Rethinking off-highway vehicle fleet electrification

The adoption of EV vehicles in the construction industry is not without debate. But it does represent a genuine opportunity. In this article, Michael Simpson from Trelleborg AVS explains the key challenges and advantages surrounding the technology and its successful implementation.

Although not yet universally accepted, the electrification of off-highway vehicles is no longer a distant ambition – it’s happening right now. With sustainability goals and regulatory pressures mounting, many construction and heavy equipment manufacturers are making the switch from internal combustion engines (ICE) to electric powertrains, in pursuit of zero-emission construction. In fact, the off-highway electric vehicle market is set to grow from $2.24 billion in 2023 to $8.36 billion by 2033.

But this seismic shift isn’t without its challenges.

Vehicle fleet electrification brings a unique set of engineering, operational and infrastructure-based hurdles you need to address if you’re to adopt the technology successfully.

The fundamental challenges of vehicle fleet electrification

For decades, off-highway vehicles have been designed around the mechanical demands of diesel engines. The transition to electric power fundamentally alters everything from powertrain architecture to weight distribution and durability. Within that, the most pressing concerns include battery performance, vibration management and infrastructure limitations.

Vibration – still a key consideration

One of the biggest misconceptions in off-highway vehicle fleet electrification is that EVs experience no vibrations because they lack the intense mechanical forces of ICEs. Research shows that although off-highway ICEs and EVs function in very different ways, their powertrains and other equipment operating speeds are quite similar, at around 0-7,000 RPM.*[AW1] 

The speed at which an EM rotates is governed by the electrical frequency and signal supplied from the energy storage. Converters and inverters switch the current type from AC to DC, and vice versa. This process of inverting and converting has an unwanted byproduct – structural vibration.
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And it’s not only vibration that’s an issue. EVs also introduce new high-frequency ‘excitations’, emitting hums and noises ranging from 500 Hz to 15 kHz, that interact differently with the vehicle chassis and components, creating new structure-borne noise (SBN) challenges.

Battery packs, which represent the heaviest and most expensive single component of an EV, are particularly vulnerable to fatigue from structural vibration and high-frequency noise. Unlike ICE systems, where the entire drivetrain helps distribute vibrational energy, EVs concentrate forces within rigid enclosures, making them more susceptible to damage and degradation.
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It's no surprise then, that poorly mounted battery systems deteriorate faster, leading to efficiency losses and increased maintenance costs over time.
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Fixing the issue of weight and structural load in EV design

Battery packs not only introduce new vibration challenges but also significantly increase vehicle weight. Unlike an ICE, which has a centralized engine mass, EV batteries are often distributed across the vehicle chassis to optimize weight balance.

However, this distribution can create challenges in suspension design, load-bearing stress and rollover risk. Without proper engineering, the additional weight can lead to premature component wear and structural fatigue.
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Innovative battery mounting solutions help mitigate these risks. By integrating high-performance anti-vibration mounts, manufacturers can improve weight distribution, enhance vehicle stability and extend battery lifespan. At Trelleborg, we’ve engineered solutions that absorb shock loads while maintaining the necessary rigidity to keep battery packs secure. So you’re taking all the necessary steps to protect the battery (the most expensive element of the EV setup), while also having a positive impact on vehicle longevity and operator safety.

The infrastructure dilemma: charging and site adaptation

In any conversation about off-highway EVs, one topic is always raised – charging infrastructure. And this remains one of the greatest barriers to adoption. Unlike on-road fleets that can rely on urban charging networks, construction often takes place in remote locations where grid connectivity is limited. For fleet operators, this raises concerns about downtime and logistical feasibility.
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Solutions are emerging, from on-site battery swapping to solar-powered mobile charging stations, but we’re not there yet. The key for OEMs is to design vehicles with adaptable charging strategies, ensuring compatibility with multiple energy sources, fast-charging capabilities and modular battery systems.
 

What puts EVs ahead?

Despite these challenges, the benefits of off-highway EVs outweigh the drawbacks, particularly if they’re equipped with the right anti-vibration solutions. The misconception that ICE vehicles are more cost-effective in the long run is steadily being dismantled by real-world data. Here’s why:

Lower total cost of ownership (TCO)

While the initial capital cost of an EV may be higher, the long-term financial benefits quickly become clear:

• No fuel costs – electricity is more stable and predictable in price than diesel
• Fewer moving parts – electric motors require significantly less maintenance than diesel engines
• Reduced downtime – properly mounted battery systems experience less wear and tear, minimizing costly repairs

Instant torque and performance advantages

One of the most overlooked benefits of electric construction equipment is instant torque delivery. Unlike ICE vehicles that require RPM build-up, electric motors provide immediate power, improving precision, efficiency and productivity in demanding environments. This is particularly valuable in industries like construction, where rapid response times and high torque loads are crucial.

Regulatory compliance and sustainability

Governments worldwide are tightening emissions regulations, and diesel bans are already on the horizon in certain regions. Companies that invest in electrification today will avoid costly retrofitting and regulatory penalties tomorrow. Beyond compliance, the sustainability impact of zero-emission construction equipment is a significant competitive differentiator, with many project bids and contracts increasingly favoring companies that have made ‘green’ commitments.

Operator comfort and safety

The switch from diesel engines to EVs isn’t just about performance; it’s also about the people who operate these machines every day. ICE-powered equipment is notorious for its noise, vibration and harshness levels, which contribute to operator fatigue, errors and long-term health issues. Properly designed EVs, equipped with anti-vibration mounts, cab isolators and battery damping solutions, create a quieter, smoother and safer working environment.

The role of anti-vibration solutions in the future of off-highway EVs

While the industry is still debating the speed of electrification adoption, one thing is clear: OEMs that prioritize advanced anti-vibration solutions will lead the market. The adoption of high-performance battery mounts, electric motor isolators and cab suspension systems will directly impact:

• EV longevity and reliability – preventing early component failure due to unmanaged vibrations
• Operator productivity and safety – reducing workplace fatigue and increasing precision
• TCO advantages – delivering higher efficiency, lower maintenance costs and greater operational uptime

Investing in the right technology matters

The shift to electrification in the off-highway sector isn’t just about swapping engines for batteries. It’s about rethinking vehicle design, optimizing performance and ensuring that every component – from battery packs to operator cabs – is built for long-term success. Vibrations, weight distribution and infrastructure constraints are challenges that can be solved with the right engineering mindset and the right partners.
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At Trelleborg, we’re committed to helping you navigate this transition with innovative anti-vibration solutions that maximize EV performance and durability. As electrification accelerates, the companies that invest in best-in-class engineering solutions now are likely to be the industry leaders long into the future.

^{* Dependent on use case and connected gearboxes}