The signs of corrosion aren’t always easy to spot, but the damage that follows can be severe and costly. Without proper corrosion protection, corroded enclosures can lead to seal failure and water ingress, putting sensitive electrical components at risk of failure. Despite its potentially serious impacts, corrosion damage is often underestimated, even by seasoned professionals.
Electrical boxes don’t fail randomly. In most cases, the root cause comes down to materials that aren’t suited for the environment. However, corrosion damage isn’t inevitable. Understanding the benefits of stainless steel, polycarbonate, and aluminum can help ensure proper corrosion protection and support a long, safe operational life for both the enclosure and the electrical equipment inside.
Why Corrosion Protection Materials Are Essential
Electrical enclosures are the first line of defense against environmental stressors like moisture, salt, chemicals, temperature swings, and UV rays. Without corrosion protection, those elements can lead to rust, pitting, oxidation, and even galvanic corrosion. Once corrosion sets in, it’s only a matter of time before it compromises the components inside.
Corrosion starts at the surface and works its way in. Seals deteriorate. Hinges seize. Gaskets crack. As the enclosure’s integrity fails, moisture finds its way in, triggering oxidation, electrical shorts, and equipment malfunctions. Worse still, corroded contact points increase resistance and heat, creating new risks for both system stability and worker safety.
That’s where corrosion-resistant materials make a difference. Unlike conventional options that break down over time, materials like stainless steel, aluminum, and polycarbonate are engineered to withstand harsh environments and prevent the chain reaction of failure. Choosing a corrosion-resistant enclosure isn’t just good practice — it’s a strategic move to protect uptime, performance, and safety.
The Hidden Costs of Not Having Corrosion Protection
The consequences of corrosion rarely appear as catastrophic failures. More often than not, they start with seemingly small issues that build over time. Problems compound, creating a domino effect. Spots that appear to be purely surface-level at first glance can quickly evolve into a cycle of unplanned downtime, mounting costs, and recurring system instability.
The implications extend well beyond the immediate expense of repairs or enclosure replacement. Maintenance teams may spend hours tracking down intermittent failures caused by moisture ingress or corroded terminals. Unplanned downtime to replace a failed panel or troubleshoot a short circuit can disrupt production schedules, trigger emergency work orders, and require costly overnight parts or labor.
In regulated industries, corrosion has direct implications for compliance. Facilities must undergo routine inspections that assess not only system functionality but also adherence to safety and environmental standards. Corroded or damaged enclosures are an immediate red flag for inspectors and can result in requests for corrective actions, increased inspection frequency, or, in some cases, fines.
Choosing the Right Enclosure Material
Every application is unique, and so are the materials used to provide corrosion protection.
| Material | Corrosion Protection | Strength | Weight | Cost | Best For |
| Stainless Steel | Excellent (esp. 316) | High | Heavy | $$$$ | Harsh industrial, marine, food processing |
| Aluminum | Good (moderate exposure) | Moderate (denting can occur) | Lightweight | $$ | Outdoor, moderate climates, lighter-duty use |
| Polycarbonate (Plastic) | Excellent (no rust) | Very High | Very lightweight | $–$$ | Corrosive, wet, or UV-exposed environments |
Understanding the Advantages of Specific Materials
Stainless Steel
Stainless steel enclosures are the benchmark for durability and corrosion protection, especially 316-grade. They’re particularly effective in chemical, high-washdown, or marine environments. The material resists pitting, holds its seal, and offers unmatched mechanical strength.
Pros:
- Exceptional corrosion protection
- Long lifecycle
- Can be sterilized for sanitary applications
- Fire and impact resistant
Cons:
- Higher upfront cost
- Heavy and labor-intensive to install
- Can still corrode in extreme chemical exposure or if scratched
Aluminum
Aluminum provides a balance between protection and practicality, thanks to its naturally forming oxide layer that makes it suitable for most outdoor applications. It’s easier to handle and install than stainless steel, but less durable in highly corrosive or high-impact settings.
Pros:
- Lightweight, easy to install
- Good corrosion protection in mild to moderate environments
- Excellent heat dissipation
- More cost-effective than stainless
Cons:
- Softer, prone to denting
- Vulnerable to galvanic corrosion with dissimilar metals
- Not ideal for extreme chemical or marine exposure
Polycarbonate (Plastic)
Polycarbonate enclosures offer full corrosion immunity — ideal for wet, salty, or chemically aggressive environments. They’re also electrically insulating, lightweight, and surprisingly tough. In environments where corrosion protection is non-negotiable, a plastic electrical enclosure can outperform metal.
Pros:
- Will not rust, corrode, or oxidize
- High impact resistance
- Lightweight, easy to install
- Electrical insulation; no grounding required
Cost-effective and low-maintenance
Cons:
- Lower heat dissipation compared to stainless and aluminum
- Lacks natural EMI shielding (can be added with coatings)
- Limited to small sized enclosures (typically 30″ or less)
Prevent Damage & Downtime with Corrosion Protection
The surest way to avoid or reduce corrosion-related damage is to eliminate the risk at the source. That means carefully selecting materials according to the demands of the operating environment, not just looking at the price point or availability. Prioritizing corrosion protection during material selection helps ensure long-term reliability and system performance.
For example, in coastal environments or chemical plants, a standard painted steel box might have a usable life of only a few years before it needs to be recoated or replaced. Switching to 316 stainless steel or polycarbonate can dramatically extend the usable life of the box and its contents, while requiring less maintenance and offering far greater system reliability.
Non-corrosive materials eliminate the need for routine repainting, seal repairs, and structural integrity checks. Boxes that previously required repair or replacement every 12–24 months can often go a decade or more without issues. Over time, greater reliability and minimal maintenance offset any price difference compared to conventional steel.
Better materials mean better performance. It’s that simple. The protection offered stainless steel, aluminum, and polycarbonate pays for itself many times over.
And it’s not just about money. Less maintenance means fewer disruptions, fewer emergency calls, and more predictable operations across an entire network. With greater system reliability and uptime comes improved cost control and reduced operating expenses—two factors that support a strong return on investment.
Safeguard Your Investments with Corrosion Protection
Not every application requires high-performance materials, but the benefits of using enclosures designed to resist corrosion are hard to ignore.
Not sure which material is right for your environment? Our team is here to help you find the best corrosion protection for your specific needs. Contact Integra Enclosures today to get expert guidance or start your next project with the right solution.
