Overcoming Parking Lot Installation Challenges for Electric Vehicle Chargers

When it comes to installing electric vehicle (EV) charging stations, most business owners want to avoid having their property dug up. Digging in a parking lot can severely disrupt business and cause aggravation among employees. This concern forces contractors to work on set hour schedules so they can minimize the disruption to daily business activities. Additionally, repairs to the pavement don’t always match the existing asphalt, which leads to future potholes that the business will have to repair.

Common issues with parking lot work

There are a lot of unknowns that can arise when digging into parking lots to install conduit, cables, and charging equipment. Land records only go back so far, and many big manufacturers have uncovered grave sites, artifacts, and other related items below their property. Discovery of these items can stop a project in its tracks or lead to long delays.

For example, when it comes to grave sites, it is required that you notify the next of kin to get permission to move the grave. This can be a very long process depending on the age of the grave, and some U.S. states also require special permitting if you disturb more than 5,000 cubic feet of dirt.

One manufacturer has created a new department specifically to deal with issues they uncover during installations while digging a trench for conduits. Europe is facing the same issues as companies are trying to install these chargers in historic districts where special permits are required to remove sidewalks.
How can we resolve these issues? The following trends can help move these installations forward.

How can we resolve these issues? The following trends can help move these installations forward.

Transportation-related damage

One common issue that can happen is the cable getting damaged as it’s being transported to the project site or damaged during its installation. This situation stops all work until new cable is ordered and delivered. One option to avoid these problems is to use cable-in-conduit (CIC), as shown in the Photo above. This type of product can be installed in one of three ways — plowed, trenched, or directionally bored. The use of CIC can avoid digging up the ground and uncovering items that could be an issue related to permitting.

Pre-made skids with installed chargers

Pre-made skids with chargers installed on them are another great option for avoiding excavation on a job site. The skids allow a pre-made structure to sit on the ground rather than digging a foundation for the equipment.

This technique makes system expansion easier, too. With everything above ground, it is more convenient to add or reconfigure the system, if necessary. Since most commercial space is leased, customers do not want to leave a big dollar investment behind if they have to move buildings. If their equipment is on a skid, they can easily disconnect the cables and take the equipment with them.

Pre-lubed cables

Pre-lubed cables are another great option as they do not require installers to apply lube during installation. These cables can also be easily removed if the charging equipment is upgraded or removed. This solution has proven to be helpful when customers eventually upgrade or replace their cable.

Avoiding conduit

On- or under-the-ground wire raceway systems eliminate the need for conduit. One advantage of this installation technique is that, in most cases, it has 100% allowable fill by the National Electrical Code compared to 40% for conduit. This contributes to less of a support structure needed by the contractor.

Similar to the pre-made skids, a wire raceway also adds to the flexibility to easily change or modify the system. However, one issue with over-ground raceway systems is that they do not currently have a drive-over raceway that can cross between islands in a parking lot.

This is where power poles or directional boring come into play. Power poles are needed to take power up and over where vehicles have to travel in a parking lot, and then guide wires are used between the poles to support the power cables. This is similar to an electric utility power line configuration. Directional boring of conduit is used similarly, but the wires run underneath the parking lot.

Cable trays and other overhead wire installations

Overhead wire installations, like cable trays, are now being used in parking decks as well as some parking lots. With sheds over the cars, this not only protects the vehicles from the weather, but it also makes it more convenient to install cables for the charging equipment.

Above-ground concrete dividers

Lastly, above-ground concrete dividers with special channels for wire can be used to get the cables from one point to another. This is seen more with standard concrete barriers used for road work, like most people see on the interstate highways. They’re typically known as Jersey Barriers.

Channels are installed on top of the dividers and are placed in the middle of parking lot islands. This acts not only as a cable pathway but also as a barrier required by the Authority Having Jurisdiction (AHJ) to protect the charging equipment. Cable trays, conduit, and charging equipment are also being placed on these dividers to help protect and add mobility to the system. The most common application appears to be used for school bus charging stations. Some school bus storage space is leased or rented, so school systems need the option to move the system, if necessary.

These are just some of the many new techniques and innovations being deployed to keep construction workers from having to continuously restart projects or uncover hidden disasters that could halt a project entirely.