Adopting zero emission heavy-duty vehicles (HDVs) has the potential to significantly reduce your fleet's emissions

Zero emission heavy-duty vehicles (HDVs) are still at an early stage of development. As with lighter vehicles, plug-in hybrid electric vehicles (PHEVs) and other alternatively fuelled vehicles can act as transitional technologies for fleets moving from internal combustion engine (ICE) vehicles to zero emission vehicles (ZEVs). Manufacturers are currently developing a range of zero emission HDV solutions.

One of the main challenges associated with battery electric HDVs is the size of the battery required. Due to the weight and energy demands of these vehicles, large batteries are often needed. Larger batteries take up space, increase vehicle weight and may require higher-powered charging infrastructure.

Catenary charging, which allows vehicles to charge via overhead cables while driving, is being investigated as a potential large-scale solution (Catapult, 2021). However, the technology is not yet widely available or suitable for large-scale deployment. In the short term, we recommend focusing on the procurement and deployment of battery electric or fuel cell electric HDVs where operationally appropriate.

Our recommendations

Fleet managers should assess whether any existing heavy-duty vehicles (HDVs) can be replaced with zero emission vehicles (ZEVs) using currently available technology. A range of zero emission HDVs are already in operation, including battery electric buses and smaller goods vehicles. Many of these are now being manufactured at scale and introduced into fleets across the UK. Larger battery electric and hydrogen-powered lorries are also being trialled in a range of operational settings.

Vehicles that undertake short, predictable routes are often the most suitable candidates for battery electric replacement. Battery weight can limit vehicle range, making battery electric HDVs particularly well suited to urban and regional operations. These vehicles are also likely to operate in areas where lower noise levels and reduced air pollution can deliver additional environmental and public health benefits. As the market for zero emission HDVs continues to develop rapidly, organisations should regularly review emerging vehicle options and consider participating in relevant demonstration projects and trials.

Zero emission HDVs can offer lower running costs than their internal combustion engine (ICE) equivalents due to reduced fuel, servicing, maintenance and repair costs. As a result, payback periods can be relatively short. One study found that battery electric trucks could achieve parity with diesel vehicles on a total cost of ownership basis within five years (Earl et al., 2018).

The Scottish Government has set a target for public sector fleets to stop adding new ICE vehicles from 2030, including HDVs. Public sector organisations should take this into account when planning future vehicle procurement. We recommend beginning the transition planning process as early as possible to avoid unnecessary long-term reliance on high-emitting vehicles and to ensure fleets are prepared for future requirements.

Pricing

The upfront cost of zero emission heavy-duty vehicles (HDVs) remains relatively high. This is due to the current maturity of the market, lower production volumes and the cost of large battery packs. However, procurement decisions should consider the total cost of ownership rather than purchase price alone.

HDVs typically have longer operational lifecycles than smaller vehicle types. Operators can benefit from lower running costs, as electricity is often cheaper than diesel and service, maintenance and repair requirements are generally reduced.

Zero emission HDVs are expected to remain in service for at least 10 years and potentially longer if batteries are replaced as they reach the end of their useful life. As a result, these vehicles can often have a lower total cost of ownership over their lifetime than equivalent diesel vehicles.

HDV pricing varies considerably. This is partly because chassis and bodywork are often procured separately, creating a high degree of vehicle customisation. There is also uncertainty around the development of the zero emission HDV market due to the evolving nature of the technology and the relatively limited number of models currently available. Pricing is expected to become clearer as more vehicles enter service and larger-scale deployments take place.

The table below provides indicative prices for battery electric HDVs based on market analysis, discussions with manufacturers and indicative quotations. Robust pricing data for fuel cell HDVs is not yet widely available and is therefore not included. These figures should be used as a starting point for financial planning, as actual vehicle costs may vary.