What Is Corrosion Under Insulation (CUI)?
Corrosion under insulation (CUI) is a severe, hidden form of corrosion that attacks insulated pipes, pressure vessels, and storage tanks when moisture penetrates the insulation and reaches the metal surface underneath. Because the damage is concealed by the insulation jacket, CUI often goes undetected until it causes deep pitting, leaks, or unplanned shutdowns. It is one of the most costly integrity problems in the oil & gas, petrochemical, and industrial sectors, and it can occur across a wide range of operating temperatures wherever insulated carbon or stainless steel is exposed to trapped moisture.
A Live-Asset Coating That Applies With No Downtime
Royal Coatings’ 200 Series is the new standard in live-asset coating — engineered for direct-to-metal application on in-service pipes without requiring equipment downtime or facility shutdowns. Unlike conventional systems, it bonds effectively to wet, frozen, or iced surfaces, eliminating the need for abrasive blasting, dehydration, or a dry working environment. Requiring only minimal surface preparation to remove loose rust or scale, this solvent-free epoxy delivers long-term corrosion protection for critical assets even in the most challenging condensing conditions.
Why the 200 Series Beats Traditional CUI Repair
Traditional CUI repair means taking an asset offline, stripping insulation, blasting to bare metal, and waiting for a dry surface — a process that drives costly production losses. The 200 Series removes those constraints. Because it cures on wet and in-service surfaces, coating crews can protect pipework while the asset stays in operation, cutting both downtime and preparation cost while extending asset life.
Applications
Insulated Pipework & Process Piping
Direct-to-metal protection for insulated carbon and stainless steel piping in refineries, petrochemical plants, and processing facilities.
Pressure Vessels & Storage Tanks
Long-term corrosion defense for insulated vessels, tanks, and spheres where hidden moisture threatens integrity.
Cold, Wet & Condensing Service
Formulated to bond and cure on frozen, iced, or condensing surfaces where conventional coatings cannot be applied.