Advanced Polymerics, Inc. has announced new test data confirming the effectiveness of its patented Permacorr® coating in mitigating corrosion under insulation (CUI), a significant and ongoing maintenance challenge for carbon steel assets worldwide. CUI occurs when moisture becomes trapped beneath insulation or jacketing on hot equipment, leading to aggressive corrosion and chloride stress cracking in both carbon and stainless steels. Research indicates that corrosion rates can rise by approximately 30 percent for every 10°C temperature increase, with CUI-related degradation accounting for up to 40 percent of piping maintenance costs in refineries, solar, and chemical plants. In North America alone, CUI is responsible for an estimated $276 billion in costs.
Permacorr addresses the CUI issue with its innovative chemically bonded phosphate ceramic technology, which forms a molecular bond with the steel surface rather than a physical one. This permanent chemical interaction passivates corrosion cells, offering protection against oxygen and moisture. Even if microcracks develop from thermal cycling, the bond remains intact, preventing the initiation of corrosion.
Validated Performance Under Insulated Conditions
In the industry-standard Vertical Pipe (Houston) Test, which exposes coated and insulated pipe sections to cyclic wet/dry salt spray and elevated temperatures, Permacorr demonstrated no blistering, cracking, or corrosion after prolonged exposure. In comparison, epoxy-phenolic coatings typically show significant degradation after just a few cycles.
Additionally, Permacorr withstood a six-month cyclic boiling-water test (8 hours immersion, 16 hours dry), simulating the 90–120 °C temperature range where condensation, vapour, and liquid water coexist, conditions that result in the highest corrosion rates. During this testing, no observable deterioration occurred.
Reduced Lifecycle and Maintenance Costs
Stephen Jewitt, president of Advanced Polymerics, remarked, “Asset owners have long faced a trade-off between corrosion resistance, heat tolerance, and cost. Permacorr eliminates that compromise. It offers high-temperature CUI protection, faster application, and significantly lower total lifecycle costs.”
As a water-based, VOC-free, and non-toxic solution, Permacorr supports sustainability goals without compromising performance. It also does not interfere with non-destructive testing methods, such as ultrasonic or radiographic inspection, which is a key advantage for operators in industries relying on these techniques.
Single-Coat Protection up to 250°C
Permacorr’s inorganic, cementitious properties provide thermal stability up to 250°C (480°F) while maintaining full adhesion and chemical resistance. A single coat, applied at 10–15 mils (250–375 µm) via plural-component spray, is all that is required. The coating’s self-sealing nature reduces surface preparation requirements and allows it to be applied over flash rust, which cuts down on both time and application costs.
Ideal for Critical Infrastructure
Permacorr is ideal for use on insulated tanks, steam lines, process piping, and pressure vessels operating at temperatures up to 250°C. It is particularly suited for industries such as oil and gas, petrochemicals, biopharma, and power generation.
As Jewitt stated, “CUI is one of the few corrosion mechanisms that still catches operators by surprise. Permacorr provides the peace of mind that comes from knowing the coating system is working, even when it can’t be seen.”
For more information visit www.permacorr.com
