25-003 | Transforming Warehouses into Cutting-Edge EV Facilities: A Complete Design Breakdown

Atlanta, GA | Jan 2025 - Apr 2025

Electric vehicles are changing more than what we drive—they’re changing how facilities operate. Fleets are electrifying. Service models are evolving. Power demands are rising. And many of the buildings that will support this transition already exist: warehouses built for a different era, with layouts and infrastructure that weren’t designed for chargers, high-capacity electrical service, ventilation needs, or modern life-safety expectations.

That’s where design becomes the difference between “adding chargers” and building a facility that actually works.

This post breaks down how JBrennon Construction, Inc. delivered Phase 1 design for a major warehouse conversion into an EV-ready parking and maintenance hub, with 101 EV-ready parking spaces, maintenance functions, office/support space, and hazmat storage—coordinated across architecture, mechanical systems, and electrical infrastructure to reach permit-ready documentation while maintaining compliance with applicable building codes, NEC, NFPA, and ADA requirements.

Why Warehouse Conversions Are the Front Line of EV Infrastructure

New construction isn’t always the fastest path to electrification. Converting an existing warehouse can save months—sometimes years—if the design accounts for the realities of EV operations:

• High-density vehicle circulation and staging

• Charger placement and future expansion

• Maintenance workflows and indoor air quality

• Utility capacity, distribution, and resiliency

• Safety controls, hazmat separation, and code compliance

Phase 1 design established the foundation for all of it—because if the underlying infrastructure is wrong, every future phase becomes more expensive, more disruptive, and more difficult to permit and operate.

Reconfiguring Space for Real EV Operations

The architectural redesign focused on turning an open warehouse shell into a facility that could support both daily fleet parking and hands-on service work without bottlenecks. The space planning introduced distinct operational zones, each designed around how EV fleets actually function:

• EV-ready parking (101 spaces): The layout supported clear circulation, vehicle access, and dedicated charging zones with provisions for Level 2 and DC fast charging infrastructure.

• Maintenance bays: Areas were organized with appropriate clearances and support systems for EV service tasks and fleet readiness work.

• Business and support space: Office and operational zones were incorporated for management and coordination needs.

• Hazmat storage: Dedicated rooms were planned to safely separate hazardous materials such as methanol, coolant, brake fluid, and transmission fluid, supporting safer handling and compliance.

Design also accounted for operational safety: marked pedestrian movement, separation from vehicle paths, and accessibility planning consistent with ADA requirements.

Mechanical Systems That Matched the Safety Profile of an EV Facility

EV facilities bring new mechanical challenges—especially when charging, maintenance, and staged vehicle storage occur under one roof. Phase 1 mechanical design modernized the HVAC approach to support both people and process:

• HVAC upgrades were designed to improve indoor comfort and air quality across both operational and office areas.

• Ventilation and exhaust strategies were incorporated to manage maintenance-related conditions and smoke removal needs.

• Forklift battery charging ventilation was addressed through dedicated exhaust and hydrogen detection provisions to mitigate risk.

• Ductwork and performance strategies were designed with energy efficiency in mind, including sealing/insulation measures and standards-aligned fabrication expectations (e.g., SMACNA).

These systems were not “nice-to-haves”—they were foundational to running a high-activity EV and fleet environment safely.

Electrical Infrastructure Built for Charging, Growth, and Continuity

EV projects succeed or fail in the electrical design. It’s not just the chargers—it’s distribution, protection, expandability, and the ability to keep operations running when the grid doesn’t cooperate.

Phase 1 electrical design established a robust backbone for phased charger deployment and facility operations:

• Service and distribution upgrades were designed to support increased load from EV charging, lighting, and garage equipment.

• A scalable, phased approach allowed EV charging capacity to grow as utility service and project phases advanced.

• Resiliency planning incorporated two emergency LNG generators to support critical loads during outages, including lighting, HVAC, and operational systems where required.

• The design included provisions for a 2.5 MVA transformer along with switchgear/metering concepts to meet the facility’s long-term power demands.

• Safety and reliability were addressed through grounding/bonding strategy, protective device coordination, and surge protection planning.

In practical terms: the design did not treat EV charging as an add-on. It treated charging as a mission-critical power system—because in electrified fleet operations, it is.

Designing for Scalability and Long-Term Flexibility

The most expensive EV facility mistakes aren’t in the first build—they show up during expansion. Phase 1 design explicitly planned for future growth and evolving technology:

• Infrastructure corridors and distribution logic supported future charger additions with reduced rework.

• Space programming allowed maintenance and parking zones to adjust as service models evolve.

• Resiliency systems and life-safety planning supported continuity and safe operations over time.

This created a facility that could grow without “starting over” every time charging demand increased.

Why This Kind of Design Matters

A warehouse conversion like this is more than a renovation—it’s an infrastructure transition. Done well, it delivers:

• Safer fleet operations through clear zoning and code-aligned life-safety planning

• Higher efficiency with layouts that match real vehicle workflows

• Lower long-term cost through scalability and expansion-ready systems

• Reduced risk by resolving electrical and mechanical realities before construction

• Stronger resiliency and operational continuity through emergency power planning
  

This is what design-build thinking looks like at the design stage: anticipate the hard problems early, document them clearly, and set construction up for success.