How to Integrate EV Charging Stations into Commercial Electrical Design

Electric vehicles (EVs) are a regular occurrence today. It is common to visit a local parking lot near a business district or outside a public library and find a charging system in place. The more state and federal incentives drive adoption, the higher the demand for stable and consistent charging resources.

Working with the shift in how vehicles are powered requires a bit of forethought and design expertise. You wouldn’t want to install a new EV station just for financial gain without first considering the long-term implications. Retrofitting an existing building’s electrical infrastructure can be expensive, and you risk serious damage if power overloads occur while scaling to meet growing demand. Proper planning is your best bet for the EV-driven future.

Why EV Charging Is No Longer Optional

Roughly 1.4 million EVs were sold in the USA in 2021, an increase of 88% compared to 2020. Since then, the rapid proliferation of newer, cost-effective brands and changes in legislation have skyrocketed sales.

In some states, it is actually required to build new commercial spaces and multi-unit homes with EV-capable devices for charging. There are several cities throughout the USA, such as Denver, Seattle, and Austin, that all require a certain minimum percentage of parking spots with EV charging support.

Even outside of environmental considerations, there is a business incentive to install new EV chargers and substations. You can attract more tenants and buyers who prioritize sustainability, enhance the value of your property, and access rebates, tax credits, and utility-funded programs.

EV Charging Basics with Levels

Before jumping onto the “EV bandwagon,” you’ll need some basic understanding of different charging levels.

Level 1 Charging (120V)

These chargers are typically used in homes and help a vehicle get fully charged during a longer period. There is a portable charger that plugs into a 120V wall outlet, making it incredibly accessible, but not very efficient. You can expect these levels to be used for overnight charging or in low-fleet applications, such as on-site vehicles, personal EVs, and smaller vehicles (e.g., golf carts).

While these level one chargers are easy to use, they still need special considerations. Not all homes are up to date on infrastructure. Commercial buildings may require upgrades, as even the most basic charger will pull 12 to 16 amps.

Level 2 Charging (240V)

Designed primarily for commercial and public spaces, you can expect a range of approximately 10 to 30 miles per hour of charge. You must have a 240V outlet available on a dedicated circuit, as the charging speed is much faster than that of early adopter EVs compared to today’s modern models.

Some Level 2 stations will include scalable expansion and flexible deployment, utilizing networked, metered, and software-controlled usage tracking or cost-sharing. That is what makes this the most popular level being adopted right now.

Level 3 Fast Charging (480V+)

Sometimes called “turbo charging,” these EV stations offer 60-100+ miles of drivable range for every 20 minutes of charge. It requires three-phase power and large-capacity transformers due to the high traffic demand.

You cannot install Level 3 (DC Fast Chargers) without industrial-level infrastructure. That is why you primarily find these stations near rest stops, fuel stations, grocery stores, or transit depots. In addition, not every modern EV will support DC fast charging. That means the high installation costs do not always equal the potential benefits.

Planning EV Charging Integration with Electrical Design Consultants

The best way to ensure integrating any EV infrastructure into your commercial space is comprehensive and built with foresight is to hire an electrical engineering consultant for electrical design. The earlier you can get advice on proper placement and code compliance, the lower the short and long-term costs. The right team of experts will offer the insights you need, like:

• Site Evaluation & Load Capacity: Ensuring planned service handles EV demands (even during peak season) and “future proofs” your systems so the utility provider can meet vehicle needs in the next five to ten years.
• Strategic Charger Placement: Providing advice on the location of your EV chargers so they are ADA compliant, offer proximity to proper planning, avoid blocking fire lanes, allow driving visibility and lighting, and compensate for weather exposure.
• Load Management & Smart Charging Integration: Utilizing modern extensions like load balancing devices/mobile controls, time of use programming to offer charging when electricity is cheaper, and Energy Management Systems (EMS) that integrate with renewable resources like solar arrays and building automation.

The most critical factor of electrical design concerning EV charging stations surrounds safety. You want to work with a team offering permitting and code compliance reassurance. NEC articles are being constantly updated to verify proper charging operation.

These safety measures also provide essential protections, including ground fault installation, current oversizing, labeling, emergency shutoffs, and the interconnection of your EV chargers with other systems, such as backup generators or solar PV. Any new technology, even when it is being adopted rapidly, requires the care and management of properly trained experts, such as those at Dreiym Engineering.

Common EV Charging Station Pitfalls and How to Avoid Them

Even the most well-meaning developers, focused on offering amenity-rich commercial spaces, run into challenges with EV charging station planning. Many mistakes can occur without proper preparation and installation experience.

You want electrical engineers to provide proper load forecasting so none of the electrical services are undersized. That may require a costly transformer or panel upgrade, but it will ensure future expansion is possible should you need it.

Poor layout is also a challenge. Long conduit runs or difficulty accessing panels due to obstructive vehicle movement places undue hardship on your operations. You want professional electrical design to reduce work issues and maximize charger uptime.

Scalability must be in mind while designing EV charging systems. The demand is only growing, and you want to pre-install empty conduits or oversize gear so when you have to upgrade or expand, it isn’t as costly.

EV charging station installation does not operate in a bubble. When you work with an electrical design team, ask about trenching, permitting, and utility interconnection fees. If you overlook these additions, you can quickly double your installation costs or slow down production due to scheduling and worker availability issues.

EV infrastructure must account for more than the electrical plan. Experienced design consultants will coordinate with architects, civil engineers, and landscape planners to minimize conflicts arising from storm damage or structural elements.

However, when all these considerations are done right and ahead of time, you reap fantastic benefits for your commercial space. EV charging ensures you can:

• Attract more clients, customers, and tenants, especially in Class A office space.
• Improve environmental performance metrics and receive LEED certification.
• Reduce carbon footprint and support local, state, and federal sustainability initiatives.
• Direct access to multiple layers of financial incentives, reducing upfront and operational costs.
• Future-proofing a commercial space for the EV future as charging infrastructure only grows.

The goal is to cultivate long-term savings and design flexibility without risking electrical fire or damage to the electrical infrastructure. That is a delicate balancing act between performance and safety that only an experienced electrical design professional can offer.

Final Thoughts

There is no putting the EV genie back in the bottle. Consumers are flocking to EVs, and the more the infrastructure supports this demand, the greater you’ll need commercial spaces to accommodate have such amenities.

There are many design consultants specializing in EV systems, but it is essential to consider hiring electrical forensic engineers with extensive experience in holistic infrastructure. A small item overlooked in the earlier stages will lead to drastic risk down the road.

Dreiym Engineering works with property owners and developers to future-ready all electrical systems. We offer experienced and expert electrical design from industrial settings to commercial properties and multi-unit residences.

For over 30 years, we have helped clients prevent electrical fires and arc-related events through safe, proactive designs that account for load balancing and more. Give us a call today, and let’s get your commercial space ready for the future.