Building the Perfect On-Site Truck Charging or Refueling Blueprint

As the trucking industry shifts toward electric and hydrogen-powered fleets, fleet operators are faced with a new challenge of how to build an efficient, scalable, and future-ready refueling infrastructure. While traditional diesel trucks can fill up at widely available stations, zero-emission vehicles often rely on depot-based charging or hydrogen refueling systems. Creating a well-planned on-site energy hub isn’t just about installing equipment but about designing a sustainable, cost-effective system that ensures uptime, supports scalability, and maximizes energy efficiency.

The transition starts with understanding your fleet’s operational profile. Not all fleets have the same energy needs. A local delivery fleet operating within a city may require slow overnight charging for dozens of light-duty EVs, while a long-haul logistics company may need fast-charging infrastructure to support heavy-duty electric trucks with 400–800 kWh battery packs. Meanwhile, fleets adopting hydrogen fuel cell trucks must account for high-pressure refueling equipment, gas storage, and safety buffers. In both cases, accurate modeling of your daily mileage, route cycles, and dwell time is essential before any ground is broken.

Grid capacity and energy source are next. For electric fleets, your local grid must support the extra load imposed by multiple simultaneous charging sessions. This often means coordinating with utility providers to upgrade transformers, switchgear, or even establish dedicated substations. Forward-thinking fleets also pair on-site solar arrays or wind turbines with battery storage systems to reduce peak demand charges and increase energy resilience. Some facilities go a step further by becoming microgrids capable of operating independently during grid outages, ensuring fleet reliability even in emergencies.

Charger selection and layout are at the heart of a successful on-site design. There are typically three charging levels to consider: Level 2 (AC, 7–22 kW), DC fast chargers (50–150 kW), and high-power DC chargers (250–500+ kW). For heavy-duty trucks, DC fast charging is non-negotiable. Chargers must be positioned to support both parallel access (charging multiple trucks side by side) and drive-through lanes, which eliminate the need to reverse large vehicles. Pedestal placement, cable management, and vehicle turning radius are all critical details that impact driver experience and safety.

Furthermore hydrogen-powered trucks, refueling infrastructure is more complex. A standard hydrogen station includes an electrolyzer or delivery system, high-pressure gas storage tanks (typically 350 or 700 bar), a compression system, and one or more dispenser units. These systems require proper zoning, strict fire safety compliance, and buffer zones around hydrogen storage. Hydrogen refueling often takes 10–20 minutes, similar to diesel refueling, which reduces vehicle downtime but requires careful flow management to prevent bottlenecks during peak hours.

Driver amenities and workflow optimization shouldn’t be overlooked. While vehicles are charging or refueling, drivers may need rest areas, office access, or overnight lodging. The layout of your yard should promote efficient movement of trucks between maintenance bays, loading docks, and charging stations without creating congestion. Lighting, signage, and weather protection further enhance safety and driver satisfaction.In addition from a financial perspective, on-site charging and refueling infrastructure is a significant investment. A well-executed charging hub becomes not only a competitive advantage but also a strategic asset that supports operational resilience, energy cost control, and environmental goals.

At CAMC, we work closely with logistics providers, municipalities, and private fleet operators to design and deploy custom charging and refueling infrastructure. Whether you're piloting five trucks or electrifying an entire yard of 100 units, our team offers engineering guidance, hardware compatibility consultation, and software integration support.

In the end, building the perfect on-site truck charging or refueling blueprint isn’t just about infrastructure it is about building a smarter, cleaner future of transport. One that is resilient, efficient, and ready for the road ahead.