March 18, 2025
The True Cost of EV Charging Installations: Why Precast Solutions Win Over Cast-in-Place
When planning the installation of electric vehicle (EV) charging stations, selecting between precast solutions and cast-in-place (CIP) is a crucial decision that influences both immediate expenses and long-term value. This choice requires a comprehensive understanding of the Total Cost of Ownership (TCO), encompassing four key components: quality, installation, delivery, and upfront cost.
This article focuses on differences in quality and control, speed of installation, and labor and risk considerations. The next article in this series will offer a comparison between price and TCO.
Understanding Total Cost of Ownership (TCO)
TCO extends beyond the initial material costs to include all expenses over the project’s lifespan. It comprises:
- Quality: The durability and reliability of the concrete, impacting long-term performance.
- Installation: The efficiency of the installation process, including labor requirements and construction scheduling.
- Delivery: The time taken to receive materials on-site and complete the installation.
- Upfront Cost: The cost of materials and installation.
While precast solutions may have a higher upfront cost compared to CIP, the other TCO components often make it the more advantageous choice when evaluating long-term costs.
Quality and Control
Precast offer superior quality control during manufacturing. Produced in a controlled factory environment, precast products ensure consistent strength, durability, and dimensional accuracy. This process eliminates the variability and potential issues associated with CIP, where factors such as weather conditions, on-site mixing, and curing times can affect the final product’s quality.
For EV charging installations, where durability and reliability are paramount, precast solutions ensure the structure will withstand wear and tear over time. In contrast, CIP concrete, poured and cured on-site, is more susceptible to unpredictable elements, leading to a higher risk of defects or the need for repairs down the line.
Speed of Installation and Time Savings
Precast solutions offer significant time savings over CIP. Precast components are manufactured off-site and delivered ready to install, allowing for a quicker installation process without the need for curing or formwork setup. For an EV charging station, which may require a quick turnaround, the reduced time spent on-site can be a major advantage, enabling more installations per day to shorten project timelines.
In a typical precast installation, delivery and installation can be completed in just one day, while CIP may take up to seven days due to the time required for pouring, curing, and stripping the forms. The time savings associated with precast not only accelerate the project timeline but also reduce the risk of delays and associated costs, such as extended labor and equipment rentals.
Reduced Labor and Risk
Precast solutions reduce the amount of labor needed on-site, as the components are pre-made and simply require lifting and positioning. This reduces the complexity of the construction process, minimizing the potential for errors and delays. One typical error encountered is concrete poured on incorrect rough-in of conduits and anchors.
CIP, however, requires more on-site labor, including formwork setup, pouring, finishing, and curing. Additionally, the construction schedule is more unpredictable, as it is subject to weather and other environmental factors, any unexpected rain fall could delay installation for the day or affect the curing of any CIP concrete poured prior to the rain fall. For EV charging stations, where downtime can disrupt service, using precast products ensures faster deployment, reducing potential loss of business.
We’re here to help with your EV charging projects across the US. Visit EV Charging Infrastructure Solutions Center to access a wealth of resources and discover our extensive and adaptable product range.
