ESS & BESS Steel Fabrication

Large-Scale Steel Fabrication for ESS & BESS

Energy storage projects require more than battery cells and electrical systems. Utility-scale Energy Storage Systems (ESS) and Battery Energy Storage Systems (BESS) also depend on precisely fabricated steel structures to house, support, protect, and transport critical equipment.

Openex Metal Fabrication provides large-scale steel fabrication and heavy welded assemblies for ESS and BESS projects. Our manufacturing scope can include steel enclosures, battery support structures, equipment skids, base frames, platforms, access structures, PCS and transformer housings, and other engineered assemblies manufactured to customer drawings and project specifications.

With 180 acres of manufacturing space and lifting capacity up to 250 tons, Openex is equipped for projects involving large welded structures, thick steel sections, heavy assemblies, and components that require substantial fabrication, machining, inspection, finishing, and handling capacity.

ESS & BESS Fabrication Scope

BESS Steel Enclosures

Fabricated steel housings and structural enclosure assemblies for containerized and stationary battery energy storage equipment, manufactured according to project drawings, material specifications, interfaces, and environmental requirements.

ESS Skids & Base Frames

Heavy welded base frames, equipment skids, mounting structures, and support assemblies for batteries, power conversion equipment, transformers, switchgear, and other energy-storage equipment.

Battery & Equipment Supports

Structural frames, equipment supports, mounting brackets, service platforms, access structures, and other welded steel components used within or around large energy-storage installations.

PCS & Transformer Enclosures

Custom steel housings, equipment frames, support structures, and fabricated assemblies for power conversion systems, transformers, switchgear, and associated electrical equipment.

Built Around the Requirements of Large ESS Projects

ESS and BESS fabrication often involves multiple disciplines rather than a single welding operation. A project may require plate cutting, forming, structural welding, precision machining, dimensional inspection, surface preparation, coating, assembly, and controlled handling within one manufacturing program.

Openex can coordinate these manufacturing stages as an integrated fabrication workflow, helping EPC contractors, system integrators, OEMs, and engineering companies reduce the need to divide large fabricated assemblies among multiple suppliers.

From Fabrication Drawings to Finished Assemblies

ESS projects frequently involve complex interfaces between steel structures and electrical, thermal-management, fire-protection, ventilation, and battery equipment. Openex works from customer-supplied engineering drawings, 3D models, specifications, and quality requirements to manufacture the defined steel scope.

Our manufacturing workflow can incorporate material preparation, CNC cutting, forming, fit-up, heavy welding, machining, stress relief where specified, NDT, dimensional inspection, blasting, painting, and final assembly or preparation for shipment.

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  Customer Drawing Based: Fabrication according to approved drawings, models, specifications, and project requirements.
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  Integrated Manufacturing: Cutting, forming, welding, machining, inspection, finishing, and assembly can be coordinated within the manufacturing program.
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  Large Component Handling: High-capacity cranes and large manufacturing areas support heavy fabricated assemblies.
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  Quality Documentation: Inspection and manufacturing documentation can be provided according to the applicable project quality plan.

Quality Control for ESS Steel Fabrication

Structural and enclosure components used in energy-storage projects must satisfy the dimensional, welding, material, coating, and inspection requirements defined by the project. Openex maintains dedicated quality-control and inspection capabilities for large fabricated components.

• 🔍 Dimensional Inspection: Verification of critical dimensions, interfaces, alignment, and fabricated assemblies.
• 🧪 NDT: Non-destructive testing methods selected according to welding and project requirements.
• 🏭 Welding Quality: Controlled welding procedures and inspection for structural and heavy welded assemblies.
• 🛡️ Surface Protection: Industrial blasting and coating processes for fabricated steel components where specified.

Supporting ESS OEMs, EPCs & System Integrators

Openex's role can be focused on the engineered steel and fabricated mechanical scope of an energy-storage project. This makes the manufacturing model suitable for companies that already engineer, integrate, or supply the battery and electrical systems but require a capable large-scale steel fabrication partner.