For EV charging networks, scaling charging infrastructure nationwide presents unique challenges. The need to deliver charging solutions at competitive volume, scale, and speed, paired with rising material and labor costs, is influencing how networks design and build their sites. Faster installation times translate directly into lower cost, quicker revenue generation, and earlier access for EV drivers. This is where precast concrete solutions make a meaningful impact, helping streamline construction and accelerate deployment.

The Core States Energy team is proud to introduce CoreCast™: a ready-made EV foundation solution that enables seamless application and efficient construction of EV charging infrastructure.

(Patent Pending)

What is CoreCast™?

As the EV market continues to mature, clients are exploring ways to meet growing demand while managing construction costs. In response to this shift toward more efficient installation strategies, our team set out to create a solution that leverages our comprehensive design and construction expertise. Through the high volume of equipment pads we have designed and delivered, we identified that despite varying site constraints and equipment requirements, the pads themselves are largely consistent in form. This understanding, combined with collaboration across our in-house services, led to the development of CoreCast™.

The CoreCast™ concrete skid system is designed to be large enough to meet spacing requirements between equipment but compact enough to fit multiple pads on a wide range of sites. Our design team incorporated cutouts on both sides of the precast structure to support interchangeable, equipment-specific steel inserts. This approach makes CoreCast™ a universally adaptable solution across diverse client applications, allowing both the rapid deployment of current EV charging solutions and the ability to future-proof sites for the next generation of EV charging.

Precast Solutions for EV Charging Installation

Traditional EV charger installations require poured-in-place concrete foundations – a multi-day, weather and inspection-dependent process involving framing, rebar, pouring, and curing. CoreCast™ replaces this with a fully formed precast skid. Once placed on-site, the skid supports same-day equipment installation and is designed for DCFC Level 3 charging and capable of supporting next-generation Megawatt Charging Systems (MCS). This approach allows precise pad placement, rapid equipment setup, and conduit connections to be completed in hours rather than days.

Key Advantages of CoreCast™:

• Faster Installation: Prefabricated skids arrive ready to be set in place, and integrated bollards can be added in hours, not days, with ready-made bollard sleeves, dramatically shortening construction schedules.
• Weather-Resilient Deployment: Factory-controlled curing eliminates weather-related delays and delivers consistent, high-quality results.
• High-Volume Scalability: Modular, repeatable systems enable rapid rollout across multiple sites — ideal for expanding EV charging networks.
• Cost Efficiency: Universal pad compatibility and condensed installation timelines significantly reduce overall project costs.
• Future-Proof Design: Equipment can be upgraded or replaced without demolishing or rebuilding the concrete foundation.
• Seamless Project Coordination: Core States Energy’s integrated engineering and construction teams are fully involved in the design and construction processes from start to finish, minimizing the need for multiple outside consultants and streamlining the entire project lifecycle.

Core States Energy’s CoreCast™ solution transforms traditionally time-consuming and costly EV charging installations into a streamlined approach, with multiple in-house services ensuring EV applications have consistency, scalability, and high-quality results.

*On a typical 8-stall DCFC site

The Future of EV Charging Installations

The shift toward modular, precast EV charging infrastructure represents more than just efficiency — it’s a new construction philosophy. As EV adoption grows, the need for scalable, repeatable, future-proof, and reliable EV charger mounting solutions will continue to expand.

Precast concrete skids enable EV partners to move faster, standardize quality, and future-proof sites for evolving technologies surrounding high-speed public and fleet charging systems.

Precast concrete skids offer a smarter, faster, and more sustainable approach to building the EV charging networks of tomorrow. Whether an organization is deploying five stations or five hundred, adopting prefabricated concrete pads for EV charging stations can accelerate electrification, without compromising quality or performance.

The future of EV charging infrastructure is modular, flexible, and factory-built, and CoreCast™ is leading the charge.