Proposed Tesla Supercharger Installation

Project Details

This project involves the structural design and engineering for the installation of a new Tesla Supercharger station. The comprehensive scope of work includes the structural analysis and design of equipment foundations and connections for four (4) V4 Supercharger posts, a V4 Supercharger cabinet, an 800A switchgear assembly, and a utility transformer. The engineering solutions were tailored to support a modern electrical service infrastructure within an existing parking area. The design process included a detailed loading analysis to ensure stability against environmental forces. Structural elements were engineered in accordance with the California Building Code (CBC 2022), ASCE 7-16, and ACI 318-19 standards. The analysis accounted for a basic wind speed of 96 mph (Exposure Category B) and high seismic requirements, with the site classified under Seismic Design Category D (SDS=1.091; SD1 =0.572). The foundation system utilizes independent reinforced concrete pad footings (f′c=4,000 psi) designed for a gross allowable soil bearing pressure of 1,500 psf. Footing sizes vary by equipment type, such as the 6’ x 5’-6” pads for charger posts and 8’ x 7’ pads for the main cabinets, all reinforced with #5 top and bottom rebar.Equipment is secured using high-performance Hilti Stainless Steel Kwik Bolt – TZ2 expansion anchors, with diameters ranging from 1/2” to 1” to meet specific shear and tension demands. Special provisions were also included for EV Mini Rebounding Bollards to protect the infrastructure from lateral vehicle impacts.

Role

Structural Engineer/Designer

Services Provided

The scope of services included the preparation of structural analysis, design calculations, and structural drawings for the proposed Supercharger installation and associated electrical equipment foundations. Structural analyses were performed for applicable dead, live, wind, and seismic loads affecting the exterior electrical equipment, including Supercharger cabinets, utility transformers, and related concrete pad foundations. The work involved the structural design and verification of new equipment foundations, including overturning, sliding, and uplift evaluations, as well as the design verification of equipment anchorage systems and embedment requirements in accordance with the applicable California Building Code (CBC) and ASCE 7 provisions for the project location. The services also included the preparation of structural drawings identifying foundation layouts for the Supercharger cabinets, utility transformer, and associated electrical gear, together with foundation sections, anchorage details, and typical structural details, notes, and specifications suitable for CD-90 and CD-100 submittal packages. All documents were prepared to facilitate permitting, coordination, and construction implementation.