Charging Infrastructure Cost - by infrAi GmbH (Author: Mathias Schmidt)
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 first translates road freight activity into edge-level charging demand, then assigns concrete charging capacity in two steps: logistics halls first, public parking sites second. Costs are calculated bottom-up for every electrified site and then aggregated by edge and for the full network.

The central interpretation is: an edge does not need to be covered only by parking sites. Logistics halls can already supply part of the edge demand. Parking sites then fill the remaining target while always meeting the selected minimum parking contribution.

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 average charger is calculated separately for parking sites and logistics halls, using the selected charger shares in the charging configuration.

Average charging time_parking = Σ_i Parking share_i × Charging time_i
Average charger cost_parking = Σ_i Parking share_i × Charger cost_i
Average charging time_logistics = Σ_i Logistics share_i × Charging time_i
Average charger cost_logistics = Σ_i Logistics share_i × Charger cost_i

For parking sites, annual capacity per built charger follows directly from operating time, charger utilization and operating days.

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

3. Logistics halls are electrified first

Only halls above Minimum hall size are eligible. On each edge, eligible halls are sorted by hall area in descending order. The model electrifies only the selected Top halls per edge share.

Eligible halls_e = {h on edge e | Hall area_h ≥ Minimum hall size}
Selected halls_e = largest Top halls per edge share of Eligible halls_e

For every selected hall, the number of docks is estimated from hall area and the selected dock density. A selected share of those docks is electrified.

Docks_h = Hall area_h / 1,000 × Docks / 1,000 m² hall
Electrified docks_h = Docks_h × Electrified docks
Logistics capacity_h = Electrified docks_h × Dockings / dock / day × Operating days / year
Logistics capacity_e = Σ_h∈Selected halls_e Logistics capacity_h

4. Parking target after logistics capacity

After logistics halls have been considered, the model calculates how much charging capacity must still be supplied by parking sites. Two rules apply at the same time.

First, parking sites must provide at least the selected Minimum demand percentage covered of the original edge demand. This remains true even if logistics halls already exceed the edge demand. Second, the combined capacity from logistics halls and parking sites may target up to the selected Maximum edge demand supplied.

Minimum parking target_e = Demand_e × Minimum demand percentage covered
Total target_e = Demand_e × Maximum edge demand supplied
Parking target_e = max(0, Minimum parking target_e, Total target_e − Logistics capacity_e)

Example: if edge demand is 100, logistics halls provide 50, minimum parking coverage is 30%, and maximum edge demand supplied is 130%, then parking target is max(0, 30, 130 − 50) = 80. If logistics halls provide 120 instead, parking target is max(0, 30, 130 − 120) = 30.

5. Parking sites use the original V13 greedy logic

Parking sites are processed edge by edge. Within one edge, sites are sorted by full-build cost per charger. The model then electrifies sites in that order until the calculated parking target is reached. 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 parking target_e / Trucks per parking charger per year))
Parking 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 edges

If an eligible German or cross-border edge has no concrete parking site or logistics hall, the tool keeps a fallback estimate from V13. The fallback applies the average cost per supplied truck charging event from all concrete edges to the demand of the edge without concrete sites. 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
Virtual fallback cost_e = Demand_e × Average cost per supplied truck