16' x 37' Welded Substation Enclosure
A U.S. military base in Guam needed a way to weatherproof and enclose a critical transformer that communicates directly to space. Replacing the unit was not an option—the lead time for a new transformer exceeded two years and the cost would have been in the millions. The challenge was to create a durable enclosure that could withstand Category 5 hurricane conditions while also being serviceable and capable of handling the heat generated by the transformer.
Solution
Panel Built, in collaboration with Abigail Kirk at Raytheon Technologies, designed and delivered a welded, preassembled, two-piece electrical enclosure. Fabricated at our Blairsville, Georgia facility, the structure was engineered to meet a 210 mph wind load, integrate impact-rated hurricane doors, and include HVAC systems capable of handling 18 tons of heating and cooling.
To address Guam’s logistical difficulties, the enclosure was manufactured entirely under one roof, then shipped in two large components. These were transported by truck to Long Beach, California, loaded onto a barge for a two-week sea voyage, cleared customs on arrival, and delivered by crane to Anderson Air Force Base. On-site welding joined the prefabricated halves together, ensuring precision alignment and structural integrity.
Key Features
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Welded Steel Modular Enclosure: Two-piece design measuring 43' x 9' x 14', preassembled for efficient shipping and installation.
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Category 5 Hurricane Rating: Engineered to meet 210 mph wind load requirements with hurricane-rated double and single swing doors.
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Serviceability: Equipped with a 26.5-foot roll-up door for easy access to the transformer.
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HVAC Integration: 18 tons of heating and cooling capacity designed to manage high heat output.
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Logistical Efficiency: Modular design minimized on-site construction and overcame material and labor shortages in Guam.
Conclusion
By leveraging modular construction, Panel Built delivered a mission-critical enclosure that provided immediate protection for the transformer while avoiding the costs and delays of replacement. Careful coordination between engineering, production, shipping, and installation teams ensured the project’s success. The completed substation enclosure demonstrates the strength of prefabricated design in addressing urgent infrastructure needs for military and government applications.
Special thanks to Abigail Kirk and Raytheon Technologies for their partnership on this project.
