UV Resistance in Electrical Enclosures: Which Materials Perform Best?

Is your electrical equipment subjected to the sun’s rays? The damage caused by UV radiation can result in severe problems, including becoming brittle, discoloring, and failing prematurely. If you choose the wrong material for electrical enclosures, you could incur expensive repair and operational costs.

But don’t stress, in this guide, we will highlight the best UV resistant materials. They will ensure your equipment remains protective, durable, reliable, shielded against harsh environments, and protects your investment.

1) Why UV Resistance Matters in Electrical Enclosures

When electrical enclosures are exposed to high temperatures for a long time, ultraviolet (UV) radiation can cause some serious damage. This is because UV radiation can decompose substances over long periods. Discolouration, fading, yellowing, and surface marking can all be symptoms easily observable.

If enclosure protection fails, the components within can be damaged as well as exposed to water, dust and debris. This can lead to short circuits and corrosion or complete system breakdown, affecting overall performance. Hence, enclosures without proper safety mechanisms increase the risk of electric shock or fire.

While not immediate, UV damage occurs in direct as well as consistent sunlight, especially in Industrial and marine sites, rooftops and deserts. These locations have little or no shade, leading to drastic changes in equipment internals.

Sunscreen isn’t just for people! Make sure to add UV protective coating so enclosures can be tan-free all day. You know harsh conditions demand attention when using equipment in the outdoors. In such cases, UV-resistant materials ensure safety and usability.

2) Common Materials Used in Electrical Enclosures

As with any engineering and design endeavour, the selection of material for an electrical enclosure should give primary consideration to its strength/durability, resistance to UV rays, cost, and specific environmental requirements. The following is a description of the most commonly used materials with their corresponding properties and applications.

i) Polycarbonate (PC)

As a thermoplastic, polycarbonate is one of the most durable and impact-resistant materials available. Its ability to maintain its structural integrity at temperatures of -40°F to 250°F means it can be used in extreme outdoor conditions. Polycarbonate enclosures are also cheaper and easier to install than their metal counterparts, which often means reduced shipping expenses.

• Key Features:

• High Impact Resistance: Polycarbonate is able to endure extreme levels of mechanical stress alongside impacts. This feature makes PC popular in areas with heavy foot traffic.

• Excellent Stability: Polycarbonate improves its performance when exposed to the sun, thanks to the introduction of UV stabilisers. Well, PC (polycarbonate) will not deteriorate in sunlight and will retain its essential properties over time.

• Lightweight and Cost Effective: Due to its lightweight, polycarbonates are simple to install and cheap to ship. They also represent a less expensive option compared to shipping metallic enclosures.

• Appropriate for Outside Use: Polycarbonate is well suited for construction applications due to its resistance to UV rays and weather conditions.

ii) Fibreglass Reinforced Polyester (FRP)

Fibreglass reinforced polyester (FRP) enclosures are made from molded fibreglass reinforced polyester. They are specifically designed to excel in industrial, chemical, and outdoor settings due to their high durability and resistance to corrosion. FRP enclosures also provide excellent UV resistance.

• Key Features:

• Superior Strength and Corrosion Resistance: The composite structure of FRP offers exceptional strength. This makes FRP highly resistant to corrosive chemicals and moisture.

• Excellent UV Stability: FRP is manufactured with UV stabilisers, which greatly enhance its resistance to warping and sun damage.

• Ideal for Industrial and Outdoor Use: FRP’s resilience makes it ideal for harsh environments, including chemical plants and outdoor installations.

iii) Acrylonitrile Butadiene Styrene (ABS)

Widely used in plastic design, ABS excel in being known for its strength and impact resistance. Although standard ABS doesn’t show resistance to UV rays, there are UV-stabilised variants available.

• Key Features:

• Good Impact Resistance: Despite being less impact resistant than polycarbonate, ABS is sufficient for numerous applications.

• Lightweight and Easy to Install: Its low weight simplifies handling and installation processes.

• Cost-Effective: ABS is an economical choice for projects with budget constraints because its raw material is widely available.

• UV-Stabilised Variants Available for Outdoor Use: Special formulations enhance ABS’s UV resistance, extending its suitability to certain outdoor applications.

iv) Polyvinyl Chloride (PVC)

PVC is a versatile thermoplastic known for its chemical resistance and affordability. It is commonly used in electrical conduits and plumbing fixtures. However, PVC is susceptible to UV degradation, so it is more suitable for indoor applications or environments with minimal sun exposure.

• Key Features:

• Chemical Resistance: PVC withstands exposure to various chemicals, making it suitable for industrial settings.

• Affordable: Its low cost makes PVC an attractive option for budget-conscious projects.

• Suitable for Indoor Applications: Due to its sensitivity to UV light, PVC is best used indoors or in shaded areas.

• Limited UV Resistance: Without UV stabilisers, PVC can degrade and discolour when exposed to sunlight.

v) Aluminium and Stainless Steel

Metal enclosures are constructed from materials like stainless steel and aluminium, which have notable strength and durability. As compared to other materials, stainless steel has excellent corrosion resistance and is great in harsh environments.

Moreover, corrosion resistance is also offered by aluminium, which means it is also lightweight. Both materials are especially useful for outdoor use in industrial and marine environments.

• Key Features:

• Strength and Durability: They can withstand extreme and physically challenging conditions.

• Corrosion Resistance: Particularly rust and corrosion resistant stainless steel claims to deal with rust even in saline surroundings.

• Harsh Weather Suitable: Withstand the demands of industrial and marine applications.

• Cost Is Higher Than Plastic Counterparts: These are comparatively expensive due to wear and tear durability.

Considerations such as environmental factors, plan exposure, and budget determine the enclosure material. For outdoor use, Polycarbonate and FRP are recommended for UV resistance, while PVC and ABS are better suited for indoor use. Enclosed metal structures allow the greatest strength suited for extreme environments.

3) UV Protection Methods and Enhancements

An outdoor electrical enclosure can be gradually and permanently damaged by UV radiation, including the cables of electrical enclosures. Sunlight exposure tends to make materials fade, crack, or become brittle. Luckily, there are ways to improve UV protection so that enclosures and other materials can be preserved for longer.

• UV Stabilizers

For plastic enclosures, which include polycarbonate or FRP enclosures, most contain UV inhibitors in the manufacturing. For example;

• Hindered Amine Light Stabilisers (HALS)
• Benzotriazoles
• Benzophenones
• Triazines
• Carbon Black
• Titanium Dioxide (TiO₂)
• Zinc Oxide (ZnO)

These additives either absorb or reflect extremely dangerous UV rays and protect the material from being damaged. They also considerably slow down the rate of enclosure damage in terms of strength, flexibility, and appearance.

• Surface Treatments and Protective Coatings

Several enclosures, which are made of ABS and PVC plastic, undergo special UV block treatments in the form of colourless or colored coatings. Such treatments prevent severe light-induced damage that can change the appearance of the enclosure over time, making it look aged.

These specially designed scrubs act as a shield that greatly decreases sunlight-induced deterioration and ageing.

• Selection of Light Color

The colour of the enclosure also determines how well UV exposure will be handled. For instance, white or light grey enclosures will reflect more sunlight and absorb less heat due to the lighter shade. This aids in alleviating overheating and minimises material degradation. With the right use of color, protection can be optimised at no additional cost.

• Installation Under Shade or Overhangs

Placement is key. Installing enclosures in the shade or under protective covers reduces exposure to direct sunlight. Overhangs, sunshields, and mounting the enclosure on the shaded side of the building are also good options. These physical means block UV rays and provide natural protection for your enclosure.

Combining these strategies helps ensure that your enclosures are optimised for strength and protection while maintaining their aesthetic appeal, even in the sunniest locations.

4) Testing Standards and Ratings for UV Resistance

To maintain the strength and longevity of electrical enclosures placed outdoors or in UV-intensive environments, different testing standards and ratings are set. Well, these are followed by the manufacturers to ensure that wiring, components, and other crucial parts are adequately shielded from ultraviolet rays.

a) UL 746C: UV Resistance Evaluation of Materials Used for Electrical Components

This document outlines essential procedures to determine the UV resistance of plastics utilised within electrical enclosures. It includes tests on the capability of materials to endure UV light exposure over periods of time without degradation. Those meeting this standard are less likely to become fragile, discolored, or lose their structural integrity from sunlight.

b) NEMA 4X And IP: Standards on UV Resistance and Environmental Protection

NEMA and IP ratings are another measure of extreme exposure, such as UV rays. NEMA 4X. For example, means that an enclosure can withstand outdoor weather conditions such as wet environments, dusty locations, and UV rays.

IP ratings have essentially the same purpose, but rather concentrate on protection associated with dust and water, and indirectly imply defence against UV abrasion.

c) Accelerated Weathering Tests ( ASTM G154, QUV Testing )

Studies like ASTM G154 Weathering test, or QUV testing, place materials under accelerated sunlight and weather simulation. This type of testing assesses how durable an enclosure will be during actual weather conditions, ensuring its stability against UV rays, and that it is hard-wearing overall.

Such standards and tests ensure that the enclosure will endure UV radiation and elemental abrasions throughout its use.

5) Material Comparison

Below is a graphical representation of the most common materials and their properties with respect to electrical enclosures. Just take a look;

6) Application Scenarios

It is very important to consider the operating conditions while choosing materials for electrical enclosures. Each environment has its own unique set of requirements, which, if satisfied, will result in prolonged protection and performance. The following are some of the most familiar situations where different materials work best:

• Solar Power Systems: The PC and FRP materials have a high level of durability. It also protects solar equipment from being damaged by sunlight and other outdoor elements because the UV-resistant fibreglass is used.

• Telecommunications Equipment: Polycarbonate is also frequently used in the enclosures of telecom equipment. It has UV stability and impact resistance, which makes it suitable for outdoor terms like rooftops or other industrial spaces.

• Industrial Machinery: For industrial settings where enclosures are subjected to chemicals and UV, FRP is the most suitable material. It gives UV protection and corrosion resistance, while Stainless Steel strengthens and protects the enclosure from harsh chemicals.

• Marine Environments: The best material to use in Marine settings is aluminium and stainless steel. Because they are unrivalled in protection from saltwater corrosion and UV rays. Thus, they can be used in offshore and coastal locations.

• Indoor Applications (Commercial Buildings): Fast and easy to install, indoor electrical systems use ABS or PVC as they are economically friendly. Both materials are exposed to little UV radiation, which makes providing protection possible. They are used in electrical control panels.

• Outdoor Electrical Control Panels: For outdoor electrical panels, PC and FRP materials are the most suitable because they protect the devices from radiation. Also, the strength of these materials makes them withstand harsh conditions for extended periods.

7) Conclusion

Alright! So, selecting the appropriate material for electrical enclosures greatly affects performance, UV resistance, and durability. We saw that Polycarbonate (PC) and Fibreglass Reinforced Polyester (FRP) are suitable for outdoor applications, stainless steel and aluminium are appropriate for marine or industrial extremes.

At Saipwell, we specialise in tailored thermal and operational protective needs with our broad range of high-grade enclosures and equipment. We offer corrosion-resistant enclosures and also solutions with UV protection that are dependable and purpose-built. Protect your equipment using proven Saipwell products, no matter the environment.

For more details and to place an order, you can contact us right now!.