How to Prevent Rusting in Electrical Enclosures

Rust may seem like a small issue at first, but in the world of electrical enclosures, it can lead to serious consequences like damaged circuits, compromised safety, frequent breakdowns, and unplanned downtime. For businesses that depend on equipment performance and operational reliability, preventing corrosion in electrical enclosures is not just a maintenance task, it’s a business essential.

At Bartakke Enclosures, we understand the harsh conditions many of our customers face – whether it’s the humid air of coastal regions, chemical-laden industrial zones, or simply the wear and tear of time. That’s why we believe in educating our clients on how to prevent rusting in electrical enclosures using a combination of smart material selection, design, and ongoing care.

Why Do Electrical Enclosures Rust?

Rust is the result of iron reacting with oxygen and moisture, forming iron oxide a brittle, flaky substance that gradually eats away at the material. While this is common in mild steel or poorly coated enclosures, even stainless steel can rust under the right (or wrong) conditions, especially when exposed to salt spray, acidic fumes, or poor ventilation.

Why Do Electrical Enclosures Rust?

Rust is the result of iron reacting with oxygen and moisture, forming iron oxide a brittle, flaky substance that gradually eats away at the material. While this is common in mild steel or poorly coated enclosures, even stainless steel can rust under the right (or wrong) conditions, especially when exposed to salt spray, acidic fumes, or poor ventilation.

Best Practices to Prevent Rusting in Electrical Enclosures

Use the Right Material for the Right Application

Always start with material selection. At Bartakke, we offer a range of enclosures including:

• Mild Steel: Cost-effective, suitable for indoor or controlled environments.
  
• Stainless Steel (SS304/SS316): Ideal for corrosive or outdoor applications.
  
• Aluminum or FRP (on request): Lightweight and rust-proof, suitable for specific use cases.
  

For marine, chemical, or food-processing industries, we highly recommend SS316L-grade enclosures, known for their high resistance to salt and acid corrosion.

Protective Coating and Surface Treatment

Even with strong materials, surface coating is your armor. Our enclosures go through:

• Zinc phosphate pre-treatment
  
• Multi-layer powder coating
  
• Optional epoxy or PU top coats for aggressive environments
  

A properly applied coating seals the metal surface, keeping moisture out and preventing oxidation.

Enclosure Design Matters

Rust often forms where water collects edges, gaps, and joints. Good design practices include:

• Sloped roofs to prevent water pooling
  
• Smooth welds and sealed joints
  
• Proper gasket sealing (IP65 or IP66 certified)
  
• Drainage holes or breathers for condensation release
  

A well-designed enclosure can drastically reduce the risk of rust buildup, especially in outdoor installations.

Humidity and Moisture Control

Moisture trapped inside the enclosure can be as damaging as exposure outside. We suggest:

• Desiccants or dehumidifier pouches inside the enclosure
  
• Breather vents that allow air exchange without water ingress
  
• Use of Vapor Corrosion Inhibitor (VCI) solutions like Plastabs, which release anti-corrosion vapors in a sealed space and are safe for electronics
  

Such solutions are non-conductive, non-toxic, and ideal for control panels or MCCs in sensitive environments.

Avoid Galvanic Corrosion

Using dissimilar metals (e.g., stainless steel enclosure with zinc-coated bolts) can lead to galvanic corrosion. Always ensure compatible materials are used for:

• Mounting brackets
  
• Hinges
  
• Fasteners and clamps

Periodic Inspection and Cleaning

No matter how durable the enclosure is, routine checks make a difference:

• Inspect for surface damage or scratches (which can expose the metal)
  
• Wipe off any standing water or chemical deposits
  
• Touch up coatings if chipped or worn
  

Even simple steps like removing dust or ensuring tight gasket seals help maintain the enclosure’s lifespan.

Bonus Tip: Consider Your Installation Location

A poorly chosen location like placing an enclosure under dripping pipes or in a splash zone can accelerate corrosion. Evaluate environmental exposure during the design and installation phase.

Conclusion: Long-Lasting Protection Starts with Smart Choices

Rust doesn’t happen overnight, but it builds silently. With the right combination of material selection, protective design, anti-corrosion techniques, and regular care, you can significantly extend the life of your electrical enclosures and reduce maintenance costs.

At Bartakke, we don’t just manufacture enclosures, we help you choose the right solution for your operating environment. If you’re looking for custom-built, rust-resistant electrical enclosures in India, our expert team is happy to help.