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(Insulation & Corrosion) Surface Decontamination Significantly Reduces Vulnerability to CUI

CUI (corrosion under insulation) is a pervasive, difficult and high-liability issue for petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical, seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect or near-perfect metal hygiene, thus reducing expected coating life by 30 to 75 percent. Because conventional surface preparation processes have historically been unable to adequately relieve microcontamination of metal surfaces, organizations have settled for an uneasy balance between economic and physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes and rely more heavily upon barrier coatings to supply needed corrosion control.

Product Number: 20-COAT_DEC21
Author: Loren L. Hatle
Publication Date: 2021
Industry: Coatings
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CUI (corrosion under insulation) is a pervasive, difficult and high-liability issue for petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical, seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect or near-perfect metal hygiene, thus reducing expected coating life by 30 to 75 percent. Because conventional surface preparation processes have historically been unable to adequately relieve microcontamination of metal surfaces, organizations have settled for an uneasy balance between economic and physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes and rely more heavily upon barrier coatings to supply needed corrosion control.
However, coatings cannot fill the gap; no matter how advance the coating, surface-tolerance does not extend to application over chloride or sulfate contaminated steel, as coating performance is highly dependent upon unimpeded bonding with the surface it is meant to protect. Consistent coating adhesion is impaired by microcontaminants present in metal surfaces during fabrication as well as those potentially embedded during surface preparation blast processes occurring in field maintenance.
To ensure maximum bonding of protective coating to metal, surface preparation must include metal decontamination processes to fully eradicate the full array of microcontaminants that impede coating adhesion to ensure maximum asset resilience against problems such as stress corrosion cracking (SCC) and other CUI vulnerabilities. Case studies prove that early adoption of novel surface decontamination technologies confer complete permanent microcontaminant removal for improved protective coating bond strength to reduce economic investment in maintenance and increase long-term coating reliability, thus reducing vulnerability to CUI.

CUI (corrosion under insulation) is a pervasive, difficult and high-liability issue for petrochemical, power, shipping, and other industries. Situational variations (meteorological, geographical, seasonal, etc.) can confound conventionally specified surface preparation attempts to achieve perfect or near-perfect metal hygiene, thus reducing expected coating life by 30 to 75 percent. Because conventional surface preparation processes have historically been unable to adequately relieve microcontamination of metal surfaces, organizations have settled for an uneasy balance between economic and physical feasibilities that exclude the possibility of achieving ideal surface preparation outcomes and rely more heavily upon barrier coatings to supply needed corrosion control.
However, coatings cannot fill the gap; no matter how advance the coating, surface-tolerance does not extend to application over chloride or sulfate contaminated steel, as coating performance is highly dependent upon unimpeded bonding with the surface it is meant to protect. Consistent coating adhesion is impaired by microcontaminants present in metal surfaces during fabrication as well as those potentially embedded during surface preparation blast processes occurring in field maintenance.
To ensure maximum bonding of protective coating to metal, surface preparation must include metal decontamination processes to fully eradicate the full array of microcontaminants that impede coating adhesion to ensure maximum asset resilience against problems such as stress corrosion cracking (SCC) and other CUI vulnerabilities. Case studies prove that early adoption of novel surface decontamination technologies confer complete permanent microcontaminant removal for improved protective coating bond strength to reduce economic investment in maintenance and increase long-term coating reliability, thus reducing vulnerability to CUI.

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