Corrosion under pipe supports (CUPS) is a localized but high-consequence degradation mechanism because it occurs where pipes contact beams, saddles, and other support structures—areas that tend to retain moisture and are difficult to inspect. This article explains CUPS as the result of a combined mechanical-and-environmental micro-environment at the support interface. Movement and vibration from fluid flow, thermal expansion, and nearby rotating equipment can gradually erode protective paint at the contact point, exposing bare metal. Once the coating barrier is compromised, restricted airflow at the interface traps moisture, encouraging crevice-style corrosion. The article also notes the added corrosion risk associated with metallic pipes resting directly on metallic supports due to electrochemical interactions in the presence of moisture.
The article then introduces the RedLineIPS SmartPad System, developed by Cogbill Construction (Texas, USA), as an all-composite solution intended to address the root causes of CUPS: friction/coating damage, moisture retention, and metal-to-metal contact. It describes the system’s main components—FRP SmartPads, a pre-installed closed-cell Hydroseal gasket that compresses to form a watertight seal, non-metallic SmartBands, and a SmartTool used to tension and trim the banding. Optional PTFE strips are also mentioned for aggressive chemical environments.
A key practical emphasis is maintainability: the installation process is presented as fast and epoxy-free/weld-free, with easy removal and reinstallation to support quick visual inspection. The article also compares SmartPads to welded metallic plates, epoxied FRP wear pads, thermoplastic half rods, and wraps/liners—summarizing typical drawbacks (moisture trapping, curing time, point loading, slipping/tearing) and positioning SmartPad’s sealed, saddle-shaped, non-metallic interface as the differentiator.
Key mechanisms covered
- Coating erosion from friction and vibration at pipe–support contact points
- Moisture retention / restricted airflow crevice conditions that promote localized corrosion
- Metal-to-metal contact effects (electrochemical/galvanic-type corrosion risk) at metallic interfaces
- Crevice corrosion initiation from trapped electrolyte films at the support footprint
- Inspection-driven corrosion risk when solutions hinder access; mitigated by quick remove/reinstall for visual checks