Custom Top-Open Paint Booth for Heavy Transformers: A Success Story in Saudi Arabia
Introduction At CoatTech, we specialize in solving complex industrial coating challenges. Recently, we partnered with Nal Gulf Machine Tools, a prominent reseller in Saudi Arabia, to design and manufacture a specialized large-scale paint booth. The project required a unique approach to accommodate the massive size of industrial transformers and the client's specific facility constraints.
The Challenge: Heavy-Duty Handling Coating industrial transformers presents a logistical challenge. Because of their immense size and weight, maneuvering these workpieces into a standard side-entry paint booth is highly inefficient and sometimes impossible. The client relied heavily on existing overhead crane systems to move their transformers. They needed a high-performance painting environment that would not obstruct their crane operations or require a complete overhaul of their facility's workflow.
The CoatTech Solution: Precision Top-Open Design To meet these demanding requirements, our engineering team developed a custom-built Top-Open Paint Booth. This innovative configuration allows heavy transformers to be safely and precisely lowered directly into the workspace using the client's existing overhead cranes.
Once the workpiece is in place, the specialized roof mechanism closes securely, creating an isolated, controlled environment that meets the highest standards for industrial painting and ventilation.
Key Project Highlights
1.Seamless Crane Integration: The roof-loading design completely eliminates the need for complex floor-level maneuvering, drastically reducing loading and unloading times.
2.Large-Scale Capability: Engineered with expansive interior dimensions specifically tailored to house oversized industrial transformers.
3.Superior Airflow Management: The booth ensures optimal overspray capture and exhaust, guaranteeing a flawless finish while maintaining a safe, clean environment for operators.
4.Facility Optimization: By adapting to the existing overhead lifting equipment, the solution maximized the client's operational floor space without requiring costly structural modifications to their building.
Technical Specification:
| Technical Specifications for Top-Open Transformer Spray Booth |
| Model: Custom Top-Open Spray Booth (Tailored for Jib Crane Operation) |
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| Component / Parameter |
Detailed Specifications |
| Internal Dimensions |
4400 × 3700 × 3500 mm (L × W × H) |
| External Dimensions |
4520 × 5300 × 4500 mm (L × W × H) |
| Down-draft Exhaust Pit |
Central pit design. Dimensions: 4000 × 3000 mm, Depth: 800 mm. Supported by a square tube framework. Covered with 30 × 4 mm flat iron heavy-duty gratings. Load-bearing capacity: 500 KG/m². |
| Main Entry/Exit Doors |
Drive-through design (front and rear). Door opening: 3000 × 3200 mm (W × H). Folding type doors with a square tube framework and color steel plate cladding. PU core insulation. Features square tempered glass observation windows and mechanical pressure locks on the central panels. Can be used as personnel access doors. |
| Wall Panels |
Assembled with high-strength rock wool insulation panels. Effective width: 1150 mm, Total thickness: 50 mm. Inner and outer skins are 0.426 mm white color steel plates with a rock wool core. |
| Roof / Top Panels |
Assembled with high-strength rock wool insulation panels. Effective width: 1150 mm, Total thickness: 50 mm. Inner and outer skins are 0.426 mm white color steel plates with a rock wool core. |
| Lighting System |
Top lighting: 2 rows (4 sets × 4 tubes = 16 pcs of 18W tubes). |
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| Side lighting: 2 rows (4 sets × 4 tubes = 16 pcs of 18W tubes). |
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| Uses dedicated T8 LED tubes for spray booths housed in IP65 explosion-proof lighting fixtures. Total Illuminance: ≥ 1000 LUX. |
| Plenum Chamber |
Dimensions: 4400 × 3700 × 500 mm (L × W × H). Supported by square tube brackets. Features sheet metal bent powder-coated filter frames at the bottom and a support net on top. |
| Top Opening Design |
Roof features a 500 mm wide full-length access slot designed for the jib crane chain/hoist passage. The slot is equipped with pneumatic dampers on both sides (normally open, automatically closes when painting starts to ensure sealing and negative pressure). |
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| (For Jib Crane) |
| Cabinet Unit |
Welded square tube structure, side-mounted configuration. |
| Supply Air Unit |
Equipped with 1 set of double-inlet centrifugal fan (belt-driven). Explosion-proof motor power: 5.5 KW. Fan model: TAE-500H. Total air volume: 20,000 m³/h (Approx. 11,770 CFM). Features a rotary handle manual adjustment damper. |
| Exhaust Air Unit |
Equipped with 1 set of double-inlet centrifugal fan (belt-driven). Explosion-proof motor power: 7.5 KW. Fan model: TAE-450H. Total air volume: 20,000 m³/h (Approx. 11,770 CFM). Features an exhaust air rotary handle manual adjustment damper. |
| Filtration System |
1. Primary Supply Air Filter: EN 779 Class G3. |
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| 2. Sub-high Efficiency Ceiling Filter: Full-depth 3D adhesive coated; EN 779 Class F5. |
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| 3. Paint Stop Glass Fiber Filter: Installed on both the floor pit and the bottom of the exhaust cabinet. Green air inlet side, white air outlet side; EN 779 Class G3. |
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| 4. Activated Carbon Filter: Granular activated carbon specifically for adsorbing VOCs (benzene, xylene, etc.) for zero external fume emission. |
| Electrical Control System |
Control Panel featuring conventional relays and push buttons. Includes: painting/lighting switches, fault indicator & alarm, main power switch, emergency stop button, and pressure gauge (Manometer). |
| Ducting System |
Includes 3 sections of 700 × 700 × 1000 mm exhaust ducts, 1 piece of 90° elbow, and 1 piece of 45° elbow. |
| Total Power Capacity |
14 KW |
| Included Documents |
Maintenance manual, electrical wiring diagrams, certificate of conformity, packing list, and 3D layout drawings. |
| Remarks & Warranty |
1. Equipment warranty is 1 year. The supplier provides free service for quality issues during this period. Paid services are available after the warranty expires. |
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| 2. Consumables (lighting tubes, filters) and human-induced damages are excluded from the warranty. |
Contact Us Today Ready to optimize your heavy equipment coating process?
Contact Tim, Overseas Marketing & Sales Manager, to discuss your custom spray booth requirements and secure a technical consultation.
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