PREFABRICATED WATER DISTRIBUTION SYSTEMS ENGINEERED FOR RELIABILITY
factory-built Water Booster Pump Stations Built for Tomorrow’s Infrastructure
Reliable water distribution is the backbone of any growing community, demanding systems built for long-term performance and efficiency. At EFI-Solutions, we design and manufacture custom, factory-assembled booster pump stations tailored to your exact engineering and site requirements.
Above-Grade Booster Stations
Complete, factory-built booster stations housed within a protective, weather-resistant exterior enclosure designed for rapid above-grade field deployment.
From approved shop drawings to final delivery, our factory-packaged above-ground stations are built through a streamlined subassembly process designed for maximum quality, precision engineering, and rapid field deployment.
Step 01
Concurrent Subassembly & Skid Fabrication
Upon release of shop drawings to manufacturing, fabrication begins simultaneously across specialized subassemblies—building the structural steel base, enclosure housing, and piping assemblies.
- Heavy-duty steel floor and frame welding
- Simultaneous pipe welding and structural fabrication
- Built to exact approved shop drawing specifications
Step 02
Skid Coating & Painting
Once base fabrication and pipe welding are complete, the steel skid moves through our dedicated coating facility for high-performance paint application prior to final component integration.
- Industrial-grade surface preparation
- High-durability protective finish for harsh environments
- Ensures full coating coverage beneath all mounted equipment
Step 03
Mechanical Assembly & Structural Integration
The painted skid and enclosure components are brought together at our main assembly facility, where pumps, valves, and piping networks are mounted and precisely fit.
- Marriage of structural floor skid and enclosure housing
- Precision positioning of pumps, headers, and valves
- Rigid mechanical fit-up for long-term operational stability
Step 04
Custom Control Panel & Electrical Integration
In parallel with mechanical assembly, custom control panels built in-house are installed, followed by complete internal station wiring and power distribution.
- In-house custom control panel construction
- Complete building electrical, lighting, and conduit runs
- Point-to-point system wiring between panels and equipment
Step 05
Comprehensive QC Testing & Delivery
Before shipment, every packaged station undergoes rigorous Quality Control testing to verify mechanical and electrical performance, ensuring seamless plug-and-play field installation.
- Complete functional and operational QC testing
- System performance verified before leaving the facility
- Prepped and loaded for safe job site delivery
Note:
Every EFI-Solutions station is custom-engineered to meet specific project demands. Features, component layouts, and enclosure options are tailored to your site requirements.
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Below-Grade Booster Stations
Heavy-duty, subterranean steel capsule stations engineered to withstand extreme soil and hydrostatic pressures while providing full internal access.
Engineered for subterranean installation, our factory-packaged below-grade stations utilize heavy-duty round and oval steel beam capsule designs built to withstand extreme earth and hydrostatic pressures.
Step 01
Structural Capsule & Outer Beam Fabrication
Fabrication begins with custom shop drawings, building round or elongated circular capsules reinforced with heavy outer structural steel beam frames designed for underground burial loads.
- Heavy-duty circular and oval structural steel beam framing
- Precision shell plate seam welding for structural integrity
- Built to withstand external soil and hydrostatic pressures
Step 02
Corrosion Defense & High-Performance Coating
The entire steel capsule structure undergoes rigorous surface preparation and receives heavy-duty protective coatings inside and out to prevent subterranean corrosion and ensure long service life.
- Industrial abrasive blast surface prep
- High-durability exterior underground epoxy coatings
- Corrosion-resistant interior finishes for harsh environments
Step 03
Subterranean Mechanical & Piping Fit-Up
Pumps, valves, headers, and internal piping are lowered into the capsule and mounted to structural supports, optimizing space within the cylindrical configuration.
- Compact, high-density mechanical piping arrangement
- Precision alignment of pumps, check valves, and isolation valves
- Integrated sump systems and maintenance access ladders
Step 04
Control Panel Integration & Electrical Wiring
UL-listed control panels (designed for station or above-grade pedestal mounting) are wired, integrating internal lighting, ventilation blower systems, and instrumentation.
- In-house custom control panel construction
- Internal capsule lighting, blowers, and environmental monitoring
- Sealed conduit runs and point-to-point electrical wiring
Step 05
Comprehensive QC Testing & Underground Shipment
Every below-grade station undergoes hydrostatic pressure testing, seal inspection, and complete electrical testing before being prepped for transport to the job site.
- Full hydrostatic piping and shell seam testing
- Operational control sequence and safety system sign-off
- Prepped with lifting lugs for straightforward field setting
Note:
Every EFI-Solutions station is custom-engineered to meet specific project demands. Capsule dimensions, piping arrangements, and control options are tailored to your site requirements.
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Multi-Section Booster Stations
Large-footprint above-ground stations built in precision factory sections that mate together seamlessly on site for simplified transportation and rapid assembly.
Engineered for large-footprint applications, our multi-section above-ground stations are built in precision factory sections designed to join together cleanly on site. This approach allows for maximum quality control, streamlined shipping, and rapid field assembly.
Step 01
Concurrent Subassembly & Frame Fabrication
Fabrication begins simultaneously across individual station sections—constructing heavy-duty structural steel floor frames, enclosure walls, and piping headers engineered to mate perfectly in the field.
- Heavy-duty split-skid steel floor and structural frame welding
- Simultaneous pipe welding and multi-section frame fabrication
- Built to exact tolerances for seamless field alignment and mating
Step 02
Sectional Coating & Protective Finish
Once frame welding and pipe spools are completed, each individual station section moves through our coating facility for industrial-grade paint application prior to equipment installation.
- Industrial abrasive blast surface prep across all structural frames
- High-durability protective finish engineered for harsh environments
- Full coating coverage across base members and mating flanges
Step 03
Mechanical Integration & Precision Fit-Up
The painted base frames are brought together on the factory floor for precision mechanical integration, mounting pumps, valves, and piping networks across split lines.
- Precision alignment of floor skids and enclosure wall sections
- Exact fit-up of split-line piping, flanged connections, and headers
- Rigid structural coupling ensuring exact alignment during field setting
Step 04
Control Systems & Interconnect Wiring
In-house custom control panels are integrated with internal lighting, HVAC, and power distribution, utilizing organized terminal junctions for fast field interconnectivity.
- In-house custom UL-listed control panel construction
- Complete building electrical, lighting, and raceway conduit runs
- Clearly labeled junction points and quick-connect interconnections
Step 05
Match-Marking, Full QC Testing & Shipping
Every multi-section station undergoes complete factory pre-assembly, match-marking across all split points, and operational QC testing before being prepped for transport.
- Full functional and operational QC testing of joined sections
- Precision match-marking on structural, piping, and electrical split lines
- Secure section-by-section packaging and loading for safe job site transit
Note:
Every EFI-Solutions station is custom-engineered to meet specific project demands. Station footprints, split-skid dimensions, and component layouts are tailored to your site requirements.
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Skid-Mounted Booster Stations
Open or partially enclosed pumping systems mounted on structural steel bases, designed for space-efficient installation inside existing buildings or larger facilities.
Designed for installation within existing structures or integration into larger facilities, our open and partially enclosed skid-mounted booster systems deliver factory-packaged performance in a compact, space-efficient footprint.
Step 01
Structural Steel Skid & Header Fabrication
Fabrication begins with heavy-duty structural steel frame welding and precision pipe spools engineered specifically to accommodate plant access limits and facility footprint requirements.
- Rigid structural steel base frame welding and structural prep
- Simultaneous pipe manifold welding and header fabrication
- Engineered to match precise mechanical connection points
Step 02
Skid Coating & Surface Finishing
Before mounting pumps, valves, and electrical components, the fabricated steel skid moves through our coating facility to receive industrial-grade blast prep and a durable protective paint finish.
- Abrasive blast surface preparation across all frame members
- High-durability protective finish for industrial environments
- Ensures 100% coating coverage beneath all equipment bases
Step 03
Mechanical Assembly & Equipment Fit-Up
Pumps, isolation valves, check valves, flow meters, and piping manifolds are precision-mounted onto the painted structural skid, optimizing space for operator access and routine maintenance.
- Compact, high-efficiency equipment layout and pump positioning
- Precision alignment of manifolds, flanged connections, and valves
- Vibration-isolated mounting for quiet, smooth operation
Step 04
Control Panel Integration & Wiring
In-house custom UL-listed control panels are mounted directly to the skid, followed by point-to-point wiring of pump motors, pressure transducers, and safety instrumentation.
- In-house custom UL-listed control panel construction
- Neat, industrial-grade conduit runs and instrumentation wiring
- Single-point power connection ready for facility hookup
Step 05
Comprehensive Hydrostatic Testing & Shipping
Every skid system undergoes thorough hydrostatic pressure testing and electrical operational checks, ensuring true plug-and-play installation when delivered to your facility.
- Full hydrostatic piping pressure and leak testing
- Operational control sequence and VFD performance testing
- Prepped with corner lifting eyes for easy positioning indoors
Note:
Every EFI-Solutions skid-mounted booster system is custom-engineered. Frame dimensions, pump configurations, and control packages are fully tailored to integrate with your facility layout.
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Tilt-Back Booster Stations
Compact, low-profile above-ground pump stations featuring an insulated fiberglass lid that tilts open effortlessly with gas-strut assistance for uninhibited maintenance access.
Engineered for small-footprint above-ground applications, our tilt-back booster pump stations combine heavy-duty mechanical components with an insulated fiberglass lid that tilts open effortlessly for complete, uninhibited service access.
Step 01
Compact Skid & Piping Fabrication
Manufacturing begins with welding the structural steel base frame and fabricating custom suction and discharge piping manifolds engineered specifically for low-profile, above-grade pad mounting.
- Heavy-duty structural steel skid base welding
- Precision piping spool fabrication tailored for low-profile footprints
- Built-in structural hinge mounts for fiberglass lid integration
Step 02
Surface Prep & Protective Finish
The steel skid base and piping assemblies pass through our coating facility for thorough abrasive blast prep and the application of high-durability protective coatings built to withstand weather exposure.
- Industrial-grade blast prep across all steel base members
- High-performance exterior epoxy coating system
- Corrosion-resistant coating coverage on all structural surfaces
Step 03
Mechanical Integration & Fiberglass Lid Assembly
Booster pumps, valves, and piping networks are mounted to the coated skid, followed by the installation of the fiberglass enclosure with gas-strut lift assists for smooth opening.
- High-efficiency pump layout optimized for tight space constraints
- Fiberglass enclosure with UV-resistant gelcoat exterior
- Gas-assisted strut hardware providing easy 360-degree maintenance access
Step 04
Control Panel & Electrical Integration
In-house custom UL-listed control panels (designed for internal enclosure or external pedestal mounting) are wired directly to pumps, sensors, and environmental controls.
- In-house custom control panel construction
- Sealed conduit runs and point-to-point electrical wiring
Step 05
Hydrostatic QC Testing & Delivery Prep
Before leaving the factory, each tilt-back station undergoes complete hydrostatic pressure testing, seal inspection, and full electrical sequence testing to guarantee turnkey field operation.
- Full hydrostatic piping pressure and leak testing
- Electrical control sequence and safety device verification
- Factory pre-assembled for rapid, simple concrete pad installation
Note:
Every EFI-Solutions tilt-back booster station is custom-engineered to meet specific site requirements. Enclosure dimensions, pump selections, and control options are tailored to your project specs.
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CONNECT WITH EFI-SOLUTIONS FOR WATER DISTRIBUTION EXPERTISE
DIVE INTO THE FUTURE OF WATER DISTRIBUTION WITH US
Navigating the complexities of water distribution? EFI-Solutions is your trusted partner for ensuring efficient water pressure, flow and quality. Whether it's booster pumping stations, water metering, or other applications, let us be your guide. Reach out to us for specialized advice on your water distribution needs at 618-533-1351 or contact us here to start a conversation today.
If you would like to connect with a project engineer or if you have questions call us at 618-533-1351 or schedule here.
