Background

The U.S. Postal Service selected the Terre Haute Sorting & Delivery Center (S&DC) as one of the first facilities for fleet modernization and electrification. It contracted for the design and installation of 76 parking spaces with charging ports to support the electrical vehicle (EV) rollout. An external contractor performed the commissioning, including the electrical, network, charging, and safety testing in early February 2024. The Terre Haute S&DC was commissioned on February 8, 2024, and carriers began using 21 EVs for delivery in May 2024.

What We Did

Our objective was to assess whether the Terre Haute S&DC was prepared to utilize EVs in delivery operations and the functionality of the EV infrastructure and vehicles. Our audit work, which included conducting observations and using a contractor to perform tests at the facility, was substantially completed before the issuance of the Executive Order, Unleashing American Energy, January 20, 2025.

What We Found

The Terre Haute S&DC infrastructure was sufficiently prepared to support EV use for delivery operations, and all 21 EVs at the facility were being used on local routes. We, however, identified some infrastructure implementation issues related to parking space sizes and electrical panels that hindered operational efficiency and posed safety risks. We also identified other opportunities to enhance charger functionality and facility and equipment security. For example, we found instances of chargers not functioning on a consistent basis — one for 132 consecutive days — as service request requirements were not communicated to local staff and the Postal Service lacked oversight mechanisms for notifying key parties of functionality issues. We also found that the related infrastructure was not secured properly and had insufficient signage. For example, the parking lot gate to the facility and key electrical panels were unlocked, putting nearly $1.6 million in assets at risk.

Recommendations and Management’s Comments 

We made four recommendations to address the issues identified in the report. Postal Service management agreed with three recommendations and disagreed with one. Regardless of the disagreement, we consider management’s comments responsive to all recommendations, and corrective actions should resolve the issues in the report. Management’s comments and our evaluation are at the end of each finding and recommendation.