External corrosion at pipe support locations is a well-documented but often underestimated threat to the integrity of above-ground piping systems. At these interfaces, friction from thermal expansion, vibration, and operational movement can progressively damage protective coatings, exposing bare steel to moisture, salts, and contaminants. When combined with restricted airflow and direct metal-to-metal contact between the pipe and its support, these conditions promote the formation of localized corrosion cells that are difficult to detect and expensive to remediate.

In this article, published in World Pipelines, Hani Almufti and Yulman Flores examine why many conventional CUPS mitigation methods fall short over time. Welded metallic saddles, while effective at reducing friction, maintain electrical continuity and can trap moisture in crevices beneath the pipe. Round bars and point-contact supports may increase airflow but introduce coating damage and localized stress. Flexible wraps and flat isolation sheets often migrate, tear, or degrade, re-exposing the pipe surface. Even traditional epoxy-bonded FRP wear pads—while effective in new construction—present challenges when applied to already corroded or uneven pipe surfaces and require time-consuming installation and cure periods.

The article presents the SmartPad System as a composite, non-metallic pipe support interface designed to address corrosion drivers directly at the point of contact. By combining an FRP saddle, a pre-installed closed-cell Hydroseal gasket, and composite banding, the system eliminates metal-to-metal contact, protects coatings from frictional wear, and creates a sealed interface that limits moisture ingress. A key focus is inspection efficiency: the ability to remove and reinstall the system in seconds enables routine visual inspections without welding, epoxy, or line shutdowns. Through field examples from Gulf Coast installations, the article illustrates how interface-based support design can reduce corrosion risk while improving maintainability and lifecycle performance.

Key Mechanisms Covered

• Coating degradation due to friction and micro-movement at pipe–support contact points
• Crevice and moisture-retention corrosion beneath saddles and bonded wear pads
• Galvanic corrosion caused by metal-to-metal contact between pipe and support structures
• Point-loading and stress-assisted corrosion associated with round bars and narrow supports
• Inspection-driven corrosion risk where bonded or permanent solutions limit access and visibility