Overview
Company: Pritchard Companies
Type: Dealer Charging
Location: Mason City, Iowa
Case Study Publish Date: October, 2024
Vehicle Class: Medium Duty, Class
Case Study
Setting the Stage: Preparing for EV Compliance
The transition to selling commercial electric vehicles presents unique challenges for OEM dealers. Beyond selling traditional internal combustion engine (ICE) vehicles, dealers must now meet strict EV compliance standards set by OEMs. These requirements often include installing on-site chargers, upgrading facilities to support EV maintenance, and ensuring infrastructure scalability.
In Mason City, Iowa, Pritchard Companies partnered with SHAED to navigate these hurdles and meet General Motors’ compliance standards. This case study explores the challenges they faced, the solutions implemented, and the key lessons learned, offering valuable insights for dealerships preparing to electrify their operations.
The Mason City Project
Project Overview
General Motors’ commercial dealerships aiming to sell electric vehicles, such as Bright Drop, must meet stringent EV compliance requirements. This includes installing EV charging infrastructure at locations where the vehicles will be housed during the sales process. To achieve compliance, Pritchard Companies undertook a comprehensive project that required the installation of two Level 2 charging ports, a new hydraulic lift for the shop, and the procurement of an electric forklift. The project was estimated to take 4–6 months, with an anticipated cost of approximately $207,000
OEM Requirements:
- Installation of 2 L2 Chargers minimum of 19.2kW
- Installation of new hydraulic lift for the service bay
- Procurement of a new electric forklift
- Installation of new 240V outlet inside the service bay for L1 charging
Vehicle Overview:
Types of Vehicles: Class 2 and Class 3, Medium duty all electric vehicles
EV Deployment Timeline: June,2024 -September, 2024
Charging Overview:
Charging Infrastructure:
- 2 – L2 22.5kW Chargers
- Future infrastructure for 1- 7.5kW L2 charger
Charging Infrastructure Project Cost:
- Anticipated cost ~$207,000
- Cost per port: $41,400
- Cost per kW: $3,943
- Final cost after optimization ~$132,000
- Cost per port: $26,400
- Cost per kW: $2,515
Challenges
The rise of electric vehicles has introduced significant challenges for dealerships aiming to meet OEM compliance requirements. At the Pritchard Companies’ Mason City location, these challenges highlighted the complexities of transitioning to EV infrastructure:
- Understanding and Meeting OEM Compliance Requirements:
General Motors’ EV compliance standards required precise alignment with technical specifications, including charger types, power outputs, and infrastructure readiness. - Selecting the Right Charging Infrastructure:
Deciding on charger types and configurations required careful consideration to align with both current needs and future scalability. - Power Supply Assessment:
Ensuring adequate on-site power or arranging for additional utility feeds proved critical to maintaining project timelines and budgets. - Choosing an Effective EPC Partner:
Selecting a reliable Engineering, Procurement, and Construction (EPC) contractor was vital for project execution, balancing cost-effectiveness with quality outcomes.
Solutions
The Mason City project addressed these challenges through strategic planning and execution, resulting in a successful deployment and key insights for future dealership EV compliance efforts:
- OEM Compliance Achieved Through Thoughtful Planning:
By thoroughly understanding and adhering to General Motors’ requirements, Pritchard Companies installed a 19.2kW high-powered Level 2 charger and a 7.2kW charger. Future-proofing measures, such as pre-installed conduit for expansion, ensured long-term compliance readiness. - Selecting the Right Infrastructure:
The dealership carefully selected chargers tailored to its operational needs, striking a balance between functionality and cost-effectiveness. While a DC fast charger was initially considered, it was ultimately deemed unnecessary for this use case. This decision, based on a thorough understanding of the dealership’s requirements, highlighted the suitability of Level 2 chargers for their operations. By opting for L2 chargers, the dealership not only met compliance standards but also achieved significant cost savings, reducing expenses by approximately $45,000 per station. - Proactive Power Supply Solutions:
Early engagement with the local utility ensured that power requirements were efficiently addressed, minimizing potential schedule disruptions. By proactively assessing and leveraging onsite power availability, the dealership avoided costly upgrades and delays. This strategic approach not only kept the project on track but also resulted in significant savings, reducing equipment and labor costs by approximately $75,000 - Strategic EPC Partnership:
Leveraging an OEM-recommended EPC contractor streamlined the project’s execution and ensured high-quality outcomes. By carefully evaluating multiple EPC options, the dealership was able to control costs while selecting a partner with in-depth knowledge of dealership requirements. This strategic choice expedited the project timeline, reducing the typical completion time from 6–8 months to just 4 months.
Closing Summary
The Pritchard Companies’ successful EV compliance project in Mason City, Iowa, exemplifies the transformative potential of strategic planning and collaboration in dealership electrification. By addressing challenges such as aligning with General Motors’ stringent standards, optimizing charging infrastructure, and proactively resolving power supply issues, the dealership not only achieved compliance but also set a foundation for scalable future growth.
This project highlights critical lessons for the industry: thoughtful preparation, selecting the right partners, and leveraging tailored solutions can dramatically streamline the transition to EV readiness. By reducing project costs by 36% from an estimated $207,000 to a final optimized cost of $132,000, Pritchard Companies demonstrated that EV deployment can be both effective and cost-efficient when approached with precision.
As EV adoption accelerates, the Mason City project serves as a roadmap for dealerships nationwide. It underscores the importance of innovation, adaptability, and a commitment to sustainable practices in shaping the future of the automotive industry. Pritchard Companies’ achievement is not just a win for Mason City but a testament to what is possible for dealerships embracing the EV revolution.
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Written by John Lanham
January 2025
