How to Plan Your EV Charging Station Design

Despite a slight slowdown in sales this year, electric vehicles (EVs) continue to grab a larger share of the market. Globally, Bloomberg projects that EV sales will hit 20% of new vehicle purchases by year-end, up from 17% in 2023. In some estimates, they’ll make up more than two-thirds of global new car sales by 2030.  

That’s a vast increase in the number of EVs in need of regular recharging. And for commercial properties — whether apartment complexes, office buildings, or retail centers — that surge in demand represents a massive need for more onsite electric vehicle charging stations to ensure the satisfaction of employees, customers, and tenants. Now is the time to prepare for these changes by making it possible for EV drivers to charge anywhere they stop for extended periods.  

Yet, overhauling a property to deliver power to hundreds of vehicles is a complex undertaking. Without proper planning and design, the project could easily go off the rails with inflated budgets, extended timelines, or insufficient upgrades. Let’s explore a few critical aspects of planning your EV charging station design to ensure your project goes smoothly.

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Importance of EV Charging Design

Electric vehicles represent a substantial change to our refueling habits. An EV-dominant future is one in which we spend much more time charging our cars at home, work, or while we shop, rather than during a quick stop at the gas station.

Upgrading facilities to meet that level of electricity demand requires extensive planning. Property owners must reconsider parking lot layouts, where to lay new conduit, how much additional power they will need, how they’ll manage load demand, and much more.  

To top it off, owners must consider not only how to meet drivers’ charging needs next year but a decade from now. Undershooting on charging infrastructure will only lead to greater expenses down the road, so planning and design must be detailed enough to minimize long-term costs and maximize benefits.

(Related: Best Commercial EV Charging Stations)

Factors to Consider When Planning Your EV Charging Station Design

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With so much riding on the design process, property owners must understand the top priorities for planning an EV charging station design. Here are seven key considerations to ensure the project goes smoothly and sets your property up for long-term charging success:

1. Number of Charging Stations Needed

Accurately projecting how many charging stations to install ensures your property is configured to meet the needs of tomorrow’s customers, tenants, or employees. This is the difference between a satisfied and frustrated user base, especially when it comes to office buildings or apartments where drivers spend a lot of time.  

And, as noted, it’s essential to plan for what you’ll need 10 years from now. If two-thirds of new car purchases will be EVs by 2030, consider how many chargers you’d need to meet that demand without requiring users to wait in line. Even if you don’t install the optimal number of chargers to meet future needs immediately, you should plan for the ideal total and run the electrical conduit now. These smart design decisions will significantly reduce your long-term costs.

2. Type of Chargers to Install  

When planning your EV charging station design, you can choose between two types of chargers that will provide sufficient power for commercial applications. Level 2 chargers require 208- or 240-volt circuits and generally deliver about 25 miles of charging power per hour. Level 3 chargers, also known as DC Fast Chargers, require up to 1,000 volts and can often recharge an EV battery from zero to 80% in just 30 minutes.

Level 2 chargers are sufficient for commercial properties where users spend several hours or more. Retail facilities that must accommodate more users for short stops may want to consider Level 3 chargers, but they are more expensive. In most cases, property owners should plan for enough Level 2 chargers to meet future demand.

3. Onsite Power Capacity

Once you know the type and number of charging stations you’ll install, you can assess your current power capacity and determine any upgrade requirements. You’ll need to consider two key aspects of capacity:

• Power requirements for each individual charging station: This concerns how much you want users to be able to charge during their typical stay at your property. For instance, if employees usually commute from 60 miles away, do you want them to fully recoup the cost of commuting by recharging enough for the return trip? Your charging stations and their respective circuits must be set up to achieve your goals.
  
• Power requirements for the entire site: From a broader site perspective, you can think in terms of averages. Consider how much the average user needs per day multiplied by the number of users to get a view of the total daily charging demand. This will tell you if your existing power supply needs an upgrade.

4. EV Charging Management Methods

While it’s possible to plan and budget for some capacity upgrades, others are simply unrealistic. The costs of complete electrical overhauls would be astronomical, and utility companies would likely take years to complete them.

That doesn’t mean you can’t design your property upgrades to meet charging demand. EV charging load management allows you to work within the constraints of existing infrastructure to deliver sufficient power.

Rather than doling out electricity indiscriminately, load management relies on software to determine which vehicles get charging priority. This can be first-come, first-serve distribution or adaptive charging that automatically adjusts based on various demand factors. The option you choose for your site will impact what type of upgrades you need, making it another critical factor in EV charging station design.

5. Where Chargers Will Be Installed

Charging station location is another practical consideration that can dramatically affect project cost and user satisfaction.  

Installing chargers on dirt or grass instead of concrete will substantially reduce excavation costs. Additionally, the closer chargers are to the power supply, the less you’ll have to spend to run conduit to them.

However, immediate cost isn’t the only consideration. For instance, installing all EV chargers close to the building might create conflicts if drivers of gas-powered vehicles regularly take those spots out of convenience. In other cases, as in California, you may need to ensure a certain number of EV-charging spots are accessible to drivers with disabilities.

6. Local Regulations and Permitting Requirements

Regulations affecting EV charging station design extend far beyond ADA compliance. When planning your installation, national and local codes apply to power systems, charging equipment, load management, and more.  

Project success depends on extensive knowledge and planning in this department, as permitting delays or regulatory compliance issues can be extremely costly. It’s essential to work with an installation partner who knows local and national requirements inside and out.

7. Charging Station Reliability and Reputation

Of all the aspects of designing your EV charging station, your project partner is perhaps the most important. With so many factors, your EV charging provider and installer must not only understand regulations but also have the hardware, software, and service reputation to fit such a complex undertaking.

Ultimately, this decision and planning process will affect your property for the next decade, if not longer. Be sure to vet your EV charging partner to ensure you won’t spend the next 10 years fielding angry emails or calls from drivers who are frustrated that charging stations don’t work properly. For more information on hardware, check out our article on the cost of commercial EV charging stations

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EV Charging Station Design Features to Consider

EV charging stations aren't one size fits all. In fact, there are a lot of different design features to take into account as you plan your designs. From setting up billing options to providing the ideal mounting options for your space, make sure you've considered these key elements. 

Environmental Factors

Temperature shifts can have a significant impact on charging rates for your EV station. In fact, the more the temperature drops, the longer it can take to charge a battery. The Idaho National Laboratory found that at 32 degrees Fahrenheit, EV batteries take in an estimated 36% less energy than when the battery is charged for the same amount of time at 77 degrees Fahrenheit. Overheating can also interfere with charging, slowing down charge times and making it more difficult for vehicles to get the power they need.

Furthermore, extreme temperatures can have an even more severe impact. Whether the EV charging station is installed indoors or outdoors can also have a significant impact on charging solutions. Fortunately, there are several architectural solutions that can protect your charging stations and make them work more effectively no matter the temperature, including options like using a solar parking canopy with EV chargers to increase sustainability or installing pavilions, pergolas, and shade structures around charging stations. These solutions can help protect against extreme weather and make it easier to manage temperature changes. 

Billing Systems

Billing for the power used to charge electric vehicles is a great way to create an additional income stream for your company, especially when you're using solar power to generate the energy used for charging. However, it's important to install effective billing and payment options for those solutions. You may use solutions like time-based or energy-based pricing, depending on your specific needs. (Note that the California Type Evaluation Program (CTEP) requires chargers to clearly display energy output and price in kWh to ensure pricing transparency.)

Common payment options include:

• App-based payment
• Kiosk-based payment
• On-charger point of sale
• Plug and Charge

You can also use wall-mounted or pedestal options for your chargers, allowing you to select the solution that best fits your available space and needs. 

Signage

Installing the right signage for your charging stations is essential. Not only must you meet federal guidelines, but you may need to consider individual state guidelines or regulations as standards change and improve. Your signs need to identify that the charging station and parking space are intended for EVs only, what the charging fees are for public use, and any payment methods and cost calculations users need to know in order to make the most of the station. 

General Compliance

ISO 15118 is an international standard that determines how the charging station and the electric vehicle communicate with one another, covering the exchange of information between the two devices. Information exchanged may include:

• Car identification
• Charge control
• Charging status

Meeting ISO 15118 standards is key for not only protecting the immediate functionality of your charging station but also ensuring that it is future-proofed. In addition, companies may want to take into account the importance of using equipment that is UL-certified, which means that the equipment meets essential scientific safety, quality, or security standards. Working with a partner like PowerFlex that is familiar with local, state, and federal regulations and how they apply to EV charging stations is essential to remaining in compliance as understanding of these technologies increases and regulation options improve. 

Challenges in EV Charging Station Design

Many companies find that there are challenges they have to consider when evaluating EV charging station design requirements and solutions. Being aware of those challenges upfront can make it easier to develop an effective design that will continue to meet your needs over time. 

Keeping Up with Changes

As technological understanding increases, new regulations emerge at the local, state, and federal levels. Those new regulations may govern not only what information you have to provide to users, but also what types of solutions you can use and how you can bill for your charging stations. Common concerns can include:

• Technological standardization, ensuring compatibility between different EV models and chargers
• Inconsistent policies across regions can make it difficult to expand infrastructure across regions
• Regular updates to the National Electrical Code, which changes every three years

Because not all states adhere to the same requirements, including National Electrical Code standards, it can be difficult to ensure that you remain in compliance with the latest shifts in regulations. However, working with a partner like PowerFlex can ensure that the knowledge and experience you need are at your fingertips. We'll keep up with changes in regulations so that you can focus on making the most of your charging stations and other green power options. 

Potential Need for Additional Electric Grid Capacity

The increased use of EVs leads to an increased need for electrical power, which means additional strain on the electrical grid. Furthermore, that can mean increased strain on the wiring for a given facility. You may need to update your electrical service wiring or make upgrades to your power distribution infrastructure. Without these upgrades, it can prove more difficult to keep up with the increased electrical draw, leading to outages or other challenges. 

Security and Privacy Concerns

Security is a key concern any time you increase technology. You must make sure that you are protecting user data from unauthorized access, especially as EV charging networks become part of a larger smart grid. A coordinated attack on multiple chargers could trigger a catastrophic disruption of the grid, leading to larger-scale planning. 

Future Planning with Uncertainties

You can only plan so far ahead, and there will always be variables that may be difficult to account for. That can include:

• Scaling charging stations as your needs grow
• Adding more capability to your EV charging station as technology increases
• Changing physical hardware
• Implementing new communication protocols

You want to be able to upgrade your system as these new options come available without completely removing the charging station, which can prove highly expensive. By partnering with PowerFlex, you increase your ability to future-proof your operations and keep up with your ongoing needs. We work with you to not only understand your current needs but also create a long-term strategy that takes your goals into account. 

Potential Growing Demand of Public DCFC

With the growth in the adoption of EVs, there may be a need to add more public charging in urban areas for EV drivers. While home-, business-, and fleet-based charging are expected to remain the primary solutions for EV charging, the need for expanded public charging availability will continue to expand along with it. The number of publicly available EV chargers has doubled since the start of the Biden-Harris administration, and demand is expected to continue to grow in the future. Making your business part of that solution is essential. 

The Importance of EV Charging Station Design, Continuous Upgrades, and Integrations

Electric vehicles represent a substantial change to our refueling habits. An EV-dominant future is one in which we spend much more time charging our cars at home, work, or while we shop, rather than during a quick stop at the gas station.

Upgrading facilities to meet that level of electricity demand requires extensive planning. Property owners must reconsider parking lot layouts, where to lay new conduit, how much additional power they will need, how they’ll manage load demand, and much more.  

To top it off, owners must consider not only how to meet drivers’ charging needs next year, but a decade from now. Undershooting on charging infrastructure will only lead to greater expenses down the road, so planning and design must be detailed enough to minimize long-term costs and maximize benefits.

In short, maintaining your EV charging station design is essential to its future.

A Safer Infrastructure, Thanks to Compliance

Compliance helps to ensure that the EV infrastructure is safe and reliable for EV drivers. This includes staying on top of maintenance and upgrades so you can improve your awareness of changing needs and solutions. 

Reliable Charging Stations EV Drivers Can Depend On

Unmaintained EV charging stations can be unreliable, which can make it difficult for drivers to keep their vehicles operating efficiently. Taking care of regular maintenance and upgrades allows you to keep up with the needs of drivers using your stations and prevents that loss of productivity. 

Adapting to Changes as They Happen

Big changes are coming to the EV industry, and keeping up with those changes is essential to maintaining your charging stations. Whether you're providing them as a solution for your fleet, your employees, or the general public, staying on top of the latest industry changes means that you can accommodate the latest EVs, prevent compatibility issues, and provide an overall better experience for your users.

Contact PowerFlex to Design and Install Your EV Charging Solution

Sound like a lot to consider?  

With PowerFlex, you’ll find a partner who can manage every aspect of EV charging station design. From initial planning and equipment procurement to installation and ongoing management, we take the hassle out of your hands so you can focus on other crucial aspects of managing your property. Our policy and incentive experts will also ensure you secure any rebates and tax incentives for which your project qualifies.

Not only that, but the PowerFlex X™ intelligent energy management platform offers Adaptive Load Management® to help you reduce implementation costs by up to 60%, limit peak-time charging costs, and efficiently manage ongoing charging demands.

Reach out to PowerFlex today so we can start planning an EV charging system that will meet your needs — today and tomorrow.