Corrosion Under Insulation

Corrosion Under Insulation (CUI) Products

Corrosion Under Insulation (CUI) can no longer be considered an ‘out of sight, out of mind’ issue. Aging infrastructure has brought CUI to the forefront, with costs surrounding CUI-related problems estimated to be in the billions of dollars each year. However, this number can be greatly reduced by implementing systems which allow for early detection, access for inspection, ongoing monitoring, moisture mitigation, and safeguards to isolate problem areas. While there is no way to prevent CUI mitigation fully, monitoring strategies can greatly reduce the incidence and costs (human, capital, social, and environmental) related to CUI and Stress Cracking Corrosion (SCC) on thermally insulated assets. 

At Integrity Products & Supplies, we pride ourselves on being CUI Specialists™. Our in-house Research & Development (R&D) team, combined with global procurement, allows us to provide innovative and cost-effective solutions to CUI problems. We have commenced R&D projects, and our technical findings made their way to peer-reviewed publications. With our findings, our products align with the most recent industry standards ASTM G189-07, API 583, and NACE SP 0198.  Our Corrosion Under Insulation products is designed to work together as part of a holistic CUI monitoring and mitigation system or on their own, depending on the needs of each specific application.   

Our product line is constantly evolving, so contact us directly for the most up-to-date solutions to fit your needs.  

Integrity Insulation Ventilation System 

The Integrity Products Insulation Ventilation System (IVS) is a 3-part system consisting of Integrity Perforated Dimple Wrap™, Integrity Vents™ and Integrity Drains™. These work together to promote airflow along the insulation system which limits moisture and condensation build-up in the insulation and can assist in drying out wet insulation.

INTEGRITY VENTS™  Integrity Products Integrity Vents™ provides ventilation to the insulation system. The louvered design protects the insulation from water ingress while promoting airflow along the insulation system. These are installed every 3m at the 3 and 9 o’clock positions. They make use of the air gap created by the Integrity Perforated Dimple Wrap™.

INTEGRITY DRAINS™  Integrity Products Integrity Drains™ are designed to create a drainage point for moisture ingress while also promoting airflow along the insulation system. These are gravity-assisted and as such are installed at the 6 O’clock position in the metal cladding. They make use of the air gap created by the Integrity Perforated Dimple Wrap™

INTEGRITY PERFORATED DIMPLE WRAP™ Integrity Products Integrity Perforated Dimple Wrap™ creates a consistent 6mm air gap between the insulation and the metal cladding. Each sheet is perforated with 8 holes per sq inch which allows any moisture trapped in the insulation to pass through to the outer cladding and drain away

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Integrity PTFE Spacer Wrap^TM

 Integrity Products Spacer Wrap allows you to establish a non-contact insulation system by creating a unified and consistent air gap between the insulation and the process pipe. This system separates the insulation system (a common source of water infiltration) and the process pipe. The air gap prevents any moisture ingress from coming into direct contact with the pipe. Made from a high performing polytetrafluoroethylene, the Spacer Wrap works with all types of insulation and in various applications.

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Integrity Perforated Dimple Wrap

Integrity Products’ Perforated Dimple Wrap is designed to create a consistent 6mm air gap between the insulation and the metal cladding. Used in conjunction with our vents and drains, this 3-part system creates the Integrity Products’ Insulation Ventilation System. This high-quality Polyvinyl Chloride (PVC) material is design for flexibility and strength which can help protect the insulation and the outer cladding from mechanical damage. Its unique perforations and raised dimples allow any moisture or vapor trapped in the insulation to pass into the gap that has been created, drain to the 6 o’clock position, and exit the system through the drains.

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Integrity Perforated Corrugated Aluminum Wrap

Integrity Products’ Perforated Corrugated Aluminum (PCA) is designed to create a consistent 6mm air gap between the insulation and the metal cladding. Used in conjunction with our vents and drains, this 3-part system creates the Integrity Products’ Insulation Ventilation System. This high-quality aluminum material is design for flexibility and strength which can help protect the insulation and the outer cladding from mechanical damage. The PCA inner jacketing allows any moisture or vapour trapped in the insulation to pass into the gap that has been created, drain to the 6 o’clock position and exit the system through the drains.

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Mica High Temperature Spacer Ring

Integrity Products High Temperature Mica Spacer Ring is designed to create a non contact insulation system for high temperature applications. The Mica Spacer Ring is used in conjunction with standard metal cladding to ensure complete separation of the insulation and process pipe. The Mica is made from high-grade mica paper injected with a high temperature resistant silicone resin allowing the Mica Spacer to withstand high temperatures. The Mica Spacers are riveted onto an Aluminum band to establish an even stand off and a strong foundation for the remaining inner cladding, insulation, and outer cladding installations.

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Integrity Insulation Spacer Silicone

The Integrity Products Insulation Spacer (silicone) allows you to establish a non-contact insulation system by creating a unified and consistent air gap between the insulation and the process pipe. This system helps mitigate Corrosion Under Insulation (CUI) risk by creating an air gap between the insulation system (a common source of water infiltration) and the process pipe. This air gap prevents any moisture ingress from coming in contact with the pipe.  Made from high performing silicone rubber,  the insulation spacer is held in place with our spacer band to ensure strategic placement locations on the process pipe and works with most types of insulation and in various applications.

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Integrity Insulation Spacer PPS

The Integrity Products Insulation Spacer allows you to establish a non-contact insulation system by creating a unified and consistent air gap between the insulation and the process pipe. This system helps mitigate Corrosion Under Insulation (CUI) risk by creating an air gap between the insulation system (a common source of water infiltration) and the process pipe. This air gap prevents any moisture ingress from coming in contact with the pipe. Made from a flame-resistant, non-combustible polyphenylene sulfide (PPS), the Insulation Spacer works with most types of insulation and in various applications. 

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Integrity Drainplug

Used alongside metal jacketing and caulking/sealants, the Integrity Products Drainplug provides extra protection against corrosion under insulation (CUI). Made with flame-resistant, non-combustible Polyphenylene Sulfide Black (PPS), Integrity Products Drainplugs allow any water or moisture that penetrates the insulation system to drain out freely.

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Integrity Water Indication (WUI)

Water Indicator WUI uses a unique patented solution with a water sensitive ball of expanding elastomer to indicate the presence of water under insulation. This efficient system allows for easy detection within 24 to 48 hours of water exposure, pointing out critical areas for inspection. The system can easily be reset for reuse. Made with tough, electrically conductive, all-weather Polyamid, the Water Indicator WUI can be used in all climatic conditions. The composition of the Polyamid makes it applicable on high temperature equipment with an operational temperature of up to 150°C (302°F) in contact areas.

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Integrity Termination Gasket

Integrity Products Termination Gasket compartmentalizes your pipe insulation system. Installed at regular intervals or at strategic locations, the Termination Gasket will stop moisture travelling along an insulation system and destroying the insulation. By containing any leaks or water ingress, you can potentially save millions of dollars on the removal and install of insulation. The Termination Gasket is non-metallic providing a completely watertight solution in comparison to metal end cap terminations, saving future maintenance costs and failures due to corrosion under insulation (CUI). Made solid state silicone rubber, Integrity Products Termination Gasket is self-extinguishing, non-melting in fire, and halogen free.

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Integrity Clamp Covers™

Integrity Products’ Integrity Clamp Covers™ are designed to make it quick and easy to seal protrusions around pipe clamps on insulated piping systems. These clamp covers are made from a high-performing EPDM rubber for extra protection against temperature, mechanical damage, weathering, and UV and ozone exposure. The task of trying to install cladding around pipe clamps on insulated piping systems has traditionally been very difficult — requiring an excessive amount of time from even a skilled tradesperson to complete! Now with Integrity Clamp Covers™, you can achieve a neat and tidy finish with a water-tight seal in a fraction of the time.

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Integrity Tank Chime Spacer

Typically any insulated storage tank is susceptible to corrosion under insulation (CUI) and tank failures. The problem begins when moisture ingress in the storage tank’s insulation moves vertically down alongside the tank shell, collecting at the bottom over the tank chime, around the shell plate and the weld joints. With the absence of any drain points or stand-offs, the moisture is trapped, causing CUI and costly failures. Integrity Products Tank Chimes Spacer is designed to create a horizontal (i.e. alongside bottom plate axis) stand-off between the storage tank chime and the edge of the insulation to allow drainage of the accumulated or trapped moisture before it can cause significant corrosion on the chimes and weld joints. This also provides access for NDE/NDT companies to perform visual and mechanical inspections.

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Integrity Pipe Seal

Integrity Products’ Pipe Seal is made from high-quality silicone rubber and is designed to easily fit the circumference of protruding nozzles on insulated tanks, vessels, and heat exchangers. This will form a watertight seal, protecting the insulated equipment from moisture ingress and reducing the risk of Corrosion Under Insulation (CUI).

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Integrity Termination Seal

Integrity Products Termination Seals are an effective and long lasting solution to replace traditional metal end caps. They are made from a high quality silicone rubber and designed to form a watertight seal for metal end caps at insulation terminations. They offer an easy seal solution between the process pipe and the end cap which is a high-risk area for moisture ingress. To accommodate all pipe diameters this product is supplied in 100’ coils and is easily cut to suit the circumference of the pipe.

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Integrity Flange Belt

Integrity Products Flange Belts provide a circumferential seal over the adjoining collars of flanges. This offers long term protection from external corrosive elements. The adjoining faces of flanges with gaskets generally form crevices which trap moisture, this allows the development of crevice corrosion and may lead to process leaks. Made from a high temperature rubber this flange belt is heat resistant up to 240°C (464°F), and suitable for flanges of all sizes.

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