How Safe-T-Cover Engineered a Custom Glycol Enclosure in 3 Weeks

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)

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 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