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Corrosion Under Insulation

Corrosion under Insulation (CUI) is a threat to the process industry in a wide sense. If neglected, the corrosion process is mostly well hidden under the insulation system and becomes only obvious due to severe integrity failures.

CUI Inspection and Remediation

KAEFER has extensive experience in assessing and remediating Corrosion Under Insulation (CUI) since its inception in 1918. Its aim is to provide clients with an efficient service that reduces the cost of identifying CUI, improves plant thermal efficiency and helps prevent major failures and unplanned plant shutdowns.

KAEFER initiated the use of real time radiography for CUI inspection- KAEFER Insulated Pipe Scanning equipment. We refer to this as KIPS.

We have dedicated and experienced CUI inspection technicians who utilise the following 4 step process to identify CUI:

  1. Carrying out Thermal Imagery Surveys complete with thermal efficiency results and CUI indicators
  2. Undertaking Real Time Radiography (RTR) scans and Moisture Content Measurement (MCM) concentrating on CUI indicators results from our thermal imagery surveys
  3. Non Destructive Testing (NDT) where/when applicable to confirm wall thicknesses
  4. Remediation of effected areas – offering knowledge on latest coatings and insulation/cladding technologies as preventative measures to safeguard against further CUI or loss of thermal efficiencies.

KAEFER are currently carrying out inspection services for AGL, Santos, Incitec Pivot, BHP, Ichthys, APA, Vermilion Energy, WesCEF & EM&I.


Remediation Solutions

Once the CUI has been identified, KAEFER can provide a remediation solution utilising a number of coating and insulation solution and will consider environmental conditions, process conditions, cost, safety, life expectancies and quality requirements.

KAEFER has a dedicated R&D testing facility in Western Australian to simulate on site conditions for these solutions.


We have developed our own approaches to fight CUI, e.g. by an own coating system specification guideline, definition of best practise insulation system design to prevent water ingress in the system and to prevent CUI.