How K-Aerogel Insulation Helps Combat CUI (Corrosion Under Insulation)
In heavy industries such as oil & gas, petrochemical, and power generation, Corrosion Under Insulation (CUI) remains one of the most persistent and costly maintenance challenges. Hidden beneath layers of insulation and cladding, corrosion quietly weakens pipelines, vessels, and equipment. Often going undetected until it causes serious damage.
At the heart of this issue is moisture. When water seeps through insulation, it gets trapped against the metal surface, setting off electrochemical corrosion. And because these systems are usually insulated for temperature control, detecting the corrosion early is extremely difficult.
At the heart of this issue is moisture. When water seeps through insulation, it gets trapped against the metal surface, setting off electrochemical corrosion. And because these systems are usually insulated for temperature control, detecting the corrosion early is extremely difficult.
The Root Cause of CUI
CUI happens when water, oxygen, and metal interact under insulated surfaces. Traditional materials like mineral wool or fiberglass tend to absorb and retain moisture, creating a perfect environment for corrosion to thrive,especially in humid climates like Malaysia’s, or in offshore applications where exposure to seawater and condensation is constant.
Why Traditional Insulation Often Fails
Most conventional insulation systems focus only on thermal performance, not moisture protection. Over time, water infiltration reduces insulation efficiency, increases weight (leading to sagging), and accelerates corrosion beneath the surface. Maintenance teams often face unplanned downtime or costly shutdowns to inspect and repair corroded systems.
How K-Aerogel Acts as a Defense System Against CUI
K-Aerogel insulation changes the game. Its hydrophobic and nanoporous structure repels liquid water, preventing it from penetrating the insulation layer while allowing vapor to escape. This breathability keeps equipment dry and corrosion free over extended service life.
Key advantages include:
Hydrophobic protection – prevents moisture ingress even after mechanical compression or aging.
Consistent performance – maintains low thermal conductivity in both wet and dry states.
Dimensional stability – resists sagging or cracking that could otherwise create corrosion points.
Key advantages include:
Hydrophobic protection – prevents moisture ingress even after mechanical compression or aging.
Consistent performance – maintains low thermal conductivity in both wet and dry states.
Dimensional stability – resists sagging or cracking that could otherwise create corrosion points.
When applied to critical equipment such as process piping, heat exchangers, or dual-temperature columns, K-Aerogel not only improves insulation performance but also extends asset integrity.
Real-World Applications and Benefits
Most conventional insulation systems focus only on thermal performance, not moisture protection. Over time, water infiltration reduces insulation efficiency, increases weight (leading to sagging), and accelerates corrosion beneath the surface. Maintenance teams often face unplanned downtime or costly shutdowns to inspect and repair corroded systems.
Long-Term Value
Preventing CUI isn’t just about protecting steel, It’s about preserving operational reliability. K-Aerogel delivers peace of mind to plant owners and maintenance teams by combining hydrophobicity, flexibility, and durability into one efficient solution.
Conclusion
As industries move toward higher efficiency and safety standards, CUI mitigation is no longer optional. It’s essential.
With K-Aerogel, companies can finally address corrosion at its root cause: moisture infiltration. The result is cleaner, safer, and more sustainable operations, one insulated system at a time.
With K-Aerogel, companies can finally address corrosion at its root cause: moisture infiltration. The result is cleaner, safer, and more sustainable operations, one insulated system at a time.