Corrosion under pipe supports (CUPS) is a recurring integrity concern in industrial piping systems, as support interfaces naturally promote localized corrosion through coating damage, moisture retention, and restricted access for inspection. At these locations, thin electrolyte films can persist beneath contact points, while metal-to-metal continuity between the pipe and its support may contribute to galvanic effects. Over time, these conditions accelerate corrosion in areas that are difficult to monitor and expensive to remediate.

This article examines the primary corrosion mechanisms active at pipe support interfaces, including crevice and differential aeration corrosion, galvanic interactions, and corrosion promoted by micro-movement and under-deposit conditions. It explains why traditional support arrangements and bonded wear pads often struggle to eliminate these drivers, particularly in environments subject to wet–dry cycling, vibration, and thermal expansion. The discussion emphasizes the importance of addressing corrosion at the interface itself rather than relying solely on coatings or periodic inspection.

The SmartPad System is presented as an interface-based mitigation approach that focuses on electrical isolation, moisture control, and coating preservation at pipe supports. By using non-metallic support components and a closed-cell sealing layer at the pipe–support contact surface, the system is designed to reduce the formation of corrosive micro-environments while maintaining structural load distribution. The article also highlights practical considerations related to installation and inspection, including the ability to temporarily lift and re-secure the support for visual examination. Together, these elements illustrate how support design can influence long-term corrosion performance and lifecycle maintenance strategies in supported piping systems.

Key mechanisms covered

• Crevice & differential aeration corrosion at pipe–support contact points where oxygen gradients and trapped electrolytes develop
• Galvanic corrosion driven by electrical continuity between metallic pipes and supports in the presence of moisture
• Micro-movement and fretting-assisted corrosion caused by thermal cycling and vibration at constrained interfaces
• Under-deposit / thin-film corrosion promoted by retained moisture, salts, and contaminants beneath support footprints
• MIC (microbiologically influenced corrosion) risks in intermittently wet, shielded support crevices