Some projects don't fit a catalog. The equipment is oversized, the configuration is non-standard, the timeline is tight, and the cost of getting it wrong is high.
That's exactly the kind of project we live for.
When an existing Safe-T-Cover customer needed two large, fully custom enclosures for a complex glycol pump system — and needed them fast — standard options were never on the table. Here's how our team delivered a solution built to exact specifications, on time and a day ahead of schedule without sacrificing product quality.
About the Project
| Industrial HVAC / Glycol Systems | |
|---|---|
| Project Type | Custom aluminum enclosure — two units |
| Equipment | Multi-pump glycol systems with air separator and expansion/bladder tanks |
| Mounting | Skid-mounted (non-standard) |
| Timeline | 3 weeks, sign-off to on-site |
| Outcome | On-time delivery, one day early |
The Challenge
A Complex System With No Room for Error
The customer had a system that simply couldn't be protected by anything off a shelf — and they were also in a time crunch. They needed two purpose-built industrial enclosures for glycol pump configurations that were large, mechanically complex and skid-mounted — not the standard concrete slab most enclosures are designed around.
The first enclosure would house a four-pump glycol system with a tangential air separator tank and bladder tank. The second would protect a three-pump glycol system, also with a tangential air separator tank and expansion tank. Both had to be ready for demanding industrial environments — exposure to temperature swings, mechanical stress and the kind of continuous-use conditions that quickly reveal weaknesses in inferior materials.
The design requirements were specific:
- Large enough for maintenance crews to move around inside
- Multiple penetrations for system supply and return lines
- Hinged door access to control panels
- Removable access panels for routine maintenance and component replacement
- Louvers for continuous airflow and thermal management
- Skid-mount configuration (non-standard base attachment)
The Strategic Approach
Safe-T-Cover's engineering team didn't hand the customer a catalog and ask them to pick something close. We worked directly with the customer to design both enclosures from the ground up, translating operational requirements into precise engineering specifications.
That collaboration covered every dimension, penetration, access point and airflow consideration — with close attention to the environmental conditions the enclosures would face in the field. The process moved quickly for two reasons: 1) both sides stayed aligned, and 2) because our team has built enough complex industrial enclosures across industries to know exactly where custom jobs go sideways without careful, proactive planning.
Our experienced estimating team was involved early, which kept the project on track from materials sourcing through manufacturing. Aluminum was the clear choice from the start — not mild steel, plastic, polycarbonate or non-metallic alternatives. For applications that demand strength, corrosion resistance and long-term performance in outdoor or semi-outdoor environments, aluminum is the material that consistently delivers against the elements.
The Solution
Industrial Enclosures Designed To Overcome Potential Obstacles
The larger of the two enclosures measured 71" wide × 175" long × 109" tall — just over nine feet in height. Both units required custom machining of individual components, assembly and pre-delivery testing before they ever left the facility. Product quality was non-negotiable at every stage.
Marine-grade aluminum construction was selected for its ability to withstand harsh environmental conditions — UV exposure, moisture, temperature extremes — without the corrosion, warping or degraded performance that plastics, polycarbonate and metallic alternatives like steel can exhibit over time. These enclosures are designed to exceed and outlast the equipment inside them.
Key build specs:
- Hinged access doors to control panels on both units
- Removable wall panels for 360-degree maintenance access
- Custom penetration points for supply and return lines
- Louver systems sized for adequate airflow and thermal management in each configuration
- Skid-mounting design on both units in lieu of standard slab attachment
The Results
From design sign-off to shipping and on-site delivery: three weeks. For fully custom, large-format industrial or manufacturing enclosures built to detailed mechanical specifications, that's a fast turnaround by any standard. Additionally, the customer received both units a day ahead of their requested ETA.
The project met every specification the customer outlined at the start. No compromises on access, airflow, mounting or structural integrity. No back-and-forth over fit or function after the fact.
Custom Doesn't Have to Mean Costly or Slow
For industrial applications like glycol systems, PRV stations, fire suppression or pump control, the real cost savings come from getting the spec right the first time — not from choosing a cheaper enclosure and retrofitting around it.
Safe-T-Cover's fabrication process is purpose-built for customization. Because components are machined and assembled to order — not pulled from fixed molds or limited stock sizes — our team can accommodate a wide range of dimensional requirements, non-standard base configurations and application-specific penetrations. That flexibility doesn't come with the delays and cost premiums you'd expect from suppliers whose business model depends on volume over versatility.
The result: enclosures that are designed for your installation environment, purpose-built to the certifications and standards your application requires, and delivered on a timeline that doesn't hold up your project.
Safe-T-Cover Builds More Than Backflow Enclosures
Backflow preventer enclosures are our foundation, but our capabilities extend across industrial equipment protection for many industries: glycol pump systems, fire control stations, PRV assemblies, quench tanks, control valve vaults and more. If your application has dimensional, environmental or access requirements that standard products can't meet, that's exactly the kind of project our engineering team is built for.
Spec Your Custom Enclosure. Contact Us Today.
Tell us about your project. Our team will work with you to design an enclosure with features that fit your equipment, your environment and your timeline.
Call us at 1-800-245-6333, chat with us online or send us a request to get started on your custom enclosure.
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