6/16/2025 McCall Macomber
Written by McCall Macomber
Commercial electric trucks promise to bring cost savings from lower fuel consumption as well as environmental benefits. But how may their heavier loads impact pavement?
Illinois Center for Transportation and Illinois Department of Transportation explore this answer in the joint project, “R27-252: Impact of Heavy Commercial Electric Vehicles on Flexible Pavements.”
John Senger, IDOT’s bureau chief of research, leads the project along with civil engineering researchers Angeli Jayme, Jaime Hernandez and Imad Al-Qadi.
The group aimed to quantify the impact of commercial e-trucks on Illinois pavements, which are expected to have larger, heavier batteries and more torque, increasing damage to pavement.
“Like any technology, it became a question of if we have the new technologies that we’re supposed to serve on our roadways, what do we do?” said Jayme, ICT research scientist and current Arizona State University assistant professor.
“Are there aspects that we need to change in how we design pavements, how we analyze pavements or how we even think of the longevity of those pavements in terms of how we do rehabilitation and maintenance?” she added.
When evaluating how commercial e-truck loads may impact pavement, several variables need consideration, particularly pavement configuration and battery placement, which manufacturers are still designing how to optimize with a truck’s load.
The researchers considered three potential battery placements and various acceleration levels on four pavement structures in Illinois likely to experience commercial e-trucks.
Key to their approach is their use of advanced numerical modeling to simulate how the four pavement structures will behave when experiencing various loads from e-trucks compared to a typical semitruck.
The models highlighted that transportation agencies may need to adjust design strategies and rehabilitation schedules to reduce deterioration from commercial e-trucks, particularly those for surface layers, which may face increased shear strains.
They proposed recommendations for IDOT’s pavement design, including an adjustment metric for e-trucks that enables a full-truck comparison of conventional and electric semitrucks.
“It was very important that we translate all those advanced models into something tangible,” said Hernandez, assistant professor at Marquette University. “That’s why we fit the results inside the design methodology that IDOT currently has.”
Another key aspect of the work involves evaluating long-term impacts on pavements throughout the entire life cycle — from material production to end of life.
They evaluated anticipated environmental and economic impacts as use of the technology increases through life cycle assessment and life cycle cost analysis, respectively.
“Due to the current truck battery weight, a detailed life cycle cost analysis and environmental assessment were needed,” said Al-Qadi, ICT director and Grainger Distinguished Chair in Engineering.
“Our team found that e-trucks will need 18% more trips to move the same amount of goods, putting strain on our roads, so we suggested new surface materials and maintenance strategies to ensure energy and cost savings from using e-trucks are realized,” he added.
Al-Qadi credits the work of the project team, which involved collaboration between industry, IDOT and academia, as well as graduate students Johann Cardenas, Murryam Hafeez and William Villamil for contributing to the success of the project and helping IDOT get ahead of future challenges.
As more electric vehicles are hitting roadways, IDOT has the tools ready to update their pavement design for commercial e-trucks and are better prepared for any maintenance or rehabilitation needs.
“Even as people’s personal vehicles become more and more electric, we’re going to see issues within our transportation networks,” Senger said. “Everybody’s going to quickly become aware of the issues that this project is highlighting and addressing.”
“IDOT is getting ahead of the curve in order to be able to adjust for the potential negative impacts of the additional weight and torque capabilities of these vehicles,” he said. “That way we can still provide a safe and reliable transportation system for the public.”