Electric heavy goods vehicles (HGVs) currently weigh two to three tonnes more than their diesel equivalents. This added weight comes from the heavy battery packs needed for commercial-range electric trucks. Associated Asphalt warns that this increase could place unprecedented strain on the UK’s road network, which is already under pressure.
Weight increase affects road wear
Electric HGVs’ extra mass results in higher axle loads. This accelerates structural damage to carriageways across local and national roads. Damage includes rutting, potholes and quicker material degradation. The UK’s roads may face intensified maintenance demands if the transition to electrification is not carefully managed.
Lessons from the US
Research from New York points to the infrastructure impact of heavier electric trucks. Studies estimate that heavier electric HGVs could increase annual road and bridge repair costs by up to 12% by 2050. While the UK’s zero-emission HGV adoption is at an early stage, it has grown sharply, with registrations rising by 170.5% in 2025 to more than 1,000 vehicles.
Government policy and industry readiness
The UK government commits to banning sales of new non-zero emission HGVs up to 26 tonnes from 2035. All new HGVs must be zero-emission from 2040. Associated Asphalt highlights the challenge this poses, urging government and industry to plan for the infrastructure impacts ahead of time.
Dr Paul Phillips, Technical Director at Associated Asphalt, said: "The weight of electric HGVs is not to be overlooked. The cumulative effects of heavier vehicles and increasing traffic are already accelerating road deterioration. If electric HGV uptake accelerates, this damage could rise exponentially, putting unprecedented strain on the network."
Preparing UK roads for heavier vehicles
To address these challenges, Associated Asphalt recommends a coordinated strategy between government and industry. This would include reviewing vehicle weights, axle loads and road construction standards. Infrastructure investment schedules must also align with the pace of electrification.
Dr Phillips added: "The transition to zero-emission HGVs is essential, but we must ensure the underlying infrastructure supports it. Luckily, this shift is still in its early stages, so there is time for proactive measures. Understanding the impact of heavier vehicles will help us keep the road network resilient for the demands ahead."
Without such cooperation, the combined effects of heavier electric HGVs and increasing traffic could worsen the condition of UK roads, raising maintenance costs and affecting road user safety and experience.
