As electric vehicles grow, most operators are not building new sites — they are retrofitting chargers into forecourts that were designed decades ago. Adding EV charging to service stations is very achievable, but it needs early planning around electrical capacity, civil works and how EV bays coexist with fuel trading.
Start with electrical capacity
Fast and ultra-rapid DC chargers draw serious power, and the single biggest constraint on most existing sites is the incoming supply. Before anything else, assess the site’s available capacity, the distance to the network connection and whether an upgrade or new transformer is required. This lead item can take longer than the construction itself, so it is where planning must begin.
Civil and structural works
- Charger foundations — engineered footings and equipment pads for heavy DC units.
- Cable trenching and conduit — routing high-voltage runs from the supply to each bay.
- Switchgear and distribution — space and protection for the new electrical infrastructure.
- Canopy and weather protection — shelter for both drivers and equipment.
- Bay layout and access — space for vehicles to charge without blocking fuel traffic.
Fit EV bays around fuel operations
The hardest design problem is co-locating EV bays with a live forecourt. Charging vehicles dwell far longer than refuelling ones, so bays need to sit where a stationary vehicle will not block pump access, tanker deliveries or the entry and exit. Often the answer is a dedicated EV zone at the site edge rather than squeezing chargers between islands.
Dwell time changes the site
Because EV charging can take 20 minutes or more, drivers spend real time on site — which is why chargers pair naturally with an upgraded convenience offer, seating and amenities. Planning the retrofit is a chance to rethink the store, not just add a plug.
Build it around trading
Like any fuel-site works, the retrofit should be staged so the forecourt keeps trading. Trenching, electrical works and foundations are sequenced behind hoarding and often out of hours, with the network connection coordinated to avoid disrupting the live site.
Future-proof the design
Trenching and switchgear are the expensive, disruptive parts. Sizing conduit, ducting and electrical capacity for more chargers than you install today means the next expansion is a straightforward add-on rather than another full dig-up.
Related services
Part of our Fuel & Convenience Infrastructure hub. It aligns with EV Charging Station Construction, Fuel Forecourt Upgrades and Service Station Refurbishments.
Get expert advice
Planning EV charging for an existing site? Contact Blake Ballard Building to scope the electrical and civil works.