Electric vehicles (EVs) are typically heavier than traditional internal combustion engine (ICE) vehicles, raising concerns about the adaptability of road infrastructure.
As countries around the world, including New Zealand, strive for a greener future, it is crucial for engineers and policymakers to understand how this transition affects roads and infrastructure and to develop proactive solutions.
On average, electric cars weigh about 300 kilograms more than their gasoline-powered counterparts, largely due to their batteries.
A study by the University of Leeds found that the average EV generates approximately 2.24 times more stress on road surfaces than a comparable gasoline vehicle.
While major highways are designed to withstand heavy loads such as trucks, residential and rural roads are more vulnerable. These roads are typically thinner and less robust, making them more susceptible to potholes and structural damage as EV adoption increases.
How EVs are impacting road infrastructure
According to the article “Heavy EVs, light roads: Rethinking road infrastructure for a greener future” by WSP, the effects of heavier vehicles, particularly electric buses, are already visible.
In Wellington, road rutting has been observed at bus stops and in areas with frequent acceleration and braking. These early signs emphasize the need for urban planners and infrastructure managers to update current design standards to enhance road durability as the use of electric vehicles (EVs) increases.
In addition to roads, bridges, and tunnels may also face increased strain. In the United Kingdom, many structures were originally designed to accommodate heavy 44-ton trucks.
However, aging infrastructure, especially structures with stressed concrete and steel, requires ongoing monitoring and, in some cases, reinforcement to handle evolving load demands, including those from heavier EVs.
Designing infrastructure for a heavier future
Adapting infrastructure to support heavier vehicles presents financial, technical, and environmental challenges.
Transitioning from asphalt to more durable materials such as high-strength concrete and reinforcing roads, bridges, and parking facilities with steel can be costly and carbon-intensive.
Britpave, a UK concrete paving association, recommends using high-strength concrete pavements as an alternative to traditional asphalt. Concrete’s rigidity allows it to distribute vehicle weight more effectively, reducing deformation and extending road life.
While concrete has a higher upfront carbon footprint, its durability, often lasting up to 50 years, can result in lower maintenance needs and reduced lifecycle emissions.
Meanwhile, asphalt producers are developing stronger, more heat-resistant mixes to improve performance under increased stress. Advances in EV battery technology are also helping reduce vehicle weight without compromising energy capacity, which could lessen long-term infrastructure impacts.
Balancing sustainability and infrastructure resilience
Policy also plays a key role in shaping outcomes. Governments can encourage the adoption of smaller and lighter EVs through incentives such as tax breaks or regulatory measures. At the same time, infrastructure investments must align with broader sustainability goals.
As the transition to electric vehicles accelerates, engineers and policymakers must strike a careful balance.
Supporting EV adoption while minimizing infrastructure damage and carbon emissions will require coordinated planning, innovation, and long-term investment.
Sources:
Heavy EVs, light roads: Rethinking road infrastructure for a greener future. (2025, October 7). WSP. Retrieved from https://www.wsp.com/en-nz/insights/heavy-evs-light-roads
Can Our Road Infrastructure Handle Heavier Electric Vehicles. (2025, May 3). Highways Today. Retrieved from https://highways.today/2025/05/03/road-infrastructure-electric-vehicles/
Concrete roads needed to counteract damaging impact of electric vehicles. (2023, June 27). Britpave. Retrieved from https://www.britpave.org.uk/news/Concrete-roads-needed-to-counteract-damaging-impact-of-electric-vehicles/131764
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