10 Considerations When Designing Industrial Enclosures

Industrial enclosures protect critical electrical and automation systems from harsh conditions in manufacturing, outdoor installations, and hazardous locations. However, optimal enclosure design requires careful planning. To ensure your enclosure meets operational requirements, withstands environmental challenges, and provides reliable protection, here are ten essential considerations to factor into your design process.

1. Environmental Conditions

Before selecting an industrial enclosure, evaluate environmental factors thoroughly. Consider temperature extremes—hot and cold—as well as exposure to moisture, humidity, dust, and dirt. In corrosive or harsh environments, choose enclosure materials specifically resistant to corrosion and chemical damage. In hazardous locations with flammable gases, vapors, or dust, select certified explosion-proof enclosures for safety and regulatory compliance.

2. Material Selection

Choosing appropriate enclosure materials directly impacts performance, durability, and longevity. Steel, stainless steel, aluminum, polycarbonate, and fiberglass offer unique benefits. Stainless steel and aluminum are highly corrosion-resistant, ideal for harsh industrial environments. Polycarbonate and fiberglass are lightweight, non-metallic alternatives offering excellent insulation, impact, and corrosion resistance. Match your material selection precisely with environmental and operational demands.

3. Ingress Protection Ratings (IP/NEMA)

Understanding ingress protection standards such as IP (International Protection) ratings and NEMA (National Electrical Manufacturers Association) ratings is vital to safeguard internal components. IP ratings (e.g., IP65, IP66) specifically indicate protection against dust and water ingress. Meanwhile, NEMA ratings classify enclosures based on protective capabilities and environmental resilience, including indoor, outdoor, washdown, or hazardous locations. Always select ratings aligning precisely with your intended application environment to protect sensitive internal components.

4. Thermal Management and Ventilation

Heat management within an enclosure is critical to maintaining reliable equipment operation and extending component lifespan. Electronic equipment generates heat, and excessive heat accumulation can lead to component failure. Options like active cooling systems (fans, air conditioners, heat exchangers) or passive ventilation strategies effectively manage internal temperatures. Designing proper airflow and ensuring appropriate thermal regulation helps avoid costly downtime and component replacement.

5. Size, Space, and Future Expansion

Selecting an enclosure size based purely on current component requirements is a common oversight. Remember to allow ample internal space for wiring, cable management, and airflow. Equally important, anticipate future equipment expansions or modifications. Choosing a slightly larger enclosure initially can accommodate system growth, reduce long-term costs, and simplify maintenance tasks.

6. Ease of Maintenance and Accessibility

Efficient and safe access to enclosure contents is a priority during design. Consider hinged doors, removable panels, viewing windows, and ergonomically friendly design features to enhance maintenance, inspections, and troubleshooting. Additionally, allowing sufficient clearance around internal components ensures technicians can perform tasks safely and efficiently, minimizing downtime and improving operational efficiency.

7. Safety and Compliance Standards

Safety regulations and compliance standards are paramount for industrial enclosures. Adhering to recognized standards such as UL, CE, and CSA ensures the enclosure meets critical quality and safety requirements. Complying with NEC (National Electrical Code) and IEC (International Electrotechnical Commission) standards is essential for electrical safety. For enclosures used in explosive or hazardous atmospheres (Class I, Division 1/2 locations), specific certifications and explosion-proof construction are mandatory.

8. Mounting and Installation

How and where you mount your enclosure significantly influences its structural integrity, performance, and ease of installation. Enclosures can be wall-mounted, free-standing, floor-mounted, or even pedestal-mounted depending on the application. Ensuring structural strength, stability, and ease of integration with existing infrastructure are key considerations. Planning ahead for efficient installation saves valuable time, labor, and resources.

9. Security and Access Control

Protecting sensitive internal components isn't just about environmental factors—security also matters. Consider integrating secure locking mechanisms or keyless access control systems. Limiting unauthorized access ensures personnel safety, prevents accidental damage, and safeguards against theft or tampering. For added protection, some enclosures integrate seamlessly with broader facility automation and security systems.

10. Cost and Budget Constraints

Finally, cost and budget play critical roles in enclosure selection and design. Balancing initial costs with long-term maintenance, operational efficiency, and total cost of ownership is vital. While less expensive enclosures may initially seem attractive, they might lack sufficient durability or protection, leading to frequent replacements or maintenance costs. Investing in high-quality enclosures matched precisely to application needs ultimately saves money and improves operational reliability.

By addressing these ten key considerations in your industrial enclosure design process, you'll protect your valuable electrical and automation equipment, ensure safety and compliance, simplify maintenance, and position your operations for long-term efficiency and reliability.

Have Questions? We’re Here to Help!

Call 800-575-5562 today. Our solutions experts are ready to assist you.