle are large.

Against that: higher purchase price, uncertain residual values, and the risk that charging is unavailable when needed — which for a haulier is a revenue loss rather than an inconvenience.

Which is why fleets electrify predictable routes first and long-haul last, regardless of what the technology can theoretically do.

What is actually happening

Urban and regional electrification is proceeding commercially without needing to be argued for.

Long-haul is in pilot deployment, with real trucks on real routes and corridor charging being built in a small number of places.

The regulatory driver matters: several jurisdictions have set emissions standards for heavy vehicles that effectively require substantial zero-emission sales share within the decade, which is forcing investment ahead of the economics in some segments.

Whether that is good policy depends on whether the infrastructure arrives at the same time, which is currently the open question.

trucksfreightmegawatt charginglogistics
Ravi Shankaran
Editor, Muskeology

Ravi spent nine years as a powertrain engineer before turning to writing. He is unimpressed by anything that has only ever worked on a stage.

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