EVAI, a provider of AI-powered data analytics for fleet operations, released findings from a new industry survey showing that fleet managers continue to face barriers in using advanced data to guide electric vehicle (EV) adoption and total cost of ownership (TCO) tracking.

The March 2025 online survey of more than 2,500 fleet executives highlights key frustrations around high upfront costs, infrastructure concerns, and the lack of real-time tools needed to confidently convert from internal combustion engine (ICE) vehicles to EVs.

Most Fleets Have 50+ Vehicles and Are Just Starting Their EV Transition

Fleet size remains large across respondents, with many only partially through the EV adoption process or still weighing their options.

• 41% manage fleets with 51-100 vehicles

• 39% oversee fleets with more than 100 vehicles

• 41% have partially transitioned to EVs

• 40% are still exploring EV options

Cost, Infrastructure, and Resale Concerns Are Keeping Fleets on the Fence

Despite interest, the same top barriers continue to stall EV plans across all fleet sizes.

• High upfront vehicle costs (20%)

• Charging infrastructure concerns (20%)

• Uncertain resale value (20%)

Operational Savings and ESG Goals Are Leading the Push to Electrify

Fleet managers see financial and environmental benefits but need help justifying the switch.

• Lower operational costs (20%)

• Sustainability and ESG goals (20%)

• Government incentives (20%)

Many Fleets Want to Track TCO But Lack the Right Tools to Do It

A near-even split reveals some fleets are ahead with TCO tracking, while others still lack the systems to monitor it effectively.

• 41% rigorously track TCO

• 40% need better tools to track it

• Most important TCO cost factors: vehicle purchase price (29%) and charging infrastructure costs (21%)

Long-Term Savings Are Top of Mind, But Fleets Still Need Hard Numbers

Most fleet leaders are focused on the long game but lack of predictive data holds back investment.

• 70% consider long-term operational savings when evaluating EV investments

Fuel Efficiency and Maintenance Costs Are the KPIs That Matter Most

When evaluating EV fleet performance, energy and maintenance metrics lead the way.

• Top KPIs: fuel/energy efficiency (21%) and maintenance costs (21%)

Real-Time Insights Could Speed Up EV Adoption for Many Fleets

If better data tools were available, a significant number of fleet managers would move more quickly toward electrification.

• 41% are very likely to accelerate EV adoption if real-time TCO tools are available

Fleets Are Asking for Better Comparisons and Battery Analytics

To make informed decisions, managers want more transparency on EV costs and battery performance over time.

• Most-needed data: EV vs. ICE cost comparisons (41%) and predictive battery analytics (39%)

The Bottom Line

Fleet managers remain committed to electrification, but say the lack of accessible, real-time data makes it hard to build a strong business case. Concerns about return on investment and operational disruption persist, especially without tools that provide visibility into long-term costs and performance.

“Fleet managers are clearly committed to electrification, but they need better tools and insights to move forward confidently,” said Ian Gardner, founder and CEO of EVAI. “Our goal is to give them the advanced analytics they need to make informed decisions, select the right EV and charging solutions, and manage that ecosystem to deliver the promised ROI.”

About 61% of survey respondents said access to real-time data would directly help them optimize fleet operations, further underscoring the need for purpose-built tools to support EV transitions.