Building Charging Infrastructure: 3 Common Concerns You Need Not Be So Concerned About

It's not as hard as it looks... if you plan it right!

2025 is looking to be "the year of the EV" (source), which means even more infrastructure will be required to maintain the momentum from 2024. Building infrastructure may seem daunting - especially to support fleet electrification - so we’re excited to kick off 2025 with a 3-part series focused on EV charging infrastructure. While infrastructure build-out may indeed be the key to moving EVs and electrification forward in the new year, it’s not nearly as scary to plan and implement as you may think!

In this first article of the series, we will explore the key considerations for fleet charging infrastructure, debunk some common misconceptions, and highlight why building the supporting infrastructure is not only quite feasible but, when planned correctly, can even be beneficial to the long-term operations of fleet operations.

In the following 2 articles, we’ll dive more deeply into the challenges and considerations associated with infrastructure and charging station planning and implementation for Charging Point Operators (CPOs).

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Introduction

As electric vehicle (EV) adoption in fleet operations accelerates, many fleet managers, engineering teams, and financial decision-makers are concerned about the costs and challenges associated with building and integrating supporting EV charging infrastructure. While the transition from Internal Combustion Engine (ICE) vehicles to EVs presents a range of technical considerations, the build-out of charging infrastructure isn’t as daunting as it might seem. In fact, advances in charging technology, grid integration, and strategic planning can ease the transition and make infrastructure development both manageable and cost-effective.

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Concern #1 - EV Infrastructure Requires Major Construction Overhauls

The Concern: Fleet operators often believe that installing EV charging stations requires large-scale construction projects, resulting in major disruptions, long installation timelines, and high upfront costs. This misconception can cause decision-makers to delay electrification, fearing that the scale of the work may impact current operations.

The Reality: While the installation of EV chargers does involve some planning, the reality is far more manageable. In most cases, fleet operators can leverage their existing electrical infrastructure, especially if the fleet operates out of a central depot or hub. With advancements in charging technology, chargers can often be integrated into existing power grids with minimal disruption.

For example, Level 2 chargers are cost-effective and efficient for many fleet operations, particularly for vehicles that can be charged overnight or during extended downtime periods (source). However, while Level 2 chargers are generally easier to install than DC fast charger and most fleets only need low to moderate power to meet their needs, they may still require electrical upgrades depending on the existing infrastructure and the number of chargers being installed. For example, older homes or buildings with 100A electrical panels might need upgrades to accommodate Level 2 chargers, especially if multiple chargers are being installed (source). Additionally, the installation costs can vary significantly based on factors such as location, trenching requirements, and necessary electrical upgrades (source).

3 Key Steps to Simplifying Installation:

Load Assessment: By conducting a thorough assessment of your fleet’s energy consumption and peak usage, you can determine the specific power requirements of your charging stations. This will help identify whether any upgrades to your power capacity are needed.

Modular Charging Systems: Many fleet operators start with a small number of chargers and scale up as needed. Modular designs allow for incremental build-outs, reducing the initial cost while still meeting operational needs as your fleet expands. But you need to estimate your future charging needs to avoid costly mistakes in the first step.

Site Design and Layout: Properly designing your charging site can minimize the need for significant construction. Positioning chargers strategically at existing parking bays or near electrical rooms can reduce cable runs and associated costs. Further, by estimating your future charging needs, you can include future plans at step one to greatly reduce the need for future construction.

The perceived challenges of building charging infrastructure are often overestimated. By leveraging existing grid connections and infrastructure, fleet operators can install the necessary equipment with minimal disruption and at a lower cost than anticipated.

Concern #2 - Grid Capacity: Will the Existing Power Supply Be Enough?

The Concern: Engineering and maintenance managers often question whether their existing power supply can handle the additional load required for EV charging. They worry that the fleet’s charging needs might exceed the available grid capacity, resulting in costly upgrades or potential downtime.

The Reality: Conducting a proper energy load assessment upfront is essential to avoid potential issues with grid capacity. However, in most cases, fleets can work within their existing power supply by strategically scheduling their charging sessions, or by adding complementary solutions such as onsite renewable energy or battery storage. It is important to see where you can start the transition today and where you will end up. In EV, projecting the end situation goes a long way to reducing the cost to get there. These calculations are complex, but a sophisticated modeling platform can enable you to quickly iterate through scenarios and estimate/plan your future build-out in phases so that you have a clear path forward.

Mitigation Strategies:

Preliminary discussion with local utilities may indicate that EV charging off peak hours will complement the power supply portfolio. Some utilities have implemented very advantageous pricing for overnight EV charging, and intelligent energy management platforms, including the Brightmerge platform, allow fleets to optimize when and how much they charge based on grid demand and energy pricing. By spreading out charging sessions and using real-time energy data, fleets can avoid peak demand charges and manage their overall energy consumption more efficiently.

Onsite Power Generation: Installing solar panels or other renewable energy sources at your fleet’s hub can provide a reliable source of power for EV chargers while reducing your reliance on the grid. Paired with onsite battery storage, this solution allows for energy arbitrage - buying electricity at off-peak rates, storing it, and then using it during high-demand periods.

Scaling Charging Needs: For larger fleets, it may make sense to stagger charging schedules, ensuring that only a portion of the fleet is charging at any given time. This technique can prevent overwhelming the existing electrical infrastructure.

Existing power supplies are often more than sufficient for supporting fleet electrification when combined with smart energy management, renewable power options, and staggered charging schedules.

Concern #3 - Cost: Can You Afford the Infrastructure?

The Concern: Financial managers worry that building the necessary infrastructure for EVs will result in excessive upfront costs, driving up the total cost of ownership (TCO) and eroding potential savings gained from EV adoption. (Read more about TCO in greater detail here.)

The Reality: While there are capital expenditures involved in building out EV infrastructure, the costs can often be offset by lease/buy back programs, government incentives, utility programs, and financing options designed to support EV adoption. Furthermore, once the infrastructure is in place, the ongoing operating costs for EV charging are far lower than the equivalent costs for fuel stations. Additionally, the decreasing costs of EV charging equipment and batteries help minimize total project expenditures.

Some strategies to reduce costs include:

Lease Agreements: This financial arrangement has many benefits and most financial institutions focused on infrastructure build out strategies include this as 1 of their funding solutions.
Incentive Programs: Many states and local governments, particularly in North America, offer grants, rebates, and tax incentives to help cover the cost of EV chargers and infrastructure installation. For example, the California Energy Commission provides funds to cover up to 50% of infrastructure costs through its Clean Transportation Program (source), while the Federal Government’s Alternative Fuel Infrastructure Tax Credit can offset up to 30% of installation costs (source).
Managed Charging Solutions: By integrating smart charging systems, fleets can take advantage of time-of-use (TOU) electricity rates, charging during off-peak hours to reduce energy costs. Managed charging ensures that your fleet is only drawing power when rates are low, further driving down the cost of operation.
Utility Partnerships: Many utility companies have programs designed to help fleets transition to EVs. These programs often include rebates for charging equipment, help with grid upgrades, and flexible financing options. Partnering with your local utility provider can significantly reduce the financial burden of building the infrastructure.

With government incentives, smart charging solutions, and utility programs, the initial investment for EV infrastructure can be minimized, allowing you to recoup costs over time through operational savings.

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Conclusion: Fleet Charging Infrastructure Is Feasible and More Affordable Than You May Think

Transitioning to EVs does require some investment in charging infrastructure, but the process is simpler, more cost-effective, and more scalable than many [CPOs and fleet operators] may expect. By leveraging existing electrical systems, government incentives, smart charging solutions, and utility partnerships, fleets can build out their EV infrastructure with minimal disruption and at a fraction of the anticipated cost.

The key to a successful transition lies in proper planning and optimization. What are your concerns or considerations as you plan your transition? Let us know in the comments section below.

In our next article, we'll dive deeper into the challenges and consideration for charging station location. Stay tuned!

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Brightmerge’s platform is purpose-built to help fleet owners/operators, EPCs and CPOs assess infrastructure and energy needs, plan charging schedules, and manage costs efficiently - ensuring a smooth transition to electrification without overburdening either budget or operations.

To discuss your project, send an email to Jamie Morgan to arrange a 1:1 discussion and evaluation.