Selecting the correct explosion-proof camera housing requires matching four key factors: the hazardous area certification (Class/Division/Group or ATEX Zone), the construction material (for environmental compatibility), the size (to fit your chosen camera), and the window material (for optical clarity under operating conditions). This guide covers all four factors with selection criteria for the most common industrial applications.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
The Most Important Rule: Certified Assembly Only
Before selecting materials, size, or features — understand the fundamental rule of explosion-proof housing compliance: the housing and camera must be certified together as an assembly. An explosion-proof housing is not a universal container that makes any camera inside it compliant. The certification verifies a specific camera model (or models) in a specific housing — the electronics’ heat output, the cable entry types, the thermal behavior of the assembly.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
When you see “explosion-proof housing for your camera,” be cautious. A housing listing only certifies what the test house verified. If the camera model you want isn’t on the certificate, the assembly is not certified, regardless of the housing’s rating. Always verify the complete assembly certification before purchase.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
Hazardous Area Certification Requirements
The first selection criterion is the certification required for your classified area. This is determined entirely by your facility’s hazardous area classification document — not by general rules of thumb:
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
| Area Classification | Minimum Housing Certification Required |
|---|---|
| Class I Division 1 Group D (USA) | UL Listed Class I Division 1 Group C&D (Group C covers D) |
| Class I Division 1 Group C (USA) | UL Listed Class I Division 1 Group C&D |
| Class I Division 1 Group B (USA) | UL Listed Class I Division 1 Group B — very limited selection |
| Class I Division 2 Group D (USA) | UL Listed Class I Division 2 Group D (or higher) |
| ATEX Zone 1 IIA gas | ATEX II 2G Ex d IIB T[x] Gb (IIB covers IIA) |
| ATEX Zone 1 IIB gas (ethylene) | ATEX II 2G Ex d IIB T[x] Gb |
| ATEX Zone 1 IIC gas (hydrogen) | ATEX II 2G Ex d IIC T[x] Gb — limited selection |
| ATEX Zone 2 | ATEX II 3G Ex d IIB T[x] Gc (or Zone 1 rated) |
Housing Material Selection
Explosion-proof housings are manufactured in four primary materials, each suited to different environmental conditions:
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
Cast Aluminum
The most common material for general industrial explosion-proof housings. Cast aluminum offers a good strength-to-weight ratio, is easy to machine to tight flame path tolerances, and provides adequate corrosion resistance for dry industrial environments. Standard aluminum is not suitable for coastal or marine environments (chloride corrosion) or for applications where the housing contacts aggressive chemicals.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
- Best for: Indoor manufacturing, general industrial, non-marine outdoor applications
- Not suitable for: Coastal environments, offshore, strong acid or alkali exposure
- Weight: Moderate
- Cost: Lowest of the four materials
316L Stainless Steel
316L stainless contains 2–3% molybdenum, which dramatically increases resistance to chloride pitting and crevice corrosion compared to standard 304 stainless. It is the standard material for offshore platforms, coastal facilities, food and beverage processing, and chemical plants where the housing may be exposed to aggressive cleaning agents or corrosive gases.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
- Best for: Offshore platforms, coastal facilities, chemical plants, washdown environments, food processing
- Not suitable for: Applications with hydrofluoric acid or highly concentrated chloride environments (requires higher-grade alloy)
- Weight: Heavy (2.5–3× equivalent aluminum housing)
- Cost: 3–5× aluminum equivalent
304 Stainless Steel
General-purpose stainless, suitable for applications requiring corrosion resistance beyond aluminum but without the marine-grade chloride resistance of 316L. Commonly used in indoor food processing, pharmaceutical, and general chemical environments without direct salt spray exposure.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
- Best for: Indoor chemical environments, food processing, pharmaceutical manufacturing, general corrosive atmospheres
- Not suitable for: Direct salt spray, offshore environments, sustained chloride contact
- Weight: Heavy
- Cost: 2–3× aluminum equivalent
GRP (Glass-Reinforced Plastic)
GRP (fiberglass) housings offer excellent chemical resistance against acids and alkalis that would attack both aluminum and stainless steel, combined with lower weight than stainless. They cannot be used in applications requiring high mechanical impact resistance, and their suitability for high-temperature applications is more limited than metallic housings.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
- Best for: Chemical plants with highly corrosive atmospheres, wastewater treatment, fertilizer production
- Not suitable for: High-impact applications, very high temperature environments
- Weight: Lightest option
- Cost: Comparable to 316L stainless
Material Selection by Environment
| Environment | Recommended Material |
|---|---|
| General indoor industrial (no corrosives) | Cast aluminum |
| Outdoor industrial (inland, no salt spray) | Cast aluminum with appropriate coating |
| Outdoor coastal (within 1 km of sea) | 316L stainless |
| Offshore platforms (direct sea air exposure) | 316L stainless with duplex coating |
| Chemical plant (chlorinated solvents, HCl) | 316L stainless |
| Chemical plant (strong acids or alkalis) | GRP or higher-grade alloy (consult engineer) |
| Food and beverage (washdown with chlorinated cleaner) | 316L stainless |
| Pharmaceutical manufacturing | 316L stainless or 304 stainless |
Sizing: Matching the Housing to Your Camera
Explosion-proof housings are not generic enclosures — they are designed and certified for specific camera sensor formats and body types. Key dimensional considerations:
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
- Sensor format — Most housings are designed for 1/3″ or 1/2″ sensor fixed cameras. PTZ cameras require specialized rotating housings with certified flame path joints — the rotating mechanism is the most complex and expensive part.
- Camera body dimensions — Box cameras and dome cameras have different mounting requirements. Verify that your specific camera model is listed on the housing’s certification documentation.
- Lens aperture — The front window must be large enough for the camera’s field of view without vignetting. Wide-angle lenses require larger window apertures.
- Cable entries — How many cables are needed? Power, video (coax or Ethernet), alarm inputs, wiper motor? Each entry requires a certified cable gland or conduit fitting.
- Wiper and washer provisions — If operating in rain, dust, or environments where the lens window will get dirty, verify the housing has provisions for a certified wiper/washer motor.
Window Material Comparison
| Window Material | Optical Clarity | Scratch Resistance | Chemical Resistance | Cost | Best For |
|---|---|---|---|---|---|
| Borosilicate glass | Excellent | Good | Good (resists most chemicals) | Low | Standard industrial applications |
| Polycarbonate | Good (initially) | Poor (scratches easily) | Moderate (attacked by some solvents) | Very low | Light-duty indoor applications only |
| Sapphire glass | Excellent | Excellent (second only to diamond) | Excellent | Very high | Abrasive environments, long-term deployment |
| Quartz glass | Excellent (UV transparent) | Good | Very good | High | UV-sensitive applications, IR cameras |
For most industrial explosion-proof camera applications, borosilicate glass is the correct choice. Polycarbonate should only be used for indoor non-abrasive environments where windows can be cleaned carefully. Sapphire is warranted for harsh abrasive environments (sand, grit, minerals) where borosilicate would degrade over time.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
IP Rating: Ingress Protection
Explosion-proof certification and IP rating are separate and independent. An explosion-proof housing can be IP65 or IP68 — the explosion-proof certification doesn’t imply any specific IP rating. For outdoor installations:
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
- IP66 minimum for outdoor fixed cameras — dust-tight, protected against powerful water jets
- IP67 for applications subject to temporary water immersion (flood-prone areas, washing areas)
- IP68 for permanent or continuous immersion (underwater inspection, below-deck marine)
- IP69K for high-pressure washdown environments (food processing, offshore deck equipment)
Frequently Asked Questions
Can I put any camera inside an explosion-proof housing?
No. An explosion-proof housing only provides a compliant installation when used with the specific camera model(s) listed in its certification. Placing an uncertified camera inside a certified housing invalidates the housing’s certification and makes the installation non-compliant, regardless of the housing’s original rating. You must use a factory-certified camera-housing assembly.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
What is the difference between 304 and 316 stainless steel for explosion-proof housings?
316L stainless contains molybdenum (2–3%) which makes it significantly more resistant to chloride corrosion and pitting than 304. For coastal, offshore, or chemical environments where chlorides or aggressive chemicals are present, 316L is required. For general industrial indoor applications without chemical exposure, 304 provides adequate corrosion protection at lower cost.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
What IP rating do I need for an outdoor explosion-proof camera?
IP66 is the minimum recommended for outdoor explosion-proof cameras — dust-tight and protected against powerful water jets. For applications with pressure washing, IP67 (temporary immersion) or IP69K (high-pressure washdown) may be required. Offshore and marine installations typically specify IP66/IP67 with 316L stainless construction.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
How do I choose between a fixed housing and an integrated explosion-proof camera?
Integrated explosion-proof cameras (camera and housing as one certified unit) are easier to specify and guarantee compliance — there is no question about certification compatibility. Separate housings designed for specific camera models offer more flexibility for camera upgrades, but each new camera model must be certified with the housing. For most surveillance applications, integrated certified assemblies are the simpler and safer choice.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
What window material should I choose for an explosion-proof camera housing?
Borosilicate glass is standard for most applications — optically clear, scratch-resistant, and thermally stable. Polycarbonate costs less but scratches easily and degrades under UV exposure. Sapphire glass offers superior scratch and chemical resistance but at significant cost premium. For abrasive or chemical environments, borosilicate or sapphire is strongly recommended over polycarbonate.
For definitions of key hazardous area terms used in this guide, see the Hazardous Area Classification Glossary.
Further Resources
Browse Veilux’s range of explosion-proof cameras and explosion-proof housings certified for hazardous areas. For regulatory reference, see NFPA 70 (National Electrical Code) and IECEx hazardous area standards.
For a complete overview of all selection criteria, see the Explosion-Proof Camera Selection Guide: Complete Hub.