Advanced Polymerics Inc. has announced new test data confirming that its patented Permacorr coating effectively mitigates corrosion under insulation, one of the most costly and persistent maintenance challenges for carbon steel assets. CUI occurs when moisture becomes trapped beneath insulation or jacketing on hot equipment, causing aggressive corrosion and chloride stress cracking in carbon and stainless steels. Studies show that corrosion rates increase by about 30 percent for every 10 °C temperature rise, and as much as 40 percent of piping maintenance costs in refineries, and solar and chemical plants can be tied to CUI-related degradation. The problem carries an estimated cost of $276 billion in North America.

Permacorr uses chemically bonded phosphate ceramic technology that forms a molecular bond to the steel surface rather than a physical one. This chemical interaction passivates corrosion cells and protects the substrate against oxygen and moisture. Even if microcracks form from thermal cycling, the underlying bond stays intact and corrosion cannot begin.

In the industry-standard Vertical Pipe Test, which exposes coated and insulated pipe sections to cyclic wet and dry salt spray and elevated temperatures, Permacorr showed no blistering, cracking, or corrosion after extended exposure. Epoxy-phenolic coatings typically show severe degradation after only a few cycles. The coating also withstood a six-month cyclic boiling-water test, with eight hours of immersion followed by sixteen hours dry, with no observable deterioration. The conditions simulate the 90–120 °C range where condensation, vapor, and liquid water coexist and corrosion rates peak.

“Asset owners have long faced a trade-off between corrosion resistance, heat tolerance, and cost. Permacorr removes that compromise. It delivers high-temperature CUI protection, faster application, and significantly lower total lifecycle costs,” said API President Stephen Jewitt. Because Permacorr is water based, VOC free, and non-toxic, it supports sustainability goals without affecting performance. It also does not interfere with non-destructive testing methods such as ultrasonic or radiographic inspection.

Permacorr provides thermal stability up to 250 °C while maintaining adhesion and chemical resistance. Only a single coat at 10–15 mils is required when applied by plural-component spray. Its self-sealing behavior also reduces surface preparation requirements and allows application over flash rust, lowering application time and cost.

The coating is suited for insulated tanks, steam lines, process piping, and pressure vessels operating up to 250 °C in oil and gas, petrochemical, biopharma, and power generation facilities. “CUI is one of the few corrosion mechanisms that still catches operators by surprise,” Jewitt said. “Permacorr provides the peace of mind that comes from knowing the coating system is working even when you can’t see it.”

This announcement supports ongoing advancements in Industrial Coatings for critical infrastructure.