How Long Do Electric Skid Steer Batteries Last?

A construction site is incomplete without the “Swiss Army Knife of the Job Site,” or in standard terms, the electric skid steer. It's a versatile machine that can do digging and grading, hauling, trenching, and even breaking concrete with the proper attachment.

Switching from the legacy diesel-powered skid steer can seem challenging, as site workers must transition from refueling to a recharging strategy. One of the key aspects to consider in electric vehicles is: how long electric skid steer batteries last, both per charge and over their lifetime?

This guide explains the key factors impacting battery longevity. We’ll cover:

• The types of batteries used in electric skid steers
• Run-time per charge under typical conditions
• The average lifespan of electric skid steer batteries
• Factors that affect battery performance
• Tips to maximize battery life
• How to know when it’s time for a replacement

We will use examples throughout the article to highlight the practicality of modern electric skid steer and how they are playing a critical role in site emission control. Let's begin!

I. Type of Batteries Used In Electric Skid Steers

It's essential to begin the article by establishing the necessary knowledge base on the types of batteries. It will help you understand how different battery types affect various aspects, such as charging, lifetime, and maintenance. Two main types of batteries are used in electric skid steers:

1.1 Lead-Acid Batteries (e.g., Flooded, Gel, AGM)

The first lead-acid battery was made in 1859. It's been around for more than a century. The technology is mature, with extensive feedback on its performance and precautions for longevity. Four main types of lead-acid batteries are still significantly utilized:

• Gel Lead-Acid: These batteries emerged with the first patent in 1934 and a more modern version in 1957.
• VRLA (Valve-Regulated Lead-Acid): These include AGM and Gel types, which were developed in the 1970s.
• AGM (Absorbed Glass Mat): Patented in 1972, experienced significant adoption from the mid-1980s onwards.
• EFB (Enhanced Flooded Batteries): A recent invention, with Exide inventing the first in 2008.

Lead-acid batteries are a vital part of diesel-powered skid steers, as they require a high initial current draw to start the engine. Modern electric skid steers often feature a single lead-acid battery to power the electronics and other support systems, as they are more affordable.

1.2 Lithium-Ion Batteries (e.g., LiFePO4, NMC)

The Lithium-ion battery revolutionized modern electronics, efficiently powering everything from smartwatches to electric skid steers. Diving deeper into these types is crucial to ensuring that, as a buyer, you understand which type offers the best battery backup and lifespan. Here is a list of Lithium-ion batteries:

• Lithium Iron Phosphate (LiFePO₄ or LFP)
• Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO₂ or NMC)
• Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO₂ or NCA)
• Lithium Manganese Oxide (LiMn₂O₄ or LMO)
• Lithium Titanate (Li₄Ti₅O₁₂ or LTO)

Each battery utilizes different manufacturing materials, resulting in distinct electrical properties.

The cathode (Positive Electrode), Anode (Negative Electrode), Electrolyte, Separator, and Current Collectors are all key components that affect battery performance and longevity. Let's compare some of these battery types head-to-head using a table:

1.3 Can We Change the Battery Type in Electric Skid Steers?

After you have an electric skid steer that comes with a pre-installed battery for powering the motor and electronics, switching to a different battery type requires careful consideration. The battery voltage should be the same for both battery types. The chargers are specifically designed to support the battery types they accommodate. Changing the battery also means changing the charger or adjusting it as per the new battery type. Changing the charging electronics incurs additional costs for the switch.

II. How Long Does a Battery Last on a Single Charge?

2.1 Factors Influencing Run-Time

The battery's lifespan depends on various factors. Studying these factors will provide insight into the amount of runtime to expect from a single charge.

2.1.1 Workload Intensity and Attachment Power Draw

The number of times the operator operates the lift, turns the electric skid steer, or accelerates and decelerates also affects the power draw from the battery. It can directly impact the battery backup. The load on the hydraulic system of the skid steer, whether it is lifting, tilting, digging, or pushing, affects the power draw. Moreover, the attachment types can also affect the battery backup.

2.1.2 Ambient Temperature Conditions

Cold temperatures below 0°C/32°F and hot temperatures above 30°C/86°F temperature can negatively impact the electric skid steer battery backup. When the temperature is low, it slows down the chemical reactions inside the battery, resulting in a reduction in capacity and power delivery. It also means that at low temperatures, the battery backup time will be reduced. In comparison, higher temperature causes permanent degradation, resulting in shorter lifespans.

2.1.3 Operator Efficiency and Driving Style

The way the operator utilizes the electric skid steer also determines the battery backup on a single charge. If the operator performs a high volume of reworks and has inefficient steering capabilities, the power draw will increase. Aggressive acceleration, hard braking, and improper load management demand high power peaks. Efficient operators utilize smooth movements, appropriate hydraulic pressure, and minimize unnecessary travel and idling.

2.1.4 Battery Type

The battery type also determines how long a battery lasts after a single charge. The key parameters that define it are Specific Energy (Wh/kg) (Typical Range) and Specific Power (W/kg). The specific energy is the amount of charge that the battery can hold per unit of weight. Higher specific energy means a smaller battery size and weight with higher power. In comparison, specific power means better acceleration, faster charging, and lift power. Analyze the particular energy and power of the battery type based on the requirement.

The most readily available battery type is LiFePO4, also known as LFP. It's mainly due to its affordability, availability, and backup characteristics.

2.2 Typical Run-Time Expectations

2.2.1 Average Operational Hours for Common Tasks

The average time spent working on a construction site (mainly in America and Canada), considering lunch breaks, is 9-10 hours a day, with a 30-minute to 1-hour lunch break, depending on project demands and local regulations. An electric skid steer is typically used intermittently during construction work. During working hours, a skid steer is usually engaged 50 to 70% of the time, which means somewhere between 4 and 5 hours. Therefore, an electric skid steer with an average run time of more than 4 hours is ideal for a typical construction site. Here are some tasks and their associated runtime for an electric skid steer:

*Note: These values are based on LFP battery technology and AILISHENG’s rated capacities across models like ALS3070EV to ALS3100EV.

2.2.2 Variances Based on Model and Application

For example, here are some electric skid steer models from the same manufacturer, each based on a different design. Observe the battery capacity and use case scenarios for each type:

III. Factors That Affect Battery Lifespan

3.1 Charge Cycles and Depth of Discharge

The depth of discharge is a fundamental concept to understand to comprehend battery lifespan based on battery cycle life. Depth of discharge is the energy extracted from the battery before it's recharged to 100%. Using battery power from 100% to 0% and then recharging from 0% to 100% means that one cycle is complete, and it's the maximum depth of discharge a user can practically achieve.

3.1.1 Understanding Battery Cycle Life

Battery cycle life refers to the number of times an electric skid steer battery can be fully charged and then fully discharged without losing its capacity. A charge cycle can also be completed by using a portion of the battery's capacity (e.g., 75%) one day and then using the remaining 25% on another day, as long as the total discharge equals 100% of the battery's capacity.

3.1.2 Impact of Frequent Deep Discharges

Frequent deep discharging your electric skid steer can lower its battery cycle life. The best way to avoid lower battery cycle life is to avoid going to low states of charge (e.g., below 20-30%). Similarly, very high charge states (above 80%) can also lead to an increase in depth of discharge and a decrease in battery cycle life.

3.2 Temperature Extremes (Hot and Cold)

• Effects of High Operating Temperatures: As mentioned earlier, higher temperatures are significant for chemical reactions that power your electric skid steer. However, high temperatures are detrimental to the material, as heat increases resistance, accelerates chemical degradation, and electrolytic decomposition. Operating a battery at 40°C (104°F) compared to 25°C (77°F) can, in some cases, halve its expected cycle life, meaning it will reach its 80% capacity threshold in significantly fewer cycles.

• Impact of Cold Weather Performance: Similarly, operating at lower temperatures or cold weather lithium plating is a significant concern. Its buildup at low temperatures can cause permanent damage to capacity and lead to dendrite formation, which can result in short-circuiting. Battery management systems avoid battery charging at low temperatures, e.g., <0°C/32°F.

3.3 Charging Habits

3.3.1 Risks of Overcharging and Undercharging

Overcharging and undercharging simply increase the depth of discharge, which eventually leads to a reduction in the available charge cycles.

3.3.2 Considerations for Fast Charging

Fast charging is great for on-site use, but it can impact the battery's lifespan. Charging at high current requires an infrastructure that can handle such a high level of power. Charging to 80% while monitoring battery health and ensuring charger and battery compatibility is key to effective and fast charging.

IV. Tips to Maximize Your Electric Skid Steer Battery Life

Now that we understand the factors that can reduce your battery cycles, we can develop a strategy to help maximize the battery life of an electric skid steer. These are easy to follow and do not disrupt actual site work:

• Daily Charging Levels: Always charge between 20% and 80% of the battery capacity, regardless of whether you use the fast charging or slow charging method. It will help prolong battery cycle life.
• Opportunity Charging: Just like charging docks for phones. It's ideal to charge electric skid steers during short breaks at work. Think of it as grabbing a quick bite to boost your energy levels.
• Temperature Monitoring: Avoid operating the electric skid steer in extreme temperature conditions. Let the battery monitoring system warm up the battery before charging or discharging. Similarly, avoid using the machine when high-temperature light is lit.
• Battery Storage: If your electric skid steer features a quick-connect, disconnect battery system. Then ensure that the batteries are stored within the recommended temperature ranges to avoid problems such as lithium plating, accelerated degradation, capacity loss, or self-discharge, as mentioned earlier.
• Regular Maintenance: To ensure the electric skid steer performs consistently, it's essential to check the battery health regularly. Ensure that the terminals of the batteries are clean. It involves monitoring the battery health on the BMS and physically inspecting the batteries.
• Software and Firmware Updates: Electric skid steers are equipped with electronics that monitor and control all parameters to ensure optimal performance. Regularly updating the software or firmware will lead to better stability of the skid steer.
• Training Operators: It's important to train operators. Despite the massive power potential that electric skid steers provide, the thrill of instant torque that excites operators also requires them to take care of the machine. Proper usage techniques and methods should be taught for longevity. Training on charging and usage can go a long way.

V. When to Know It's Time for Electric Skid Steer  Battery Replacement

Depending on the workload and usage, the electric skid steer battery life can change. The typical lifespan of an electric skid steer's Lithium Iron Phosphate (LFP) battery is 8 to 10 years with ~2,000 to 4,000+ charge cycles. Let's look at some key factors that can prove to be critical for electric skid owners:

5.1 Signs of Degradation

It's essential to monitor the battery's performance regularly. Look for the following signs, which potentially highlight degradation of batteries:

• Significantly reduced run-time and performance
• Longer charging times
• Persistent error codes or battery warnings
• Frequent need for recharging
• Unexpected shutdowns during operation
• Inability to hold a full charge
• Noticeable heat generation during charging or use
• Irregular power output or lag in responsiveness

5.2 Estimating Replacement Costs

The prices of batteries keep changing. Therefore, it's hard to estimate a replacement cost, which can become irrelevant in a few days. Thus, consider these calculations as an approximation for battery replacement costs. Input newer values to get an approximation as per your geographical location:

• The basic formula is:

Cost = Battery Size (kWh) × Price per kWh (USD)

• If we use AILISHENG ALS3090EV electric skid steer as an example:

It has 18.2 kWh, and the battery cost is $400/kWh:

Therefore, 18.2 × 400 = $7,280

The battery replacement of an ALS3090EV electric skid steer would cost $7,280 in 8 to 9 years of careful usage.

Conclusion: Battery Replacement & Construction Companies

Construction companies require a viable electric skid steer solution to minimize their operational costs and ensure compliance with green zones, thereby avoiding the regulatory expenses associated with diesel-powered skid steers. Electric skid steers equipped with high-end batteries, which provide endurance, performance, and longevity, can reduce construction costs and enable work in urban areas and green belts.

If you are looking for an electric skid steer with Lithium Iron Phosphate (LiFePO4 or LFP) and a state-of-the-art monitoring system, then consider the AILISHENG EV Series—including models like the ALS3070EV, ALS3080EV, ALS3090EV, and ALS3100EV. These machines are engineered for reliability, low maintenance, and zero-emission performance, making them ideal for construction firms operating in emission-regulated zones.

Each model features:

• Durable LFP batteries with long cycle life (up to 10 years)
• Smart energy management system for real-time monitoring and efficiency
• Fast, quiet, and robust operation across a range of site tasks
• Low daily energy cost compared to diesel fuel
• Compact designs are perfect for urban, indoor, and noise-sensitive projects

Visit the AILISHENG Electric Skid Steer Loaders to explore all their models.