According to Consumer Reports, many automakers have detailed plans to change large portions of their fleets over to electric vehicles (EV) within the next decade, with some announcing goals for full EV lineups within five years.
A record 1.2 million electric vehicles were purchased by U.S. buyers in 2023, according to Kelley Blue Book. The EV share of the total U.S. vehicle market was 7.6% in 2023, which increased from 5.9% in 2022.
The Cox Automotive Economic and Industry Insights team is calling 2024 “the Year of More” when it comes to EVs. The team states that “more new product, more incentives, more inventory, more leasing, and more infrastructure – will combine to push EV sales higher in the year ahead.” The team forecasts that the EV share of the U.S. market in 2024 will reach 10%.
To foster the U.S.’s transition to electric vehicles, the Biden administration’s Federal Sustainability Plan requires all federal agencies to change to light-duty electric vehicles by 2027 and heavy-duty zero-emission vehicles by 2035. Federal agencies have also committed to adding an additional 24,000 charging stations at federal facilities by the next fiscal year.
Also, the 2022 Inflation Reduction Act has committed $2 billion for automotive manufacturing facilities producing new EVs. Additional government funding includes an increase in tax credits for purchases of new and used EVs, which will bring the benefits of clean energy to communities across the nation. For example, Hyundai and Ford announced they are offering cash rebates as high as $7,500 per EV.
How are EV Factories and Charging Infrastructure Being Affected?
To increase the production of electric vehicles, auto manufacturers have had to speed up the design and construction of EV factories and charging infrastructure. According to Engineering News Record, “Infrastructure designers and contractors say they have not seen a shift in transportation this big since the automobile replaced horses and carriages in the 1920s.”
What Changes Are Being Made to Assembly Lines?
The production of electric vehicles in manufacturing facilities that currently make internal combustion engine (ICE) vehicles will require a significant overhaul to their existing assembly lines, as there are major design and construction differences between the two vehicle types.
According to Stanley Engineered Fastening, “EV motors have very few moving parts; they do not require engine oil or transmission fluid. EVs need no exhaust systems, alternators, fuel injectors, or starters. All of these familiar ICE vehicle components will be entirely absent from EV production lines. Because there will be so many fewer parts in an EV, compared to its ICE counterpart, the assembly process will be simplified.”
Most electric vehicles are built around their battery packs, which are placed under the vehicle floor to lower the center of gravity. Because of their weight and bulk, manufacturers will prefer to have these battery packs built and assembled as close to their assembly line as possible.
Across the U.S., automotive manufacturing facilities are planning major renovations to support the production of electric vehicles. For example, a $1.5 billion expansion will add 2,625,000 sq. ft. to an Ohio auto manufacturing facility. Rivian converted a former Mitsubishi factory to a production facility for a reported cost of $750 million.
According to Jeff Hammoud, Rivian Chief Design Officer, to plan for facility renovations “you’re working very closely with supply chain, manufacturing, and engineering. They will tell you how much space they need for all the stations, and the flow of the production line running…there’s a lot of planning that goes into that.”
How Can GPRS Help Auto Manufacturers with Plant Renovations?
To complete facility renovations, auto manufacturers and general contractors will require existing as-built data of the manufacturing facility to plan the new tooling and assembly processes. GPRS can deliver comprehensive and up-to-date as-built facility data with utility locating, concrete scanning and imaging, 3D laser scanning, video pipe inspection, leak detection, drone photogrammetry, and mapping & modeling services prior to planning and construction.
3D laser scanners can capture every detail of an automotive manufacturing facility – the structural, architectural, and MEP features, plus underground utility and concrete markings – at incredible speed with millimeter accuracy. 3D laser scanning can provide auto manufacturers and general contractors with an overall site plan, capturing exact building dimensions, locations, and layout.
Subsurface utilities, including electric, natural gas, water and more can be located with ground penetrating radar (GPR) and electromagnetic (EM) locating technology and marked on the surface using paint, flags, and other appropriate means. GPRS can deliver 2D subsurface utility maps with precise information about the location, depth, direction, and distance of buried underground utilities.
During concrete scanning, GPR and EM locating equipment locate the exact position and orientation of objects embedded in concrete, including post tension cables, rebar, utilities, conduits, and pipes. This information arms construction teams with the precise detection, evaluation, and mapping of embedments, when preparing to cut, core, drill, or anchor into concrete. Accurate imaging data is essential to the safety of the crew, maintaining the integrity of the structure, and preventing costly mistakes.
Video pipe inspection (VPI) can assess and document an existing sewer system’s condition and functionality, to remedy any problems and reroute drains, if needed during the facility renovations.
Comprehensive GPRS as-built data aids in design, communication, collaboration, and sequencing during facility renovations.
What is the Plan for EV Charging Stations?
The U.S. Dept. of Transportation is working with municipalities, states, and local governments to build a national network of 500,000 publicly accessible EV charging stations by 2030. The Federal Highway Administration documents that 160,000 public EV chargers are active across the U.S. today, but at the end of 2022 only 28,000 were direct current, fast-charging, Type 2 ports versus slower Type 1 ports.
Automakers Ford, General Motors and Rivian agreed to make their EVs capable of using the North American Charging Standard (NACS) ports, which is based on charger hardware that automaker Tesla has been using.
The Inflation Reduction Act includes a provision for businesses that install EV charging equipment to receive a federal tax incentive of up to 30% of the total cost of equipment and installation. Also, developers can achieve a tax credit of up to $100,000 for installing charging equipment in their project.
Many places are expected to add EV charging station infrastructure, including travel centers, airports, gas stations, car dealers, parking garage, grocery stores, and more.
In building a 32-acre waterfront development in Vancouver, Washington, Gramor Development had to meet a state requirement that 10% of all parking spaces be infrastructure-ready for EVs, says Matt Grady, Gramor Vice President and Director of Development. “We went to great lengths to see where to cluster them so that cabling can work for all the conduits.”
“California, Oregon, and Washington are planning a 1,400-mile EV corridor along Interstate 5 between Canada and Mexico, with 34 stations and five hydrogen fuel stations planned,” said Jimmy O’Dea, assistant deputy director for transportation electrification at the California Dept. of Transportation.
The construction of an EV charging station requires coordinating with a number of contractors and understanding utility company requirements. “There has to be coordination with utilities and local transformer upgrades that [will] need to take place,” said Andrew Conley, HNTB project director.
A detailed plan of the electrical infrastructure such as transformers, switchgear, cabling and power distribution units, and mechanical infrastructure, including charging equipment, mounting and enclosures, cooling systems and safety equipment, must be created.
How Can GPRS Help Plan EV Charging Infrastructure?
GPRS can map a site with utility and concrete layouts to plan for EV charging station infrastructure upgrades. Our team of experts can mark the location of all utilities and concrete embedment’s at the site and deliver comprehensive maps and models to your team.
Prior to excavation and construction, all utilities, including electric, natural gas, and water can be located with GPR and EM locating and marked on the surface using paint, flags, and other appropriate means. GPRS can deliver 2D and 3D subsurface utility maps with precise information about the location, depth, direction, and distance of buried underground utilities.
Concrete scanning arms you with the precise location of post-tension cables, rebar, utilities, conduits, and pipes embedded in concrete. This data helps prevent mistakes and keep your crew safe when preparing to cut, core, drill, or anchor into existing concrete.
How Can I Access Accurate As-Built Data?
GPRS’ SiteMap® (patent pending) delivers comprehensive as-built data in a cloud-based software from all GPRS services – including utility locating, concrete scanning and imaging, 3D laser scanning, video pipe inspection, leak detection, drone photogrammetry, and mapping & modeling services.
All project data is aggregated, organized, and stored in SiteMap®, making it the single source of truth for your job site. Any file size and type can be quickly accessed and securely shared with your team, eliminating information silos and the mistakes they can cause.
GPRS as-built site data can help you execute your plant renovation and charging infrastructure plan flawlessly. Our team of experts is ready to rapidly respond to any site in the U.S., usually within the lead time of only one or two days. Additionally, we can be on-site short-term or long-term, depending on your needs. With over 500 Project Managers stationed across the United States, GPRS has an unmatched nationwide service network that makes it quick and easy for you to find an expert Project Manager in your area.
Frequently Asked Questions
What Is 3D Laser Scanning?
3d laser scanners use LiDAR (light detection and ranging) to measure and record precise locations and distances, ultimately producing a point cloud file. The technology enables you to produce highly accurate digital measurements and images quickly and easily for use in construction and engineering projects. 3d laser scanning is a revolutionary tool to document existing conditions. It is invaluable in design, prefabrication, asset management, and facility modifications.
What Is As-Built Documentation?
As-built 3D documentation is an accurate set of data for a site or project. It reflects all changes made during the construction process and show the exact dimensions, geometry, and location of all elements of the work. Data can be delivered in point clouds, 2D CAD drawings, 3D BIM models, 3D mesh models, digital twins, floor plans, and more for construction design, prefabrication, clash detection, facility modifications, and asset management.
Who is COX Automotive?
Cox Automotive is the world’s largest automotive services and technology provider. Fueled by the largest breadth of first-party data fed by 2.3 billion online interactions a year, Cox Automotive tailors leading solutions for car shoppers, automakers, dealers, retailers, lenders and fleet owners. The company has 25,000+ employees on five continents and a family of trusted brands that includes Autotrader®, Dealertrack®, Kelley Blue Book®, Manheim®, NextGear Capital™ and vAuto®.