CUI / CUF and High-Temperature Coatings – AMPP SP0198

Failures caused by corrosion under insulation (CUI) and corrosion under fireproofing systems (CUF) represent a significant share of integrity incidents affecting pipelines, equipment, according to industry studies.

Standards-Based Diagnosis and Real-Service Condition Approach

We evaluate the actual operating conditions of each asset—including temperature range, insulation type, moisture presence, thermal cycling, and inspection accessibility—to design tailored solutions in accordance with:

• AMPP SP0198: Guide for the control of CUI and CUF in insulated or fireproofed materials
• ISO 12944: Anti-corrosion performance in severe atmospheric environments
• AMPP standards and complementary API or NORSOK regulations, where applicable

This standards-driven approach enables effective risk mitigation in the following critical scenarios:

Advanced Operational-Performance Coating Systems

Our coatings are engineered to maintain thermal stability, adhesion, and moisture resistance under aggressive thermal cycling conditions. Solutions include:

• Reinforced ethyl silicate coatings, phenolic epoxies, and hybrid systems with modified resins
• Compatibility with thermal insulation systems (mineral wool, beads, ceramic insulation, etc.)
• Specified film thicknesses and multi-coat systems defined according to environment, asset criticality, and equipment geometry

According to the Steel Structures Painting Manual (AMPP, former SSPC), the design of anti-corrosion systems must consider “the most severe expected environmental condition, not the average.”

Unlike conventional systems, Aplika integrates coatings with insulating properties to:

• Reduce equipment surface temperature by up to 50%, improving HSE safety
• Prevent burn injuries from accidental contact with steam lines or hot-fluid systems
• Minimize heat losses, improving energy efficiency in continuous processes
• Control condensation under insulation, mitigating CUI risk caused by cold/hot thermal cycling

Specialized Technical Support and Execution Control

We support the entire process with engineering and QA/QC oversight in accordance with international standards:

• Initial asset condition assessment
• CUI and CUF diagnosis in accordance with AMPP SP0198
• Definition of technical specifications and application procedures
• Technical inspection using certified instruments (DFT, surface profile, humidity, temperature)
• Control of film thickness, coating sequence, environmental conditions, and curing in compliance with ISO / SSPCrequirements

Measurable Operational Benefits

Implementing specialized coating systems for thermal environments delivers tangible benefits:

• Reduction of unforeseen failures and unplanned shutdowns
• Extension of service life for critical pipelines and equipment
• Improved personnel safety and HSE compliance
• Enhanced thermal efficiency of the system
• Reduced costs associated with corrective maintenance

With Aplika, protection against CUI, CUF, and high-temperature exposure shifts from a reactive measure to a proactive operational integrity strategy, supported by international standards and on-site technical control.

Request a specialized technical evaluation and protect your assets with certified solutions.