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Corrosion Under Insulation Repair Services

Hidden Corrosion Discovered Beneath Insulation Systems

Corrosion under insulation (CUI) is often discovered only after insulation removal, API inspection findings, wet insulation, or rust staining expose hidden metal loss beneath insulated pipes, storage tanks, and process equipment. Trapped moisture beneath damaged insulation systems can cause severe pitting, wall thinning, and loss of containment long before problems become visible. Banks Industrial Group (BIG) restores deteriorated insulated assets using advanced industrial repair systems and protective coatings designed to rebuild damaged metal, restore structural integrity, and help facilities avoid costly replacement projects and extended downtime.

corrosion under insulation pipe restoration and protective coating example

Corrosion Under Insulation Repair Benefits

  • Restore deteriorated insulated pipes, tanks, and process equipment without costly replacement
  • Repair hidden wall loss and severe pitting discovered beneath insulation systems
  • Restore structural integrity to insulated assets damaged by trapped moisture and wet insulation
  • Address corrosion discovered during API inspections, maintenance outages, and insulation removal
  • Protective coating systems can be applied to operating hot equipment up to 302°F
  • Minimize shutdown work and operational disruption with rapid industrial repair execution
  • Long-term protection against moisture intrusion and future corrosion beneath insulation
  • Cold-applied repair methods help reduce welding and hot work risks in operating facilities
  • Practical in-place repair solutions for hard-to-access and difficult replacement scenarios
corrosion under insulation before and after repair example showing rusty pipe and carbon fiber wrap solution

Thin-wall pipe damage caused by corrosion under insulation can often be structurally restored in place using Belzona Superwrap—avoiding difficult and costly replacement.

Need CUI Repair?

Restore Structural Integrity Before Failure Occurs

Corrosion under insulation develops when moisture penetrates damaged or aging insulation systems and becomes trapped against metal surfaces. Over time, hidden corrosion can cause wall loss, pitting, weakened pipework, and loss of containment in insulated carbon steel, stainless steel, and low-alloy assets. Common causes include damaged jacketing, condensation, poor insulation installation, weather exposure, and temperature cycling.

BIG specializes in the repair and rebuilding of deteriorated insulated pipes, storage tanks, and process equipment using advanced Belzona polymer repair composites, protective coatings, and composite reinforcement systems. Rather than defaulting to expensive replacement projects, our team helps facilities restore damaged assets quickly and safely while extending remaining service life.

Depending on the condition of the asset, repairs may include:

  • Composite pipe reinforcement using Belzona SuperWrap II
  • Rebuilding pitted and deteriorated metal surfaces
  • Thin-wall pipe restoration
  • Protective coatings for insulated hot pipework and vessels
  • Corrosion-resistant barrier coatings for long-term protection
  • Repairs completed while equipment remains operational in many applications

Overcoming API 653 Inspection Challenges

Learn how advanced inspection methods help identify corrosion under insulation before major damage occurs. Read the API 653 inspection article here →
tank wall corrosion hidden under insulation detail

Corrosion under insulation often develops unnoticed on storage tanks and process vessels, especially near the base where trapped moisture can accumulate and accelerate metal loss.

tank base corrosion rehab protective coating applied to bottom area

After removing active corrosion, a protective epoxy coating was applied to shield the tank wall from future corrosion under insulation and extend service life.

grit blasting surface preparation done prior to coating application

Grit blasting creates a clean, properly profiled surface that helps protective coatings achieve long-term adhesion and corrosion resistance.

Why Facilities Choose BIG for Corrosion Under Insulation Repairs

Industrial facilities choose Banks Industrial Group because we understand the operational urgency and hidden risks associated with corrosion under insulation. Our crews specialize in restoring deteriorated insulated assets discovered during API inspections, maintenance outages, insulation replacement, and corrosion investigations—helping facilities respond quickly before leaks, failures, or unplanned shutdowns occur.

  1. Solutions for Hidden Corrosion Damage: BIG repairs concealed wall loss, pitting, and deteriorated metal surfaces revealed beneath insulation systems on pipes, tanks, and process equipment.
  2. Practical Alternatives to Costly Replacement: Many insulated assets can be structurally restored in place, helping facilities avoid difficult replacement projects and extended downtime.
  3. Fast Response for Inspection Findings: Our experienced crews provide rapid repair execution for corrosion discovered during maintenance shutdowns, insulation removal, and turnaround work.
  4. Long-Term Protection Against Moisture Intrusion: Protective coating and restoration systems help shield repaired assets from future corrosion caused by trapped moisture and wet insulation.
  5. Safer Cold-Applied Repair Methods: Many repairs can be completed without welding or hot work, helping reduce safety risks in operating industrial facilities.
  6. Experience With Difficult Industrial Environments: BIG performs corrosion under insulation repairs in hard-to-access areas, elevated pipe systems, process facilities, power plants, and other demanding industrial environments.

Corrosion Under Insulation Repair Examples

The examples below show how corrosion under insulation is often discovered only after insulation removal, maintenance outages, API inspections, or visible rust staining expose hidden deterioration beneath insulated assets. These projects demonstrate BIG’s ability to restore deteriorated pipes, storage tanks, process vessels, and HVAC equipment using practical in-place repair methods designed to avoid costly replacement and extended downtime.

corrosion under insulation on pedesphere tank pipe is revealed under black foam insulation

Severe corrosion is revealed below black foam insulation.

corrosion under insulation superwrap repair of pedesphere tank pipe

Superwrap II returns strength to the corroded pipe.

Hidden Pipe Corrosion Under Insulation

This severely corroded pipe was discovered high atop a pedesphere tank at a power plant, where access and replacement would have been difficult and costly. BIG used Belzona SuperWrap II composite reinforcement to restore the pipe in place—an ideal solution for confined and hard-to-reach areas.

corrosion under insulation damaged fuel oil heater cylinder

Corroded fuel oil heater cylinder revealed.

fuel oil heater cylinder repaired with belzona

Cylinder repaired with Belzona.

Insulated Heater Cylinder Corrosion

BIG restored severely deteriorated insulated oil heating cylinders at a power generation facility using Belzona repair composites and protective coatings. The repair helped avoid replacement costs while reducing operational and environmental risk. Read the Storage Tank Case Study →

chemical processing vessel with thin-wall metal loss

Before: Hidden corrosion and metal loss threatened the structural reliability of this chemical processing vessel.

chemical processing vessel thin-wall metal loss repair

After: Structural integrity was restored using a high-strength Belzona composite wrap system.

Tank Wall Corrosion Revealed

Corrosion under insulation created hidden tank wall thinning beneath the insulation system. BIG restored the weakened area using Belzona composite repair materials and protective coatings, helping prevent future moisture intrusion and avoiding costly tank replacement. See Tank Repair →

corrosion under foam insulation on storage tank is exposed

Areas of corrosion are exposed underneath spray foam insulation.

insulated storage tank after foam insulation and corrosion repair work

Insulated storage tank after foam insulation and corrosion repair work.

Hidden Corrosion Problems With Foam Insulation

Corrosion hidden beneath spray foam insulation can spread unnoticed until severe metal loss occurs. BIG removed deteriorated foam, repaired the damaged tank wall, applied protective coatings, and restored the insulation system to help prevent future moisture intrusion and CUI.

tank base corrosion under insulation exposed at the chime angle

Tank base corrosion under insulation exposed at the chime angle.

tank-insulation-raised-for-base-inspection-1-600

Corrosion repaired and tank insulation raised for easy API 653 base inspection.

Tank Base Corrosion Under Insulation Repair

Corrosion under insulation at the tank base was repaired and protective coated after removing the rust and deterioration. The insulation system was then raised to improve drainage and keep the corrosion-prone chime angle visible for API 653 inspection access. Preventing storage tank CUI →

external chiller barrel with severe corrosion under insulation exposed

Corroded water-cooled chiller exposed.

chiller barrel external corrosion under insulation repaired and belzona protective coating applied

Complete corrosion rehab and coating.

Chiller Corrosion Under Insulation Repair

Corrosion under insulation damaged multiple chiller components, including elbows, evaporator inlets, and barrel surfaces. BIG restored structural integrity with Belzona SuperWrap II and protective coatings—helping avoid costly replacement and downtime.
Read the Chiller CUI Repair Case Study →

Step-By-Step Corrosion Under Insulation Pipe Restoration

corroded cooling tower pipe at nj university

CUI discovered on cooling tower pipes.

corroded cooling tower pipe restoration prep work

Rust removal and surface prep.

corrosion under insulation pipe coating base coat

Base coat of rust resistant coating.

corrosion under insulation pipe coating

Final moisture resistant barrier coating.

severe corrosion under insulation on cooling tower pipe

Area of severe corrosion exposed.

superwrap red release film example

Metal loss rebuilt with composite wrap.

superwrap pipe strengthening of corroded cooling tower pipe

Superwrap cured in 24-hours.

final protective coating over cooling tower pipe wrap- corrosion repair

Protective coating applied to shield repair.

Step-By-Step Corrosion Under Insulation Process Vessel Restoration

corrosion under insulation damage to process vessel

CUI on process vessel wall detected.

process vessel corrosion metal loss repair of pitting

Surface prep and metal rebuild.

through-wall metal loss repair work on process vessel

Through-wall damage is repaired.

storage tank corrosion repair with carbon fiber wrap

Superwrap restores lost strength.

Schedule a Corrosion Under Insulation Repair Evaluation

Corrosion under insulation is often discovered only after insulation removal, API inspections, maintenance outages, or rust staining reveal hidden wall loss beneath insulated assets. Banks Industrial Group restores deteriorated pipes, storage tanks, and process equipment using practical in-place repair solutions designed to avoid costly replacement projects and extended downtime. From structural restoration systems to protective coatings for hot operating equipment, BIG helps facilities respond quickly to hidden corrosion problems while maintaining safe and reliable operation.

Contact Banks Industrial Group today at 856-687-2227 or email our corrosion repair experts to schedule a site evaluation or request an estimate for corrosion under insulation repair services in New Jersey, Pennsylvania, Delaware, and New York.

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