Oil & gas, power generation, petrochemicals
Corrosion Under Insulation (CUI) prevention
The hidden threat to petrochemical and power infrastructure — how RUST GRIP® with HPC COATING® removes the need for traditional insulation and prevents long-term CUI.
Request technical adviceThe problem
Traditional thermal insulation on hot piping creates CUI — Corrosion Under Insulation — where moisture is trapped between insulation and metal, driving accelerated hidden rust. By the time damage shows, repair costs are an order of magnitude higher than prevention.
The solution
We recommend two approaches: (1) HPC COATING® as a replacement for traditional insulation — it blocks heat, is fire-rated, and removes the conditions for CUI. (2) Where traditional insulation is required, a RUST GRIP® primer reacts with existing rust and prevents new corrosion. Both approaches are backed by Chevron’s 8-year RUST GRIP® drill-pipe study.
Results
Significant reduction in CUI damage across oil, gas, and power infrastructure. Verified 15+ years of service with no performance degradation. ROI is especially high because of avoided unplanned downtime and expensive repair cycles.
Frequently asked questions
How does CUI form?
Moisture enters the void between insulation and metal through joints, breaches, or imperfect sealing. The mix of moisture + oxygen + cyclic heating drives accelerated corrosion. Insulation itself hides the damage until structural failure surfaces.
What is the advantage of HPC over traditional insulation?
HPC is a thin coating bonded directly to the metal — there is no void to trap moisture. It also solves fire (Class A) and reduces system weight.