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Corrosion Under Insulation (CUI) has long been the hidden enemy of the oil and gas industry, silently causing billions in damages annually. Now Sherwin-Williams has unveiled a breakthrough that promises to rewrite the rules of asset protection, delivering next-generation defense for pipes, valves, and vessels battling this costly threat.
What Happened
Sherwin-Williams has launched Heat-Flex® ACE, an advanced coating technology specifically engineered to combat corrosion under insulation (CUI). Heat-Flex ACE acts as a high-performance primer applied beneath traditional insulation systems, creating a robust barrier that isolates steel surfaces from moisture infiltration—the chief catalyst of CUI.
Designed to operate effectively across an extremely wide temperature range from -196°C (-321°F) to 232°C (450°F), it suits both carbon and stainless steel substrates in new constructions and maintenance projects. The coating meets rigorous industry standards, including ISO 19277:2018 CUI2 & CUI3, and Norsok M501 system 1D and 6C, demonstrating superior resistance to cracking, corrosion creep, and thermal stress.
Why It Matters
The Persistent Challenge of CUI
Corrosion under insulation is notorious for remaining undetected until significant damage occurs, leading to expensive repairs, unplanned downtime, and increased safety risks. Traditional epoxy coatings have historically fallen short due to their limited temperature resistance, difficult application, and vulnerability to cracking.
Heat-Flex ACE’s breakthrough lies in its chemical formulation that dramatically outperforms traditional solvent-based epoxy phenolic and novolac coatings, extending protection and reducing the frequency and cost of maintenance. This innovation marks a pivotal development toward mitigating a problem long seen as inevitable and expensive.
Key Details
Advanced Features and Industry Recognition
- Heat-Flex ACE provides outstanding temperature and corrosion creep resistance in harsh environments.
- Its ease of application saves time and reduces complexity during coating processes.
- It is designed for use on insulated and uninsulated pipes, valves, and vessels, supporting diverse operational conditions common in oil and gas facilities.
- The technology has earned significant industry accolades recognizing its innovation and impact on corrosion control strategies.
Neil Wilds, Sherwin-Williams’ Global Product Director for CUI and Testing, emphasizes the product’s role in transforming asset protection by mitigating corrosion for extended durations, defying the long-held belief that CUI is an unavoidable expense for operators.
What Comes Next
Sherwin-Williams’ introduction of Heat-Flex ACE signals a new era of CUI defense that could reshape maintenance practices and asset longevity in the oil and gas sector.
As operators adopt this technology, they can expect enhanced reliability, reduced operational risk, and meaningful cost savings. Ongoing advancements in coatings like Heat-Flex ACE will likely continue to elevate industry standards, prompting wider implementation of next-generation corrosion protection solutions worldwide.
The promise is clear: corrosion under insulation no longer has to be a costly inevitability but can be actively controlled with smarter, more resilient coatings.
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