What Kind of Lighting Is Suitable for Corrosive Environments?

For corrosive environments, lighting with a stainless steel or high-quality plastic housing, combined with a high IP protection rating (minimum IP66), is the most suitable choice. Standard aluminum luminaires degrade quickly due to aggressive chemicals, sea air, or humid vapors, making them unsafe and leading to high maintenance costs. This article answers the most frequently asked questions about choosing the right lighting for corrosive industrial environments.

What makes an environment corrosive to lighting?

Not every space with a bit of moisture or dust is immediately a problem, but as soon as substances are present that actively affect the housing, seals, or electrical components of a luminaire, it becomes a different story. Consider saltwater, acids, alkalis, ammonia, chlorine, or a combination of moisture and chemical vapors. The more aggressive the substance and the longer the exposure, the faster standard luminaires will fail.

In practice, the most corrosive industrial environments are found in sectors such as the chemical industry, paper industry, food processing companies, offshore platforms, harbors, and waste management. However, even within steel mills and recycling companies, aggressive fumes and dust particles can have a devastating effect on lighting installations.

What many people underestimate: the damage caused by corrosion is not always visible from the outside. Internal oxidation of wiring and connections leads to malfunctions, short circuits, and ultimately fire hazards. Corrosion thereby not only undermines the lifespan of the luminaire, but also the safety of the work environment.

Which materials are resistant to corrosion in luminaires?

Stainless steel (SS) and specially formulated technical plastic are the most corrosion-resistant materials for industrial pipe luminaires. Stainless steel offers excellent resistance to acids, alkalis, and saltwater, while high-performance plastics like polycarbonate or fiberglass-reinforced polyester can withstand a broad spectrum of chemicals without oxidizing.

Aluminum is widely used in standard industrial lighting due to its low weight and good heat dissipation. However, in corrosive environments, untreated aluminum is vulnerable. Only with a special powder coating or anodization does it offer some protection, but in the most aggressive environments, that is simply not enough.

When choosing materials, seals also play a crucial role. Silicone gaskets and seals based on EPDM rubber are resistant to extreme temperatures and a wide range of chemicals. Neoprene or standard rubber degrades much faster and leads to moisture ingress.

For the toughest applications, such as lighting in the chemical industry or offshore, stainless steel lighting with an integrated seal and corrosion-resistant fasteners the standard.

What do IP classes mean for corrosive environments?

The IP protection class (Ingress Protection) indicates the extent to which a luminaire is protected against dust and water. In corrosive environments, a minimum of IP66 is required, meaning the luminaire is completely dust-tight and resistant to powerful water jets. For immersion or permanent exposure to liquids, IP67 or higher applies.

The two numbers in an IP class represent:

First digit (0-6): protection against solid particles and dust
Second digit (0-9): Protection against water, from drips to high-pressure jets

In practice, IP66 is the minimum for outdoor industrial lighting and areas where high-pressure cleaners are used. IP69K is the highest rating and is intended for luminaires that are regularly cleaned with hot, high-pressure water, such as in the food industry or in livestock farming.

One misunderstanding recurs regularly: a high IP rating does not automatically mean a luminaire is corrosion-resistant. IP says something about the density, but not about the chemical resistance of the material itself. A luminaire with IP66 in an aluminum housing can still degrade quickly in a chemically aggressive environment. For more background on IP ratings, consult the explanation of IP and IK ratings.

When is ATEX certification required for lighting?

ATEX certification is mandatory when lighting is used in environments where explosive atmospheres may arise due to the presence of flammable gases, vapors, mists, or dust. This is European legislation (Directive 2014/34/EU) and applies to zones classified as having an explosion risk by the employer.

The ATEX zoning determines which type of certified luminaire is required:

Zone 0 / Zone 20: Permanently present explosive atmosphere (gas or dust). Requires category 1 luminaires.
Zone 1 / Zone 21: Regularly present explosive atmosphere. Requires category 2 luminaires.
Zone 2 / Zone 22: Seldom and briefly present explosive atmosphere. Category 3 luminaires are sufficient.

In the chemical industry, petrochemicals, paint production, flour processing, and offshore, ATEX zones are standard. Using non-certified lighting in these zones is not only dangerous but also punishable. ATEX luminaires are often also designed to be corrosion-resistant, as the conditions in explosion-hazardous zones are typically also chemically aggressive.

For environments that are both explosion-hazardous and corrosive, such as chemical terminals or offshore platforms, it is essential that a luminaire meets both requirements. Offshore and maritime environments represent the highest combined requirements.

How to choose the right lighting for a corrosive environment?

The right choice is made based on four factors: the nature of the corrosive substance, the intensity and frequency of exposure, the presence of explosion hazards, and operational conditions such as temperature and cleaning method. No two corrosive environments are identical, so a tailor-made approach is necessary.

When making your selection, ask yourself the following questions:

Which chemicals or substances are present and in what concentration?
Is there permanent exposure or only during cleaning?
Are there any designated ATEX zones in the vicinity?
What are the minimum and maximum temperatures?
How is space cleaned and with what means?
How accessible are the luminaires for maintenance?

Based on the answers, you can determine the material choice, IP class, and any ATEX category. Ports and terminals, where saltwater and chemical cargo meet, have different requirements than an indoor chemical storage area. View the solutions for lighting in harbors and terminals as an example of how environmental requirements are translated into concrete lighting choices.

Don't forget to factor in maintenance costs. A cheaper luminaire that needs to be replaced annually will be more expensive in the long run than a robust stainless steel luminaire with a lifespan of ten years or more. Furthermore, LED technology significantly reduces energy consumption compared to conventional light sources, which is quickly recouped in 24/7 operations.

Practical example: Boskalis Bokalift 2

The Bokalift 2 from Boskalis is an offshore heavy-lift vessel. The ship already had LED lighting from a well-known premium brand, but because spotlights were used, the light was too concentrated and the deck was insufficiently lit for the work. JEL redesigned the deck and crane lighting with 4 Orca, 12 Barracuda, 16 DarkLicht DL1 and Crane Light Stabilizers. The luminaires are IP69K near the water and fitted as standard with a C5H marine coating, resistant to corrosion in offshore conditions. The design achieves 200 lux under the crane with a uniformity of 0.70 in height, with virtually no shadows.

Salt water and corrosion close to the waterline call for a trade-off per position. Luminaires mounted right next to the water face the heaviest exposure and therefore get the highest protection rating, while the coating protects the housing in every position. Material and IP rating are the starting point, not a guarantee of good light. The same luminaires can leave a work area unusable or well lit, depending on optics, position and aiming strategy. A corrosion-resistant installation therefore requires both: the right version and a well-considered lighting design.

How JEL Products Helps Provide Lighting in Corrosive Environments

JEL Products specializes in industrial LED lighting for the most demanding conditions, including extreme corrosion. Whether it’s a chemical terminal, an offshore platform, or a production facility with aggressive cleaning processes, the luminaires are specifically designed for these environments.

What JEL Products offers for corrosive applications:

Stainless steel luminaires with high IP protection ratings (up to IP69K)
Lighting for the site areas outside the ATEX zones, with referral to a certified Ex manufacturer for the zones themselves
Luminaires that withstand extreme temperatures, from -45 °C, and up to +120 °C with the HT line
Complete project management: from lighting design to installation and commissioning
ISO9001 and VCA** certified, with assembly and custom production in the Netherlands

Every project begins with a thorough analysis of the environmental requirements, ensuring that the chosen solution matches the specific corrosive, thermal, and operational conditions. Would you like to know which luminaires are suitable for your situation? Get in touch with the specialists at JEL Products for a no-obligation consultation.

Blog

Which lighting is suitable for corrosive environments?