Unlocking successful fleet electrification: The key role of power infrastructure

Electrification represents one of the most significant shifts in transportation since the move from horse-drawn carriages to internal combustion engines. Yet as commercial fleets across the country embrace this transition, many are discovering that the biggest challenge isn't the vehicles themselves; it's the electrical infrastructure needed to power them. How fleets approach this challenge is reshaping what a successful electrification journey can, and should, look like.

The scale of the challenge

Consider this: The battery pack on an electric bus can consume as much power while charging as a small warehouse. Multiplied across a typical fleet, which could range from 50 to hundreds of buses, the power demand quickly nets out to that of a small town. According to recent ACEEE research, load from medium- and heavy-duty vehicles will be substantial. Texas alone is projected to need an additional gigawatt of peak capacity by 2030 just for fleet charging, while California will require 500 megawatts. Fourteen other states will need between 200 and 500 megawatts each.

These aren't just numbers on a page. They have real implications for the commercial fleets that keep our economy moving and that are motivated to lean into new technologies but face a sobering reality when trying to do so. Namely, grid connection timelines that stretch up to 36 months or longer. Many utilities are just beginning to grapple with these unprecedented demands, while the grid upgrades needed to meet them—from new substations to enhanced distribution feeders—can take five years or more to complete.

The traditional approach is no longer sufficient

The conventional fleet procurement playbook—specifying vehicles, placing orders, and preparing maintenance facilities—simply doesn't work for electrification. We've seen this scenario play out repeatedly: A fleet orders electric vehicles, only to discover their local electrical infrastructure cannot support their charging needs. This leads to costly delays, stranded assets, and operational disruptions that could have been avoided with proper planning.

A new power-first strategy

Forward-thinking fleets are adopting a more successful approach that begins with utility engagement long before placing a vehicle order. This aligns with what utility and commercial transportation experts are now recommending as a roadmap for the electrification process.

Here's how successful fleets are navigating this challenge:

Early assessment and planning: This process begins with a detailed power availability assessment at fleet facilities, involving working closely with utilities to find capacity on the grid, identify potential upgrade requirements, and get a realistic timeline for when power can be delivered. Smart fleet managers are learning to map their vehicle deployment schedules to infrastructure readiness, not the other way around.
Regional considerations: Power availability and utility timelines vary significantly by region. Some utilities are actively planning for fleet electrification through make-ready programs or rate cases, while others are just beginning to recognize the challenge. Understanding these regional differences is crucial for multi-site fleets planning their transition strategies.
Phased implementation: When developing a site for WeDriveU in San Jose, California, we learned that it would have taken over a year to receive the desired amount of power from the utility. Rather than wait, we decided to move forward and installed 1.4 MW chargers with software that limits the amount of power drawn from the grid to 1 MW. This approach allowed us to keep the project moving forward and to get our customer’s vehicles up and running, leaving room for adjustments once the utility has performed the necessary upgrade.

The financial stakes

The costs of getting your fleet’s power strategy wrong can be substantial. Beyond the obvious impact of having expensive assets sitting idle, fleets that discover their local power limitations too late often face additional expenses to cover temporary solutions, expedited engineering studies, and rushed infrastructure work. Conversely, fleets that start with power planning can often find cost savings through utility incentive programs, optimal rate structures, and by implementing scalable and more efficient infrastructure designs.

Looking ahead

The electrification of commercial fleets isn't just a trend; it's inevitable and absolutely critical to sustain a globally competitive economy. Regions that proactively plan for this transition will see the benefits first: improved air quality, reduced emissions, and economic growth from new jobs and investments. Those that delay risk losing out as electric fleets gravitate toward areas with robust infrastructure support.

For fleet managers, the message is clear: Successful electrification requires shifting focus beyond just the vehicles and more toward the power infrastructure that will support them. Those who engage early with utilities, have a deep understanding of their power needs, and plan accordingly will find themselves leading this historic transition.

The future of fleet operations is electric, but the path to that future runs through the power grid. Understanding and planning for your electrical infrastructure needs isn't just another box to check, it's the foundation upon which your entire strategy must be built.