Brake pads on battery-electric vehicles can run beyond 100,000 miles, cutting replacement frequency by roughly two-thirds against internal-combustion vehicles — and that idle time is exactly what puts their steel backing plates at risk. With regenerative braking handling most deceleration, the pads no longer get heated dry by routine stops, so moisture stays on the plate. Mordor Intelligence’s automotive brake pad market report identifies that corrosion as a design constraint on electrified platforms and reports that Continental recommends galvanized steel plates in response. The firm rates NVH and corrosion standards a +1.1-point driver in a segment forecast to reach USD 5.87 billion by 2031.
Highlights
- Battery-electric vehicles use regenerative braking for most deceleration, leaving pads idle and exposed to moisture corrosion on the backing plate.
- Mordor Intelligence reports that Continental recommends galvanized steel plates for brake pads, adding slightly to cost per set while significantly extending pad life.
- Rear pads held a minority of 2025 volume against the front axle’s 64.73% share but are forecast to grow at a 6.15% CAGR, and run cooler and more corrosion-prone.
- BEV regenerative systems extend pad life beyond 100,000 miles, lowering replacement frequency by roughly two-thirds versus internal-combustion vehicles.
Why Idle Pads Corrode
The mechanism is straightforward. Because battery-electric cars decelerate primarily through the motor, the friction pads sit unused for extended stretches, which leaves the backing plate susceptible to moisture corrosion. On an internal-combustion vehicle, routine friction braking generates enough heat to drive moisture out of the pad assembly. Remove most of that duty cycle and the moisture stays.
The result inverts the conventional service assumption. A pad can retain usable friction thickness for years while the steel underneath spends that time in a corrosive environment. Mordor Intelligence frames the outcome as a split in material priorities across propulsion types: hybrids prioritize fade resistance, battery-electric vehicles focus on corrosion control, and internal-combustion applications emphasize cost optimization.
Continental’s Galvanized Recommendation
The report states that Continental recommends galvanized steel plates for brake pads, and that while the treatment increases cost slightly per pad set, it significantly extends the pad’s lifespan. The attribution matters here — this is the research firm’s characterization of the supplier’s position, not a published Continental technical statement.
Corrosion is not the only specification tightening. Quieter electric powertrains have raised the prominence of brake squeal, pushing OEMs toward stricter NVH specifications that favor chamfered edges, multilayer shims and damping coatings. Mordor Intelligence concludes that suppliers capable of addressing both corrosion prevention and acoustic performance are positioned to lead the market.
Where Is the Corrosion Risk Concentrated?
The rear axle. Electronic brake-force distribution on hybrids and EVs shifts incremental load rearward to harvest energy, lifting rear-pad growth to a 6.15% CAGR, while rear pads operate at lower temperatures and are more prone to corrosion — prompting suppliers to adopt coated backing plates and water-resistant shims.
Geography compounds it. Canadian winters and comparable conditions across the northern United States raise demand for corrosion-resistant backplates and low-temperature binders that resist salt-induced delamination.
What Is Moving Pad Specifications
| Market driver | CAGR impact | Timeline |
|---|---|---|
| Safety regulation stringency (Euro 7, China 7) | +1.4% | Medium term |
| Copper-free, low-emission pads | +1.2% | Short term |
| NVH and corrosion standards | +1.1% | Medium term |
| Aftermarket e-commerce | +0.8% | Short term |
| AI-optimized formulation and testing | +0.6% | Long term |
| Pad-wear sensor demand | +0.5% | Long term |
Mordor Intelligence describes these impacts as directional rather than additive.
The Replacement Channel Question
The aftermarket generated 65.23% of 2025 brake pad revenue and is the fastest-growing channel at a 6.19% CAGR, which is where an OE-level corrosion specification either carries forward or does not. NRS Brakes, which builds its aftermarket line on galvanized steel backing plates, has pressed that argument in the independent channel for several years. The broader channel picture remains one of volume growth — the 2026 U.S. aftermarket forecast projects 5.2% growth this year — even as per-vehicle pad demand on electrified platforms falls.
Cost is not incidental to the decision. Steel backing plates traded between USD 800 and USD 900 per metric ton as energy-price instability affected mills, and smaller remanufacturers face shrinking margins under that volatility. Galvanizing adds to a component already under input-cost pressure, which is the trade-off facing every pad program specified for an electrified fleet.
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