Truck charging infrastructure cost in Germany - by infrAi GmbH (Author: Mathias Schmidt)
assuming 100% truck electrification
infrastructure data provided by: 123map GmbH
truck traffic data used: Daniel Speth et al. (Fraunhofer ISI)
No liability is assumed for the accuracy of the data, calculations, or representations
Loading edges…
Parking site
Edge
Algorithm and calculations

Executive logic

The tool estimates the annual charging infrastructure required on each German or cross-border road edge. The model translates road freight activity into edge-level charging demand, splits that demand into a depot channel and a public channel, and then builds concrete charging capacity in each channel independently. Costs are calculated bottom-up for every electrified site and then aggregated by edge and for the full network.

The central interpretation is that most heavy-truck charging happens at private depots and logistics halls, and a smaller share happens at public parking sites along the corridor. The tool sets this split explicitly through the depot share, adds a separate provisioning buffer to each channel, and then fills each channel greedily until its buffered target is met.

1. Edge charging demand

For every edge e, charging demand is derived from annual truck traffic, edge length and the usable driving range within the selected SoC window.

B = Truck range × Consumption
Usable range = Truck range × (Charging end SoC − Charging start SoC)
Demand_e = Traffic_2030,e × Edge length_e / Usable range

Demand_e is the annual number of equivalent truck charging events caused by the freight activity on edge e. The model assumes 100% BEV truck traffic.

2. Charger performance and annual site capacity

For each charger type, the charging time is calculated over the selected SoC window. Up to 80% SoC, power is constant. Above 80%, the charging curve tapers exponentially.

P_i(s) = kW_i, if s ≤ 0.8
P_i(s) = kW_i × exp(−8 × (s − 0.8)), if s > 0.8
Charging time_i = ∫ from SoC_start to SoC_end B / P_i(s) ds

The charger mix is interpreted as a count-weighted mix of physical chargers. Charger costs are averaged by charger shares. Charger capacity is not derived by dividing operating time by the average charging time; instead, it uses the share-weighted average of charger rates. This keeps the representative charger consistent with the installed average power of the selected charger mix.

Charging rate_i = 1 / Charging time_i
Average charging time_parking = Σ_i Parking share_i × Charging time_i  (for display only)
Average charger cost_parking = Σ_i Parking share_i × Charger cost_i
Average charger rate_parking = Σ_i Parking share_i × Charging rate_i
Average charging time_logistics = Σ_i Logistics share_i × Charging time_i  (for display only)
Average charger cost_logistics = Σ_i Logistics share_i × Charger cost_i

For parking sites, annual capacity per built charger follows from operating time, charger utilization, operating days and the average charger rate of the count-weighted parking mix.

Trucks per parking charger per year = 24 × Charger utilization × Average charger rate_parking × Operating days / year

3. Demand split into depot and public channels

Edge demand is divided into a depot channel served by logistics halls and a public channel served by parking sites, using the selected Depot share of demand. Each channel receives its own buffer factor, so the built capacity target can exceed the pure demand share to allow for provisioning reserve.

Depot target_e = Demand_e × Depot share of demand × Depot buffer factor
Public target_e = Demand_e × (1 − Depot share of demand) × Public buffer factor

The public buffer factor defaults to 1.0 and the depot buffer factor to 1.15, so the depot channel carries a small provisioning reserve while the public split stays at pure demand. Note that the public side already carries a temporal reserve through the parking Charger utilization (installed power is 1/utilization times the daily average), so a public buffer well above 1.0 would double-count the arrival peak.

4. Depot channel: largest logistics halls first

Only halls above Minimum hall size are eligible. On each edge, eligible halls are sorted by hall area in descending order and electrified in that order until the depot target is met. In a fully electrified truck fleet every dock of a selected hall is a charging dock, so all docks of a selected hall are electrified. The last hall required to reach the target electrifies only as many docks as needed, so the actual electrified-dock share of that hall is an output of the model, not an input.

Docks_h = Hall area_h / 1,000 × Docks / 1,000 m² hall
Logistics capacity_h = Electrified docks_h × Dockings / dock / day × Operating days / year
Depot capacity_e = Σ_h Logistics capacity_h (halls added, largest first, until Depot target_e is reached)

If the eligible halls on an edge cannot cover the depot target, the remaining shortfall is carried over to the public channel. The public channel does not carry back to the depot channel.

Public target_e ← Public target_e + max(0, Depot target_e − Depot capacity_e)

5. Public channel: cheapest parking sites first

Parking sites are processed edge by edge. Within one edge, sites are sorted by full-build cost per charger and electrified in that order until the public target is reached, including any depot shortfall carried over. The final required site may be only partially electrified.

Maximum parking chargers_p = max(1, round(Parking area_p / 1,000 × Truck spaces / 1,000 m²))
Substations_p = ceil(Built chargers_p / Chargers per substation)
Full-build cost per charger_p = (Cable distance_p × Cable cost + Substations_p × Substation cost + Maximum parking chargers_p × (Average charger cost_parking + BESS / substation ÷ Chargers per substation)) / Maximum parking chargers_p
Built chargers_p = min(Maximum parking chargers_p, ceil(Remaining public target_e / Trucks per parking charger per year))
Public capacity_e = Σ_p Built chargers_p × Trucks per parking charger per year

6. Cost calculation

Each electrified parking site and logistics hall receives the same cost categories: grid connection, substations, chargers and BESS. Parking sites use the parking charger mix; logistics halls use the logistics charger mix.

Grid connection cost_site = Nearest substation distance_site × Cable cost
Substation cost_site = ceil(Built chargers_site / Chargers per substation) × Substation cost
Charger cost_site = Built chargers_site × Average charger cost
BESS cost_site = Built chargers_site × (BESS / substation ÷ Chargers per substation)
Total cost_site = Grid connection cost_site + Substation cost_site + Charger cost_site + BESS cost_site
Edge total_e = Σ_parking sites Total cost_p + Σ_logistics halls Total cost_h
Edge total / km_e = Edge total_e / Edge length_e

7. Edge and network outputs

Coverage is intentionally not capped at 100%. Some edges can exceed the original edge demand because logistics halls and parking sites may jointly supply more than the base demand. This is relevant when comparing the spatial distribution of infrastructure costs.

Total supplied_e = Logistics capacity_e + Parking capacity_e
Coverage_e = Total supplied_e / Demand_e
Network cost = Σ_e Edge total_e + Virtual fallback cost

8. Virtual fallback and residual top-up

The virtual fallback prices demand that the concrete infrastructure does not place on identified sites. It has two roles. First, an eligible edge with no concrete parking site or logistics hall is covered entirely by the fallback. Second, on edges where the concrete depot and public channels together fall short of demand (because the available halls and parking sites on that edge are exhausted), the remaining residual demand is topped up by the fallback. Both use the average cost per supplied truck of the concrete buildout, so total demand coverage reaches 100% by construction. This is not a physical site decision; it is a residual cost estimate.

Average cost per supplied truck = Total concrete site cost / Total concrete supplied capacity
Residual_e = max(0, Demand_e − Depot capacity_e − Public capacity_e)
Virtual fallback cost_e = Residual_e × Average cost per supplied truck

9. Dynamic charging comparison

The dynamic charging comparison evaluates the selected ERS / dynamic charging cost per kilometre against the static charging cost of each edge. For every edge, the least-cost hybrid output selects the cheaper technology.

Dynamic cost_e = Dynamic charging cost per km × Edge length_e
Cost achievable with optimal charging solution per edge = Σ_e min(Static charging cost_e, Dynamic cost_e)
Savings vs static-only = 1 − Optimal per-edge charging solution cost / Static-only network cost