Engineering Challenges and Solutions

Revamping an old gas station into a modern, fully functional facility requires more than just a fresh coat of paint and updated signage. This type of project involves strategic planning, detailed coordination, and adherence to strict codes and safety requirements. In our recent site visit, we evaluated the existing infrastructure and identified the critical engineering considerations for bringing this gas station up to current standards. Here's a look behind the scenes at some of the critical discussions that shaped our design approach.

Electrical Service Overhaul: Upgrading from Open Delta

During our assessment, we first noticed the existing electrical service configuration—a Delta high-leg system—is standard in older installations but less suitable for modern usage. The clues were clear: two transformers on the pole across the street and a panel labeled "Hi-Leg." A Delta high-leg configuration results in uneven voltage levels, which can cause issues with specific equipment.

A balanced three-phase system ensures consistent voltage across all phases, which is crucial for reliable operation of the electrical equipment, especially for critical components like fuel pumps and lighting.

Strategic Relocation of Electrical Equipment

Maintaining proper clearance and separation from combustible materials is a top priority in a retrofit project like this. Our team faced a challenge when planning the placement of the new electrical service because of the location of the existing kerosene tank.

"Be mindful of our working clearances and separation from combustible or explosive materials like this kerosene tank," Carter advised during the walkthrough. To address this, we decided to shift the new electrical equipment down the wall to a safer location, ensuring compliance with safety codes and easier maintenance access.

Dedicated Circuits and Utility Stations

Modern gas stations often feature additional amenities, such as air compressors and vacuum stations, to provide added value to customers. For this project, we identified a location on the property that would allow for smooth traffic flow without interfering with other activities.

These details may seem minor, but they play a critical role in creating a safe and efficient layout that improves customer experience while minimizing congestion.

Lighting and Security Considerations

Proper lighting is essential for both customer comfort and safety, especially at facilities that operate around the clock. Our lighting plan for this project includes a mix of canopy lights for the gas pumps and security lighting around the perimeter of the building.

For the front façade, we opted for more decorative fixtures like Goosenecks, which offer both functionality and aesthetic appeal. 

Mechanical and Sanitary Systems Integration

In addition to electrical upgrades, the project requires significant work on the mechanical and sanitary systems. The crawl space below the building currently houses a mix of PVC and cast iron pipes that will need to be removed and replaced to accommodate the new slab-on-grade foundation.

Once these systems are replaced, we’ll have a more efficient and accessible setup that meets modern plumbing standards.

Understanding NEC Requirements for Fuel Stations

Fuel stations are governed by strict regulations outlined in the National Electrical Code (NEC), particularly regarding wiring methods and explosion-proof specifications. All circuits need to be carefully routed to prevent potential safety hazards.

By following these guidelines closely, we ensure that our design meets the highest safety standards and protects both the facility and its occupants.

HVAC Design Approach

For this project, the HVAC system design will incorporate a Type I hood, which is only expected to be used twice daily—once during breakfast and again at lunch. Unlike a typical restaurant that operates its hood system for long hours, the limited usage here significantly changes the cooling and ventilation needs.

The client acknowledged that the hood may create some comfort issues during these short operating periods but expressed a willingness to accept minor discomfort, particularly during the summer months when warm air infiltration can occur.

We discussed the option of installing multiple split systems throughout the space to handle sensible loads effectively, as well as adding a ducted dehumidifier in the attic to help manage moisture in the kitchen area after the hood shuts off.

For the residential portion of the building, we'll use a ducted mini-split system to create a dedicated zone that maintains comfort without being affected by the varying conditions in the commercial kitchen.

Bringing It All Together

Transforming an old gas station into a state-of-the-art facility is no small feat. It involves a blend of careful planning, engineering expertise, and attention to detail to address the unique challenges presented by older infrastructure. Our team is excited to see this project take shape, and we’re confident that the final result will be a safe, efficient, and visually appealing space that serves the community for years to come.

Stay tuned as we continue to share updates and insights from this and other projects. If you’re interested in learning more about our approach to adaptive reuse and retrofitting projects, feel free to reach out or leave a comment below!