Everyday Corrosion vs. Industrial Challenges
Corrosion is something we encounter all the time – on cars, garden tools, and other everyday equipment.
While corrosion on cars or garden tools is mostly a nuisance, managing its effects on video monitoring systems is far more complex. These systems are often installed in environments that accelerate corrosion—coastal or offshore sites exposed to salt air, refineries and process plants where chemical vapors are present, or wastewater and utility facilities with constant moisture and temperature swings. The variables involved—chemical exposure, temperature, humidity, and installation environment—make designing durable camera systems particularly challenging. As cameras are increasingly used to monitor critical industrial processes, they must be robust enough to survive the environments they protect.
At Industrial Video & Control (IVC), corrosion-resistant design is a fundamental part of ensuring reliable video performance in these demanding conditions.
Identifying the Corrosive Element
The first step in designing for corrosion resistance is identifying the corrosive element itself. Salt water, for example, is highly aggressive, especially when it builds up on surfaces and blocks oxygen exposure. This is a frequent challenge in marine and coastal environments such as shipboard operations, marinas, port facilities, and desalination plants. Chemical exposure presents even greater complexity. In industries like steel and iron production, mining, oil refining, fertilizer manufacturing, and pulp and paper, chemicals may be either process inputs or byproducts, and each can attack materials differently. For saltwater environments, 316L stainless steel remains the standard choice due to its resistance to chloride-induced corrosion. In chemical environments, however, the material selection process becomes far more nuanced. Aluminum, stainless steel, and even titanium each have limits depending on chemical type, concentration, and exposure conditions. Protective coatings and surface treatments can extend service life, but they too eventually degrade, sometimes far faster than expected when exposed to heat, acids, or alkaline solutions.
Considering System-Level Design Factors
While the enclosure material is fundamental, corrosion protection extends to every component in the system. A truly corrosion-resistant design must also account for:
- Enclosure Integrity: Ratings such as IP68 or NEMA 4X ensure protection against moisture ingress and chemical intrusion.
- View Window Materials: Glass and acrylic perform differently under exposure; choosing an optically clear, chemically compatible window helps maintain image quality over time.
- Gaskets and O-Rings: Elastomers can swell, crack, or lose elasticity depending on temperature and chemical contact, so compound selection is critical.
- Connectors, Pigtails, and Fasteners: These small parts often fail first; using compatible metals and sealed interfaces prevents galvanic reaction and moisture entry.
When Engineered Plastics Make Sense
Where feasible, engineered plastics or composite materials can be an ideal solution. These materials provide immunity to many forms of corrosion and significantly reduce weight – an advantage for mast-mounted or wall installations. Still, plastic selection is not one-size-fits-all. Compatibility with specific chemicals, exposure duration, ambient temperature range, and UV stability must all be considered. Structural behavior also matters; some polymers soften or creep under load or long-term heat. Understanding these trade-offs early in the design process helps ensure long-term reliability.
IVC’s Approach to Corrosion Challenges
IVC has extensive experience designing and testing enclosures for harsh, chemically active, and moisture-laden environments.
Recently, IVC engineered a fixed IP camera enclosure made from an engineered plastic composite to withstand intermittent exposure to 30% hydrochloric acid at room temperature. The system was developed for use inside an industrial wastewater tunnel—a setting that would rapidly degrade standard aluminum or coated-steel housings. During development, IVC carefully evaluated each component:
- The housing material was chosen for both chemical compatibility and mechanical strength.
- The viewing window was selected for acid resistance and optical clarity under continuous humidity.
- O-Rings and Fasteners were specified to prevent galvanic interaction and maintain a secure seal.
- A Network Cable Assembly was designed to ensure reliable connectivity under corrosive and damp conditions.
Independent immersion testing at an NRTL-certified facility confirmed the system’s excellent corrosion resistance and long-term durability, with only negligible impact observed on the fasteners.
Tailoring Each Design to Its Environment
Each application presents a distinct set of conditions. A design that performs well in hydrochloric acid exposure might not suit another chemical, or even a higher concentration of the same one. Variables such as vapor exposure, washdown processes, vibration, and temperature cycling all influence material performance. That’s why IVC works closely with customers to evaluate environmental risks and recommend the most suitable enclosure design for each installation. This engineering-driven approach helps ensure continuous visibility, reduces unplanned maintenance, and extends the service life of critical monitoring systems.
Ready to discuss your corrosive environment?
Contact our technical sales team today. We’ll help you build a solution that lasts where nothing else can.
(617) 467-3059 | info@ivcco.com
About the Author: Bill Richards is the co-founder and Vice President of Operations at Industrial Video & Control. He leads the company’s hardware engineering efforts and has over 20 years of experience developing products for hazardous areas. Among his accomplishments, Bill pioneered the industry’s first line of IP dome cameras certified for use in hazardous areas. Bill holds a bachelor’s degree in engineering from the University of Michigan.