Corrosion in Electrical Enclosures: Material Selection, Galvanic Risks, and the Benefits of GALVAR® Technology
Corrosion resistance is critical when selecting electrical enclosures for harsh industrial environments. Gridhaus Systems provides a full range of corrosion-resistant materials — from galvanised and Magnelis® steel to aluminium and stainless steel 316L — along with GALVAR® anti-corrosion technology that eliminates weld-zone failures. Our solutions help engineers prevent galvanic corrosion, extend equipment lifetime and ensure long-term reliability in demanding applications.
Corrosion is one of the most critical factors affecting the lifetime, safety and reliability of electrical and control enclosures. In industrial environments — especially those involving moisture, salt exposure, chemical vapours or temperature fluctuations — the choice of material determines whether an installation remains stable for years or becomes vulnerable to premature failure.
Gridhaus Systems supplies a broad portfolio of corrosion-resistant enclosures through our European manufacturing partner, covering a wide spectrum of material options and corrosion classes.
Galvanised Steel
Suitable for standard indoor and light-industrial applications. Its zinc coating provides good baseline protection, though welded or mechanically damaged areas may be more susceptible to corrosion.
Magnelis® Steel (Zn-Al-Mg Alloy)
A next-generation material offering up to 10× higher corrosion resistance than standard galvanised steel. Highly effective in coastal regions, high-humidity environments, agricultural buildings with ammonia exposure, and outdoor installations.
Aluminium
Lightweight and naturally corrosion-resistant. Ideal for enclosures requiring reduced weight, improved heat dissipation or easier handling, commonly used in HVAC, telecom and control-system applications.
Stainless Steel AISI 304 (1.4301)
A strong option for environments demanding good corrosion resistance such as food-processing, pharmaceutical and clean-area installations. Less suitable for marine or high-chloride environments.
Acid-Resistant Stainless Steel AISI 316L (1.4404)
Premium-grade stainless steel offering excellent resistance to pitting and crevice corrosion. Ideal for offshore, marine, wastewater, chemical and coastal environments.
Galvanic corrosion occurs when two dissimilar metals make electrical contact in the presence of an electrolyte such as moisture, condensation or saltwater. The less noble metal becomes the anode and corrodes at an accelerated rate.
Common scenarios include:
- Stainless steel connected directly to carbon steel
- Aluminium mounted with carbon-steel fasteners
- Mixed-material assemblies lacking insulation
- Marine and offshore structures
- Damp industrial environments
When the anodic area is small relative to a large stainless-steel surface, deterioration can be extremely rapid. Prevention strategies include insulating pads, protective coatings, corrosion pastes or selecting compatible metals and fasteners.
GALVAR® is a patented manufacturing method that replaces welding with structural gluing and riveting. Since welding disrupts the zinc protective layer on steel, welded enclosures typically corrode first along seams and joints.
This process eliminates heat-affected corrosion zones and provides:
- Preserved zinc coating with no welded areas
- High corrosion resistance suitable for C4 and C5 environments
- IP55/IP66-rated sealing with watertight bonded joints
- IK10 impact resistance
- Compatibility with mixed materials
- Lower total cost than many stainless-steel alternatives
- Optional flat-pack versions for reduced transport cost
- 5-year warranty available
GALVAR® technology is particularly suited to transport infrastructure, wastewater treatment, pumping stations, outdoor control points, ventilation systems and camera/telemetry installations.
The correct enclosure material depends on several factors, including:
- Required corrosion class (C2–CX)
- Exposure to salt, chemicals or humidity
- Risk of galvanic corrosion
- Mechanical impact and IP/IK requirements
- Hygienic or food-grade requirements
- Budget and lifecycle expectations
Gridhaus Systems assists customers in selecting the right material for their operational environment, ensuring long-term durability and compliance.
Corrosion is influenced by environmental conditions, material composition and electrochemical interactions. With a full portfolio of galvanised steel, Magnelis®, aluminium, AISI 304, AISI 316L and patented GALVAR® bonded enclosures, Gridhaus Systems delivers solutions capable of withstanding even the most demanding environments.
For technical support or project enquiries:
📧 support@gridhaussystems.co.uk