Highway EV Charging in India: How to Choose the Right Location, Charger Capacity and Business Model

Electric vehicles are changing the way people travel, but longer journeys require more than charging facilities at homes and offices. Drivers travelling between cities need charging stations that are easy to find, conveniently located and reliable when they arrive.

For businesses, this creates an opportunity to develop EV charging facilities along national highways, state highways, expressways and popular intercity routes. Petrol pumps, hotels, restaurants, highway resorts and dedicated rest stops may all be potential locations, depending on traffic patterns, electricity availability and customer demand.

However, installing a fast charger beside a highway does not automatically make it a successful business.

A viable highway charging station requires the right location, suitable power infrastructure, an appropriate mix of chargers, a realistic financial model and reliable day-to-day operations.

Here is how businesses can approach the planning process.

Why Highway EV Charging Needs a Different Strategy

Charging at a home or office is usually planned around the time a vehicle is parked. Highway charging is different because drivers may be travelling long distances and need to continue their journey after a limited stop.

That changes the factors that determine success.

A highway charging station must consider traffic volume, the types of vehicles using the route, journey distances, existing charging facilities, the duration of typical stops and the availability of suitable electrical infrastructure.

Passenger cars may need a relatively short charging stop, while electric buses and trucks can have different power and parking requirements. A location that works for private cars may not automatically be suitable for commercial vehicles.

The objective is not simply to install more chargers. It is to place the right charging facilities where people can use them conveniently and consistently.

1. How to Choose the Right Highway Charging Location

Location selection should begin with evidence rather than assumptions.

Study traffic and vehicle movement

Before committing to a site, evaluate:

• Traffic volumes, including available toll and highway traffic data.
• Whether the route connects major cities, industrial areas, logistics hubs, ports or tourism destinations.
• The presence of electric cars, taxis, delivery vehicles, buses or trucks along the corridor.
• Existing charging stations, their connector types and their accessibility.
• Expected traffic growth and nearby developments that could influence future demand.

The Ministry of Heavy Industries' PM E-DRIVE operational guidelines identify high-traffic highways and routes connecting major cities, industrial hubs and ports as relevant considerations when prioritising highway charging infrastructure.

This makes location assessment an important part of planning rather than a decision to make after purchasing the chargers.

Place charging stations where drivers already stop

Drivers are more likely to use a charging station when it fits naturally into their journey.

A charging facility near a restaurant, hotel, fuel station, washroom, food court or established rest stop can offer a more convenient experience than an isolated charging point.

For commercial vehicles, existing stopping patterns are particularly important. Charging opportunities can be planned around logistics hubs, truck parking areas, terminals and locations where vehicles already pause during their routes.

The aim is to make charging part of the journey rather than force drivers to make an unnecessary detour.

Check access, visibility and safety

A potential site should have convenient entry and exit, adequate parking, clear signage, sufficient space to manoeuvre, lighting, security and safe pedestrian movement.

Also check whether vehicles travelling in both directions can reach the facility conveniently. A charging station may have good traffic passing it but still be inconvenient if drivers must make a substantial detour to access it.

Practical tip: Visit shortlisted sites at different times of day. Observe actual traffic movement, parking behaviour, accessibility and nearby amenities before making a final decision.

2. Check Electricity Availability Before Installing Chargers

Electrical infrastructure can be one of the most important factors in deciding whether a highway charging project is feasible.

A site may have sufficient physical space for several fast chargers but may not have enough available grid capacity to operate them simultaneously.

Before finalising the project, discuss the proposed load with the relevant electricity distribution company, or DISCOM, and assess:

• Available sanctioned load and the connection requirements.
• Distance from suitable electrical infrastructure.
• Transformer, cabling, protection equipment and distribution upgrades.
• Expected electricity connection timelines and associated costs.
• Space for electrical equipment and future capacity expansion.
• The feasibility of solar generation or battery energy storage, where appropriate.

For example, installing four high-power chargers does not mean the site can safely or economically operate all four at their maximum rating at the same time.

The design should account for expected simultaneous demand, available supply and future expansion plans.

Load management can help allocate available power between connected chargers, but it cannot replace an adequate electricity connection.

3. Choose the Right Charger Capacity for the Route

There is no single charger configuration that suits every highway.

The right choice depends on the vehicles being served, the time they are expected to remain parked, the available grid capacity and the site's commercial objectives.

DC fast charging for highway passenger vehicles

DC fast chargers are often suitable for locations serving electric cars travelling long distances. Their actual charging performance depends on the vehicle's battery, charging curve, state of charge, temperature and supported power rating.

A higher-rated charger does not guarantee that every vehicle will charge at that rate.

Before selecting a charger, check connector compatibility, expected vehicle types, power requirements, reliability, warranty coverage and the availability of technical support.

Higher-power charging for buses and trucks

Electric buses and heavy commercial vehicles may require higher-power charging, larger parking bays and different electrical infrastructure.

For reference, the PM E-DRIVE operational guidelines published in September 2025 specify CCS-II DC charging capacities of 50–250 kW for electric four-wheelers and a higher-power category of 250–500 kW for electric buses and trucks, with additional requirements for the latter category under the scheme.

These are scheme-specific technical references, not a universal prescription for every private project. Final specifications should be verified against the latest applicable standards, vehicle requirements and funding conditions.

Consider a phased installation

Rather than investing in a large number of chargers immediately, a site owner may consider launching with a suitable initial capacity and adding chargers as verified demand grows.

This approach can reduce the risk of investing heavily in equipment that remains underused.

However, electrical infrastructure, cabling routes, parking layouts and land use should be planned with potential expansion in mind so that future additions do not require unnecessary reconstruction.

4. Build a Charging Hub, Not Just a Charging Point

A convenient highway charging experience involves more than plugging in a vehicle.

Depending on the target audience, useful facilities may include:

• Clean toilets and drinking water.
• Food, refreshments and comfortable seating.
• Well-lit and secure parking.
• Clear directions and charger identification.
• Reliable mobile connectivity.
• Support for drivers when a charging session fails.
• Accessible payment methods and transparent pricing.

The ideal facilities depend on the expected charging duration and customer profile.

A passenger-car charging hub may benefit from a comfortable short-stop experience, while a site serving commercial fleets may need more space, vehicle-specific parking and better coordination with operating schedules.

Amenities also create opportunities for site owners to generate additional value through food sales, accommodation, retail and other services. These should be evaluated using the site's actual customer profile rather than assumed as guaranteed revenue.

5. Evaluate the Business Model Before Investing

Highway charging projects can use different operating arrangements. The appropriate model depends on the site owner's objectives, capital availability, operational capabilities and expected demand.

Site ownership and direct operation

The business invests in the charging infrastructure and manages the operation directly or through service providers.

Potential revenue comes from charging sessions, subject to tariffs, delivered energy, operating expenses and utilisation.

This model provides greater operational control but exposes the business to installation costs, maintenance requirements and demand risk.

Partnership with a charging operator

A property owner can partner with a charging point operator or charging technology provider.

Depending on the agreement, the parties may share installation costs, responsibilities, operating revenue or other commercial benefits.

The agreement should clearly specify equipment ownership, electricity costs, maintenance responsibilities, pricing authority, customer support, revenue settlement and contract duration.

Fleet and commercial partnerships

Locations serving taxis, logistics vehicles, buses or commercial EV fleets may explore recurring usage arrangements with fleet operators.

Regular demand can make planning easier, but the agreement should account for actual vehicle schedules, charging requirements and service availability.

How to estimate financial feasibility

A basic financial model should include expected charging demand and all significant operating costs.

Estimated gross charging revenue = Daily energy sold × Average selling price per kWh × Operating days

This is a starting point, not a profit calculation.

Subtract electricity procurement costs, land rent, maintenance, software fees, staffing, network connectivity, payment costs, financing expenses and other applicable costs to estimate operating performance.

Model at least three scenarios:

• Conservative: Lower-than-expected utilisation during the initial months.
• Base case: Demand based on researched vehicle movement and comparable sites.
• Growth case: Higher utilisation supported by route growth or fleet agreements.

Do not estimate profitability using charger power alone. A high-power charger that rarely delivers energy may perform worse financially than a smaller, consistently used installation.

6. Why Charging Software and Monitoring Matter

Drivers need to know whether a charger is available, working and ready to start a session.

Operators need to understand whether chargers are operating correctly, how much energy is being sold, when demand peaks and where service issues are occurring.

A connected charging management system can help operators monitor charger status, track sessions, manage tariffs, review performance and identify operational problems remotely. Actual functionality depends on charger compatibility, system capabilities and network connectivity.

For highway locations, practical priorities include:

• Live charger availability and status.
• Reliable payment and session-start workflows.
• Remote monitoring and fault alerts.
• Energy and revenue reporting.
• Support processes when a charger becomes unavailable.
• A process for maintaining accurate station information across discovery platforms.

A failed charging session can cause more than a lost transaction. It may disrupt a driver's journey and reduce confidence in the location.

Operators should therefore monitor uptime and successful charging sessions alongside revenue and energy sold.

7. What Do Indian EV Charging Regulations Mean for Highway Projects?

The Ministry of Power issued the Guidelines for Installation and Operation of Electric Vehicle Charging Infrastructure-2024, which cover charging infrastructure on highways and expressways as well as private, semi-restricted and other public locations.

The guidelines address charging infrastructure, electricity supply, technical requirements and related operating considerations.

Separately, the PM E-DRIVE scheme includes support for public charging infrastructure and identifies eligible entities, priority locations and technical conditions. Businesses should not assume that every privately owned charging station automatically qualifies for scheme funding.

Before committing capital, review the current guidelines, relevant DISCOM requirements, electrical and fire-safety requirements, land-use conditions and the specific terms of any public-land or funding arrangement.

Useful official references:

• Ministry of Power: EV Charging Infrastructure Guidelines, 2024 (PDF)
• Ministry of Heavy Industries: PM E-DRIVE Public Charging Station Operational Guidelines (PDF)
• NITI Aayog: Electric Vehicle Charging Infrastructure and Its Grid Integration in India (PDF)

8. Highway EV Charging Site Readiness Checklist

Before proceeding with an installation, verify that the project has:

• A researched target market and evidence of likely charging demand.
• Convenient access, visibility and safe vehicle movement.
• Suitable land rights and space for the proposed layout.
• A confirmed plan for electricity supply and grid upgrades.
• Charger specifications matched to the vehicles expected to use the site.
• A realistic capital and operating cost estimate.
• A maintenance plan and a clear customer-support process.
• A monitoring, payment and reporting solution.
• A plan for measuring utilisation, uptime and financial performance.
• A practical approach to future expansion.

Frequently Asked Questions

How many highway EV chargers should a new station install?

There is no universally suitable number. The decision depends on expected demand, traffic patterns, the types of vehicles served, available electrical capacity, space and the cost of expansion. Start with evidence-based demand estimates and plan the site so additional chargers can be added when justified.

Are DC fast chargers always the best choice for highways?

Not automatically. DC fast charging can serve drivers who need to continue their journey quickly, but the best configuration depends on vehicle compatibility, charging behaviour, grid capacity and site economics.

Can hotels, restaurants and fuel stations install EV chargers?

These locations can be suitable candidates, subject to site feasibility and applicable technical, safety, electricity and local requirements. Their existing amenities may also make them convenient for drivers during charging stops.

How can a highway charging operator improve profitability?

Focus on the factors that influence delivered energy and operating costs: location, charger availability, charging demand, pricing, power costs, maintenance and customer experience. Financial projections should be based on researched assumptions and updated using actual operating data.

Conclusion

India's highway EV charging opportunity is not simply about installing more chargers. It is about building convenient, reliable and financially viable charging facilities along the routes where drivers and commercial fleets need them.

Businesses that evaluate locations carefully, plan their electricity infrastructure early, select appropriate chargers and invest in dependable operations will be better placed to respond as electric mobility expands.

Planning a highway EV charging project? Explore Savekar's EV charging solutions to learn more about charging infrastructure, connected operations and charging management for commercial locations.