Record Chinese EV exports constrain capacity

The switch to electric vehicles is reshaping breakbulk logistics through changing trade flows and the risks involved in transporting vehicles powered by large lithium-ion batteries compared to internal combustion engines. According to the International Energy Agency (IEA), global EV sales are expected to reach 23 million in 2026, or 30% of all cars sold worldwide. Electric models accounted for nearly one in 10 trucks sold worldwide in 2026. Moving electric vehicles by sea and land requires specialised handling, stronger safety measures and compliance with changing regulations. While rare, lithium-ion battery fires are difficult to extinguish. Carriers are investing heavily in ro-ro vessels equipped with enhanced fire suppression systems, climate-controlled storage and onboard battery charging capabilities. Carriers also have to manage capacity more closely due to the heavier vehicle profiles. An electric hatchback weighs up to 400 kg more than a petrol equivalent, and an electric SUV up to 500 kg more. There is also a major shift in supply lines. Chinese automakers supplied 60% of electric cars sold worldwide, while European and North American automakers were each responsible for about 15% of global sales. Chinese electric car exports doubled to a record high of more than 2.5m. This growth is continuing through 2026, causing bottlenecks due to capacity constraints. In response, Chinese electric vehicle assembler BYD is investing in its own fleet of pure car and truck carriers. Shippers are also using standard shipping containers to move EVs to Europe and other regions. The market is fluid. In response to the imposition of protective trade tariffs in markets such as the United States, European Union, Türkiye and Mexico, Chinese EV companies are building assembly plants in high-demand countries. This involves logistics demands from international ocean shipping to local supply chain routing. Landside logistics is also affected, with ports and distribution hubs investing in charging points. EV battery packs add significant weight to finished vehicles. That can affect trailer capacity, axle weight distribution, equipment selection and routing. A road or rail carrier that handles conventional vehicles may not have the right equipment to manage EVs at scale. Factors that need to be considered include the vehicle state of charge, vehicle mass, fire safety protocols, secure parking and storage, and inspection of both the battery and vehicle at origin and destination. Another impact, according to PWC, is that there is a steady decline in the volumes of components shipped by automotive manufacturers as electric vehicles require a fraction of the parts needed for an internal combustion-driven vehicle. ER