CUI Inspection - Corrosion Under Insulation

Our comprehensive corrosion under insulation testing portfolio follows ISO 19277:2018 standards to thoroughly evaluate material and coating performance under simulated corrosion-inducing conditions. We conduct specialized tests that replicate real-world scenarios where moisture infiltration occurs, examining how materials respond to temperature fluctuations, thermal shock, and moisture exposure over time to predict long-term performance and resistance to corrosion.

• Heat conditioning with cyclic testing based on CUI category 

• Adhesion evaluation pre and post-exposure 

• Artificial aging through environmental exposure 

• Thermal cycling tests with cold water quenching 

• Multi-phase CUI cyclic corrosion testing 

• Cryogenic exposure testing for applicable categories 

• Vertical pipe testing (Houston pipe test) 

We test a wide range of materials and components exposed to corrosion risks in industrial environments. Our specialists analyze carbon and low alloy steel equipment operating at high temperatures in cyclic service, as well as protective coatings designed for insulated environments. We evaluate insulation systems across various temperature ranges and validate material performance in conditions where moisture infiltration may occur. 

• Carbon and low alloy steel equipment 

• Protective coatings for high-temperature applications 

• Insulated industrial piping systems 

• Infrastructure components in cyclic service 

• Materials operating within CUI temperature ranges 

Our ISO-accredited laboratories implement multiple testing methodologies to deliver comprehensive CUI prevention strategies tailored to your specific equipment needs. We utilize horizontal square pipe tests that simulate typical CUI environments and vertical pipe tests that evaluate coating resistance to accelerated CUI conditions. These methodologies provide actionable insights that help you implement effective preventative measures for long-term infrastructure protection.

• Horizontal square pipe testing simulating real-world CUI environments
• Cyclic testing including dry heat, thermal shock, and immersion phases
• Customized testing programs for research and development
• Bespoke solutions for unique client requirements
• Testing of alternative materials and modified test regimes
• Comprehensive electrochemical corrosion testing alongside CUI evaluation

Element offers a variety of testing to verify performance for suitability under insulation in accordance with ISO19277:2018, which include:

• Heat conditioning: Cyclic heat conditioning of coatings based upon the CUI category of choice.
• Adhesion: Evaluation of heat conditioned and standard cured materials both pre and post-exposure.
• Artificial aging: Environmental exposure in the form of neutral salt spray and water immersion.
• Thermal cycling test: Repeated heating and cooling over multiple cycles from the maximum temperature of the relevant CUI category, then quenching into cold water.
• Multi-phase CUI cyclic corrosion test: A horizontal square pipe test is utilized to simulate a typical environment where CUI occurs; the test process includes dry heat, thermal shock, immersion in boiling water, steam interface, and shut downtime.
• Cryogenic exposure: Optional cryogenic cyclic testing for cryogenic categories described in the standard.
• Vertical pipe test (Houston pipe test): An optional CUI test method to evaluate the resistance of a coating to accelerated CUI conditions with shut down periods. The test includes wet/dry/heat/cool cycling of an insulated coated pipe for a total of 30 cycles.

Customized R&D testing solutions
We go beyond standard testing protocols to provide bespoke R&D solutions for clients developing new materials or protective systems. Our team works collaboratively with your researchers to design modified test regimes that address specific performance questions or validate innovative approaches to CUI prevention. This service helps you develop next-generation protection systems with proven performance characteristics before deployment in critical infrastructure.

Reducing the High Costs of Regular CUI Inspections
Regular and thorough CUI inspections can be expensive, requiring specialized equipment and skilled technicians. The costs associated with unexpected repairs and replacements can be substantial, adding to the financial burden. Our comprehensive testing services, such as heat conditioning and thermal cycling tests, ensure that coatings and materials perform optimally, thereby extending the life of your infrastructure and minimizing maintenance costs. Investing in Element's CUI inspections ultimately leads to cost savings by preventing severe damage and reducing the need for frequent inspections.

Addressing Reliability Issues in CUI Inspections
Ensuring the consistency and reliability of inspections across different inspectors and cycles can be challenging. The risk of false positives or negatives can lead to unnecessary repairs or missed corrosion, both of which have significant implications. Element’s CUI inspection services are built on a foundation of accuracy and reliability. Utilizing a variety of testing methods, including artificial aging and cryogenic exposure tests, ensures that our inspections provide consistent and precise results.  Our experienced specialists follow standardized protocols in accordance with ISO 19277:2018, reducing the risk of false positives and negatives. By delivering reliable data, Element enables you to make informed decisions about maintenance and repairs, ensuring that resources are allocated efficiently and effectively.

The Impact of Protective Coatings on CUI Prevention
As part of a holistic approach to CUI prevention, protective Coatings are often utilized in conjunction with installation design, insulation choice, and inspection regimes. In such cases, selecting an appropriate coating requires understanding the material's performance characteristics when subject to high-temperature cyclic and CUI conditions.

Our state-of-the-art facilities feature specialized equipment designed to replicate the conditions where corrosion under insulation typically occurs. Our testing apparatus can simulate environmental factors including moisture infiltration, temperature cycling, and thermal shock scenarios. This advanced equipment allows us to provide accurate assessments of material performance and coating efficacy in the most challenging CUI environments. 

• Thermal cycling chambers for temperature variation testing 

• Environmental exposure systems for artificial aging simulations 

• Specialized adhesion testing equipment 

• Horizontal square pipe test systems for multi-phase CUI evaluation 

• Vertical pipe testing apparatus for accelerated CUI condition assessment 

• Cryogenic exposure testing equipment 

Our team operates from materials testing labs across the world, providing global access to our expert capabilities. Find your nearest lab on our Locations Page.