Project Overview
A regional charging network operator secured NEVI funding to deploy EV charging infrastructure along a 200-mile interstate highway corridor. The project required 4 sites with 4 charging ports each (150kW minimum per port), full Buy America compliance, and OCPP 2.0.1 network integration.
FBK POWER was selected as the equipment supplier based on our Buy America-compliant manufacturing, UL certifications, and experience with large-scale deployments.
The Challenge
Buy America Compliance
Finding EV charging equipment with >55% domestic content proved difficult. Most manufacturers source key components from overseas.
Utility Coordination
Each site required 1MW+ electrical service upgrades. Utility timelines varied from 3-8 months, threatening the 18-month NEVI deadline.
Permitting Across 4 Jurisdictions
Each site was in a different county with unique permitting requirements, inspection schedules, and environmental reviews.
97% Uptime Requirement
NEVI mandates 97% annual uptime. With 4 sites × 4 ports, any single port failure could jeopardize compliance.
The Solution
Buy America-Compliant Equipment
FBK POWER's US assembly facility in Texas produced charging cabinets with >60% domestic content. Complete documentation including manufacturer affidavits, cost breakdowns, and steel mill certifications.
Modular Power Architecture
Split-type DC charging cabinets (4×150kW per site) with modular power modules. If one module fails, remaining modules continue operating at reduced power, maintaining uptime.
Remote Monitoring & Predictive Maintenance
OCPP 2.0.1 integration with real-time monitoring dashboard. Predictive algorithms identify potential failures before they occur, enabling proactive maintenance and 97%+ uptime.
Implementation Timeline
Application & Award (Months 1-3)
Submitted NEVI application with complete Buy America documentation, site plans, and utility feasibility letters. Awarded funding covering 80% of $1.2M project cost.
Design & Permitting (Months 4-8)
Engineering design for all 4 sites. Permitting in parallel across 4 counties. Utility interconnection agreements signed. Electrical upgrade construction began.
Equipment Manufacturing (Months 6-10)
FBK POWER's Texas facility manufactured 16 charging cabinets with Buy America documentation. Each unit underwent 72-hour burn-in testing before shipment.
Installation (Months 11-15)
Installation teams worked sequentially: Site 1 (Month 11-12), Site 2 (Month 12-13), Site 3 (Month 13-14), Site 4 (Month 14-15). Each site took 3-4 weeks.
Commissioning & Go-Live (Months 16-18)
UL inspection, power output verification, OCPP network integration, payment system testing, and staff training. All 4 sites operational by Month 18.
Results & Impact
Key Metrics
- • 4 sites operational within 18-month NEVI deadline
- • 16 charging ports at 150kW each (600kW per site)
- • 98.2% uptime (exceeding 97% NEVI requirement)
- • Full Buy America compliance with >60% domestic content
- • OCPP 2.0.1 certified with ISO 15118 Plug & Charge
- • 2,500+ daily charging sessions across 4 sites
- • $45,000 average monthly revenue per site
- • 4.7/5.0 user satisfaction rating
- • Zero safety incidents during construction
- • State DOT recognized as model NEVI project
"FBK POWER's Buy America expertise and modular equipment design were instrumental in meeting our NEVI compliance requirements. The 98.2% uptime speaks to the quality of their manufacturing."
Lessons Learned
Start Utility Coordination Early
Electrical upgrades took 3-8 months across sites. Starting utility discussions before NEVI application would have saved 2 months.
Buy America Documentation is Critical
Incomplete Buy America documentation is the #1 reason for NEVI application rejection. Work with suppliers who provide complete documentation packages.
Modular Design Reduces Risk
Modular power modules allowed us to maintain uptime even when individual modules required service. This was critical for meeting the 97% requirement.