Comparative Performance Assessment of Insulative Coating Systems for Corrosion Protection and Thermal Insulation

Abstract Corrosion under insulation (CUI) poses a significant challenge in the oil and gas industry, arising when moisture becomes trapped on metal surfaces beneath insulation layers. Thermal insulative coatings (TICs) have emerged as increasingly popular alternatives to traditional insulation systems, offering personnel protection, CUI mitigation, and enhanced thermal efficiency for high-temperature assets. Their application in both new installations and refurbishment projects demonstrates strong potential for cost savings and accelerated project schedules by eliminating the need for conventional insulation system such as blankets and cladding. TIC products are typically water or solvent-based resins containing various performance-enhancing fillers such as ceramic microspheres, aerogels, or other materials engineered to improve thermal resistance. Despite their increasing deployment, a notable gap remains in the systematic comparative analysis of commercially available TIC products, particularly regarding their corrosion protection capabilities. This study addresses that gap by examining four commercially available insulative coating systems, evaluating their thermal conductivity, validating their effectiveness for personnel protection according to NACE TM21431 standards, and assessing their corrosion resistance through water condensation and salt fog testing as specified in ISO 12944-6. To further assess real-world performance, two of the coatings were selected for field pilot applications to evaluate their ease of application and durability under operational conditions.