BESS Battery Enclosures

Fabricated aluminium and steel enclosures for BESS battery module clusters, BMS electronics, and high-voltage junction assemblies. These enclosures operate in proximity to high-energy-density lithium cells, where the primary threat is not environmental ingress but thermal runaway from within. Every design decision,, material selection, wall thickness, vent geometry, compartment isolation, and internal coating,, is evaluated against that risk first. Manufactured to your BESS design, with fire containment rating, pressure relief configuration, and IP sealing verified before dispatch.

Cell Compartment Wall Fire Rating

30 min or 60 min per EN 13501-2 / UL 263

Compartment Isolation Wall

Fire-rated structural wall; intumescent penetration seals at all cable and pipe transits

Internal Panel & Lining Material

UL 94 V-0 rated; electrolyte vapour resistant; no toxic secondary combustion products

Internal Coating

Electrolyte-resistant epoxy or powder coat; UL 94 V-0 compliant; no halogenated compounds

Pressure Relief Type

Burst disc (single-use, calibrated burst pressure) or louvred pressure relief vent (resettable)

*BESS battery enclosure programmes include a safety engineering review gate at first article stage before any fabrication is committed. This adds time relative to standard enclosure programmes and is non-negotiable for safety-critical enclosures.

Product Description

Standard enclosure design logic, maximise IP rating, minimise thermal path resistance, seal every aperture, is partially wrong for a BESS battery enclosure. Thermal runaway in a lithium cell produces hot gases, electrolyte vapour, and rapid pressure rise. An enclosure that seals perfectly under those conditions becomes a pressure vessel. Controlled pressure relief, sized for the gas generation rate of the battery chemistry, directed away from personnel and adjacent modules, is a designed feature, not a failure mode. The vent geometry, burst disc pressure rating, and exhaust direction are as important as the IP rating of the main shell.

HV Access Panel Arc Flash Rating

Category 2 (1.2 cal/cm²) or Category 4 (40 cal/cm²) per available fault current at installation

Interlock Provision

Door interlock switch provision for HV panel — actuator position and switch type per OEM electrical design

Primary Enclosure Material

6061-T6 aluminium (standard); S355 structural steel (heavy-duty or high-containment variants)

Wall Thickness

2.0–4.0 mm aluminium; 3.0–6.0 mm steel; heavier sections at structural and containment-critical zones

Weld Standard

AWS D1.2 (aluminium); AWS D1.1 (steel); ISO 3834-2 quality requirements

Gasket Material

Silicone (VMQ) or EPDM; electrolyte vapour resistant; UL 94 V-0 rated

Cable Entry

IP-rated metric cable glands M16–M63; conduit entry sleeves with intumescent seals at fire-rated wall penetrations

Operating Temperature

−30°C to +60°C continuous; seals and gaskets validated across full range

Liquid Cooling Provision

Coolant port fittings, manifold mounting provisions, and leak detection sensor provision per OEM thermal design

Environmental Compliance

RoHS 3; REACH SVHC <0.1% w/w; WEEE compliant; no halogenated materials in internal lining or gaskets

Technical Advantages

Thermal management interface enclosures house the liquid cooling distribution manifolds, coolant pump assemblies, and thermal control electronics adjacent to the cell modules. These enclosures must seal against coolant leak paths while providing maintenance access to pump and valve assemblies, and must be fabricated from materials compatible with the coolant chemistry specification. Each enclosure type has a distinct safety requirement set, and Frigate’s DFM review covers the specific requirements for the enclosure type submitted, not a generic review applied uniformly.

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Need reliable Enclosure for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Application

Grid-Scale Stationary Storage

Battery module cluster enclosures for utility-scale BESS installations. 60-minute thermal containment rating; directed venting for high-density rack arrangements. UL 9540A test-compatible construction for authority having jurisdiction (AHJ) approval.

Commercial Behind-the-Meter BESS

BMS electronics and HV junction enclosures for behind-the-meter commercial storage systems. IP66 BMS housing with isolated cell zone; arc flash Category 2 access panels for maintenance access in occupied commercial premises.

Solar-Plus-Storage Hybrid Systems

Battery enclosures co-located with solar inverter systems. Thermal management interface provisions for liquid-cooled battery architectures. Internal coating specified for the humidity and temperature cycling profile of outdoor hybrid installations.

EV Fast Charging Energy Storage

High-rate discharge battery enclosures for EV charging peak demand management. Arc flash Category 4 rated HV access for high fault current DC bus configurations. Explosion relief provision for fast-charge adjacent installations in enclosed structures.

Industrial UPS and Backup Power

Battery enclosures for industrial uninterruptible power systems in manufacturing and data centre environments. IEC 62933-5-2 compliant construction for indoor occupied building installations. Fire suppression system integration provisions built into enclosure structure.

BESS OEM Platform Programmes

Multi-enclosure-type supply for BESS OEM production programmes. Single safety review, consistent material specification, and coordinated documentation package across battery module, BMS, HV junction, and thermal management enclosure types within one platform BOM.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

Solar Inverter Enclosure

units per month

Bento Boxes for D2C Segment

Units Manufactured Monthly

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Defence-Grade Cable Supply

Cost savings

0 %

Flange Assembly for Pump

Faster Production

0 %

Having Doubts? Our FAQ

Does Frigate design the thermal runaway venting system, or does that come from our engineering team?

The venting system design, vent sizing, burst disc pressure rating, exhaust direction, is the OEM engineering team’s responsibility and must be defined in the submitted design package. Frigate manufactures the vent geometry and installs the burst disc or louvred vent assembly to that specification. The DFM review confirms the vent feature is manufacturable to the submitted geometry and that the installation is consistent with the enclosure’s overall construction.

Our BESS uses LiFePO₄ chemistry. Does that change the enclosure material or coating requirements?

LiFePO₄ has a lower thermal runaway severity than NMC or NCA chemistry, but it still produces hot gases and elevated pressure during a cell failure event. Containment wall rating, vent sizing, and internal coating compatibility are all confirmed against the specific battery chemistry specified in the design package, not assumed from a generic lithium-ion specification. Submit your cell manufacturer’s safety data sheet alongside the enclosure drawing for the most accurate DFM review.

We need IP66 on the exterior but controlled pressure relief internally. Are those compatible?

Yes, when engineered correctly. The exterior shell achieves IP66 on all faces except the designated pressure relief aperture, which is the only intentional path through the sealed shell. The relief aperture has its own sealing strategy, typically a burst disc or normally-closed pressure relief valve that maintains IP integrity under normal operating conditions and opens only at the designed relief pressure. This configuration is confirmed and tested at first article with the relief device installed.

Can Frigate supply the intumescent transit frames and burst discs, or do we source those separately?

Frigate sources and installs both as part of the enclosure sub-assembly supply. Intumescent cable transit frames and burst disc units are specified against the OEM’s design requirements, sourced from qualified suppliers, and installed during the fit-out stage of manufacture. Material certificates and pressure rating documentation for these components are included in the shipment documentation package.

What documentation does Frigate supply to support our UL 9540A submission?

Frigate supplies the enclosure construction documentation relevant to a UL 9540A submission: fire-rated panel certificates, wall construction specification, burst disc pressure rating records, intumescent transit frame fire resistance certificates, UL 94 V-0 material declarations for all internal materials, and the dimensional FAI report confirming the manufactured enclosure matches the submitted design. The UL 9540A test programme itself is run by the OEM or a designated test laboratory, Frigate’s documentation supports the enclosure construction portion of that submission.

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LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Components Built for Critical Performance

Engineered Products for Critical Applications

BESS Battery Enclosures

Product Description

HV Access Panel Arc Flash Rating

Interlock Provision

Primary Enclosure Material

Wall Thickness

Weld Standard

Gasket Material

Cable Entry

Operating Temperature

Liquid Cooling Provision

Environmental Compliance

Technical Advantages

Let's Get Started

Industry Application

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

BESS Battery Enclosures

Get Latest Price

BESS Battery Enclosures

Get Latest Price