A long-haul semi-truck's range varies by fuel type: diesel trucks typically cover 1,200–2,000 miles per tank, while CNG trucks range 400–600 miles. Electric semis like the Tesla Semi offer 300–500 miles.

Diesel Semi-Trucks

Diesel semi-trucks are the backbones of long hauls due to their great capacity for distance and efficiency. Most normal trucks run 1,200 to 2,000 miles on a full tank, depending on the weight in the load, the condition of driving on that day, and the performance of the engine. The fuel tanks of these trucks can carry 200 to 300 gallons of diesel, with an average of 6 to 8 miles per gallon. For example, a truck running at optimal highway speeds can cover about 1,800 miles on one full 250-gallon tank, and this is why diesel trucks are ideal for cross-country routes without having to make too many stops for refueling. This greatly reduces downtime and enhances the productivity of the logistics at play.

Fuel is one of the largest components of diesel trucking economics. With diesel averaging around $4.50 per gallon in 2024, a full refuel can range from $900 to $1,350, depending on the size of the tank. Truckers and fleet managers often optimize routes to include refueling stops in regions with lower fuel prices. For example, fuel in middle states can be 5-10% less expensive than it is on the coasts, which could amount to hundreds of dollars in savings on a cross-country haul. On a 2,000-mile route, for example, a truck getting 7 mpg would use around 285 gallons, taking on fuel expenses nearing $1,282 at the national average price. These figures demonstrate the need to do route planning in order to keep long-haul operations profitable.

The other important factor impacting the operation efficiency and operating cost is related to maintenance for diesel semi-trucks. A properly maintained diesel may last over 1,000,000 miles; thus, it is durable in long-haul trucking. Oil change, for instance, should happen every 25,000 miles at an estimated cost of $200 to $400, depending on the type of oil to be applied. The air and fuel filters also need to be changed every 15,000 to 20,000 miles, adding another US$100 to US$200 for each maintenance session. Neglecting these routines can reduce fuel efficiency by up to 15%, increasing operating costs. For a year of continuous operation, the maintenance cost of one truck may amount to US$10,000 to US$15,000, which is quite reasonable in comparison with their lifetime and performance.

Compressed Natural Gas (CNG) Semi-Trucks

Diesel semi-trucks are the backbone of long-haul transportation, which has a range of 1,200 to 2,000 miles on a full tank. This is dependent on key factors: generally, fuel efficiency will fall between 6 to 8 miles per gallon, while the size of the tank usually holds between 200 and 300 gallons. For instance, a truck that averages 7 mpg and has the capacity for 250 gallons of fuel can go as far as 1,750 miles without needing to refuel. These trucks are great for cross-country routes, such as the 2,700-mile trek from New York to Los Angeles, and would only need one to two stops to refuel. In fact, this long-range capability enables trucking companies to optimize schedules and reduce delivery times for better efficiency.

Fuel prices greatly affect the operational costs of diesel trucks, averaging $4.50 per gallon in 2024. It would cost a truck with a 300-gallon tank about $1,350 for a full refill, thus making fuel one of the biggest parts of a fleet's budget. A single truck, over the course of a year, would use approximately 14,285 gallons of diesel to travel 100,000 miles, which would be about $64,283 in fuel costs. Route optimization also goes hand in hand with cost management. States such as Texas and Missouri usually offer 10-15% cheaper diesel compared to states along the coasts, thus saving fleets hundreds of dollars en route through those regions. Such valuable data can enable companies to gain higher margins and become more competitive in the logistics industry.

The diesel semi-truck has to be serviced to keep them running for a long time. A well-maintained truck engine can achieve in excess of 1 million miles before replacement, making routine maintenance an indispensable task. Oil changes, due every 25,000 miles, run anywhere from $300 to $500 depending on the type of oil and service facility. Other routine tasks, like replacing fuel filters every 20,000 miles and air filters every 15,000 miles, add an additional $150 to $250 per service. Failure to maintain these schedules can reduce fuel efficiency by up to 15%, increasing operating costs significantly. Over a fleet of ten trucks, the yearly maintenance expenses can easily reach between $120,000 and $150,000, hence requiring very disciplined practices.