A full worked workplace/fleet EV charging design — 12 Level 2 stations plus a 150 kW DC fast charger, a NEC 625.42 load calculation that exceeds the existing service's spare capacity, and the load-management strategy that fits the buildout in anyway without a utility service upgrade.
The project brief: a distribution depot with an existing 800A, 480Y/277V service wants 12 Level 2 pedestal chargers for employees plus one 150 kW DC fast charger for fleet turnaround. Framed as this program's load-management case study, it is the one real project where the engineering challenge isn't sizing generation or storage at all — it's fitting a code-mandated, non-diversified electrical load onto a service that was never designed to carry it.
This module walks the whole design the way a real EV infrastructure engineer would: the NEC 625.42 load calculation showing the raw nameplate demand exceeds the site's available capacity, the NEC 625.42 EVEMS exception that closes the gap without a service upgrade, and the resulting panel, feeder, and site-layout design. The full worked numbers, complete bill of materials, and finished design reasoning are part of the unlocked module below.