SmartPads vs. the Myths: FRP Pipe Support and CUPS Protection
Abstract:
Corrosion Under Pipe Supports (CUPS) remains one of the most persistent and costly threats in industrial piping systems, particularly in corrosive environments like refineries, chemical plants, and offshore platforms. While fiber-reinforced plastic (FRP) is increasingly used in piping infrastructure, doubts persist about its mechanical performance under thermal, compressive, and vibrational stress. This article directly addresses five common myths about FRP pipe supports — including concerns over melting, sagging, cracking, and long-term retention — and introduces the SmartPad System, a patent-pending, fully non-metallic CUPS protection solution engineered by Cogbill Construction. Featuring a closed-cell gasket, high-strength FRP exoskeleton, and SmartBand tensioning system, SmartPads deliver not only CUPS mitigation but also field-replaceability and 20–30 years of service life — with faster installation and drastically lower inspection costs than bonded or welded alternatives. Supported by field load testing and long-term application data, the SmartPad System redefines what FRP supports can do — and why they may be the most robust solution on the market today.
Not All Pipe Supports Are Created Equal
Pipe supports are the silent workhorses of industrial infrastructure. Found beneath the hundreds or thousands of feet of piping that crisscross chemical plants, refineries, and offshore rigs, these small components play an outsized role in reliability, safety, and cost control, along with pipe corrosion protection.
Composite pipe supports are rapidly becoming a go-to solution for corrosion under pipe supports (CUPS), especially in facilities that need a non-metallic, inspectable, and long-lasting support system. The SmartPad System by RedLineIPS is one such CUPS protection system.
The pipe supports that are designed to protect piping from CUPS come in many forms — and more importantly, from many different materials:
- Welded carbon steel saddles
- Neoprene or rubber strips
- Thermoplastic half-round rods
- Epoxied composite wear pads
- Fiber-Reinforced Plastic (FRP) support systems
Each support and material has tradeoffs — especially in corrosive environments where Corrosion Under Pipe Supports (CUPS) is a leading cause of failure. While metallic and thermoplastic supports still dominate in many facilities, composite FRP supports are rapidly gaining attention. However, this growing interest has also brought renewed skepticism.
Spotlight on FRP: Advanced Material, Real-World Doubts
Despite its advantages, FRP often raises eyebrows:
- “Will it melt under high temperatures?”
- “Will it deform or sag under heavy pipe loads?”
- “Will it crack like fiberglass under vibration?”
These questions, and many more, are fair — often based on experience with low-grade plastic materials or brittle fiberglass panels. But modern FRP, especially when engineered for structural performance, behaves very differently.
This article explores the truth behind some of these myths, explains the science of thermoset composites, and introduces the SmartPad System — a field-proven FRP support system designed specifically for extreme-duty applications to combat CUPS corrosion. We’ll also compare this system to traditional alternatives, including metallic plates, thermoplastic half rounds, and even older-generation FRP wear pads.
What Is Corrosion Under Pipe Supports (CUPS)?
Corrosion Under Pipe Supports (CUPS) is a localized form of external corrosion that occurs where pipes rest directly on structural supports — typically steel beams or pipe racks. At these contact points, a combination of mechanical, chemical, and environmental factors converge to create ideal conditions for corrosion. Pipe vibration, thermal expansion, and fluid dynamics cause subtle but continuous motion, which gradually abrades the pipe’s protective coating. Once bare metal is exposed, the lack of airflow beneath the pipe allows moisture to accumulate, creating a crevice environment that encourages corrosion. Additionally, when metal pipes sit directly on metal supports, an electrochemical reaction known as galvanic corrosion can occur — where one metal acts as a sacrificial anode and corrodes faster than it otherwise would. Over time, these corrosion cells can penetrate the pipe wall, leading to leaks, process failures, or catastrophic rupture. CUPS is especially common in coastal plants and offshore platforms where humidity, salt spray, and temperature cycling accelerate the problem
What Is the SmartPad System?
The SmartPad System is a non-metallic, modular pipe support solution designed to eliminate CUPS and survive harsh environments. Developed by Cogbill Construction and distributed under the RedLineIPS brand, it consists of:
- A rigid FRP exoskeleton (SmartPad) with sloped saddle geometry and grooved anchor regions
- A closed-cell Hydroseal gasket pre-bonded to the pad, forming a watertight NEMA-4 seal to prevent water ingress between pipe and pad
- SmartBands — heavy-duty, continuous-strand fiber-reinforced straps for quick, no-hot-work installation
- An optional PTFE liner for chemical resistance in harsh process environments
This system supports pipe weights up to 3,000 lbs. per support point and is built for conditions including:
- Constant vibration
- UV and salt spray exposure
- Operating temps up to 400°F (204°C)
- Aggressive chemical atmospheres
Now let’s dive into the myths — and the material science that debunks them.
Myth 1: “FRP Pipe Supports Will Melt Under High Temperatures”
The Concern:
Plastic melts. Right? This common assumption comes from experience with thermoplastics like HDPE, PVC, or PTFE — materials that soften under elevated temperatures and can deform under load.
The Reality:
FRP is NOT a thermoplastic. It’s a thermoset — a material that undergoes irreversible chemical curing during manufacturing. Once cured, it does not melt, flow, or re-soften.
Glass Transition Temperature (Tg):
FRP’s thermal behavior is defined by its glass transition temperature — the point at which the resin transitions from rigid to rubber-like. But even at Tg, the structure remains intact. SmartPads are made from resins with Tg values between 220°F and 265°F (104–129°C) and are rated for:
- Continuous service up to 400°F (204°C)
- No softening or deformation below that range
By contrast, HDPE softens at ~180°F (82°C), making it unsuitable for steam lines or hot process pipes.
Real-World Use:
SmartPads have been used successfully on:
- Steam condensate return lines
- Offshore piping exposed to direct sunlight
- High-temp hydrocarbon systems
Conclusion:
Cogbill’s SmartPads are a non-metallic CUPS protection system that do not melt — their crosslinked thermoset resin and glass fiber matrix provide structural integrity well beyond standard operating temperatures.
Myth 2: “FRP Pads Will Sag or Compress Under Pipe Load”
The Concern:
In industrial environments, long-term static loads can cause certain polymers — especially unreinforced plastics or rubber — to deform over time. This process, known as creep, leads to sagging, loss of gasket compression, and eventual loss of support integrity. Skeptics argue that fiber-reinforced plastics (FRP), being polymer-based, are likely to suffer the same fate under heavy piping systems.
The Reality:
Unlike flexible thermoplastics or elastomers, FRP composites used in SmartPads are structural-grade materials reinforced with continuous glass fibers. These fibers carry the majority of the mechanical stress, giving the SmartPad exceptional compressive strength and creep resistance, even at elevated temperatures.
SmartPads are designed to support typical loads of 1,500–3,000 pounds per location and are engineered with a geometry that distributes stress across a wide saddle-shaped contact surface, eliminating point loading.
While no support should ever be subjected to extreme overload, Cogbill Construction conducted a destructive load test to validate the system’s limits. In this test, a SmartPad installed under an 8-inch schedule 100 (5/8” wall thickness) carbon steel pipe was subjected to a vertical load of 119,900 pounds. The pipe itself permanently deformed under this stress — but the SmartPad recovered its shape without damage or loss of function.
Although this was not a formalized long-duration creep test, it demonstrated the SmartPad’s elastic recovery and structural resilience under loading far beyond design expectations. In practical use, SmartPads have consistently held their shape and maintained gasket compression over years of field service.
Conclusion:
SmartPads are not vulnerable to sagging or long-term compression fatigue. Their fiber-reinforced structure, load-distributing geometry, and proven recovery under overload make them a robust choice for long-term pipe support in high-load, high-temperature environments.
Myth 3: “FRP Pads Will Crack from Vibration or Shock”
The Concern:
Aren’t fiberglass materials brittle? Won’t they chip, delaminate, or shatter under impact or mechanical stress?
The Reality:
Again, this concern confuses commodity fiberglass (used in grating or paneling) with engineered structural FRP. SmartPads use:
- Toughened thermoset resin systems
- Fiber orientation for impact resistance
- Built-in vibration tolerance
Field Evidence:
- Deployed on rotating equipment lines, pump headers, and offshore risers
- No reported cracking, chipping, or structural loss after 6+ years (30+ years for FRP exoskeleton)
- UV-stable resin systems prevent brittleness from sun exposure
Conclusion:
SmartPads are not brittle. Their structure dampens vibration and withstands real-world shocks better than many metallic or thermoplastic alternatives.
Myth 4: “SmartPads Are Just FRP Wear Pads with a Gasket”
The Concern:
Since SmartPads are made from fiber-reinforced plastic (FRP), some assume they’re simply traditional wear pads with a gasket added on — offering no real engineering advantage over standard epoxied FRP pads.
The Reality:
While both products use FRP, traditional wear pads are permanently bonded to the pipe using field-applied epoxy. This installation process introduces multiple risks: improper surface prep, poor cure due to weather or contamination, and long-term moisture ingress through bond failure or edge separation.
SmartPads eliminate all of those failure points. Instead of relying on adhesive bonding, they use a mechanically fastened system that includes:
- A pre-bonded closed-cell Hydroseal gasket that compresses to form a NEMA-4 watertight seal
- Grooved FRP saddles that cradle the pipe and guide strap placement
- SmartBands that provide secure, non-metallic, high-tension fastening without epoxy or welding
Because SmartPads can be installed in minutes, removed for inspection, and reinstalled without damage, they offer capabilities that epoxied FRP pads cannot match.
Conclusion:
Although both SmartPads and epoxied FRP pads use composite materials, the SmartPad is a patent-pending pipe corrosion protection system — not just a pad. Its design eliminates installer error and bonding risk, enables inspection access, and ensures a long-lasting seal, making it a far more advanced solution for CUPS prevention
Myth 5: “SmartBands Will Loosen Over Time, and the Pad Will Fall Off”
The Concern:
Because SmartPads are held in place by non-metallic bands rather than welded or bonded, some worry that the SmartBands might lose tension over time, allowing the pad to loosen or fall off during service.
The Reality:
SmartBands are manufactured using continuous-strand fiber-reinforced polymer, not short-fiber plastics or cable ties. They use a square-tooth locking mechanism that resists reverse motion under load, even after years of exposure. Each band is tensioned using the SmartTool, which applies consistent force that compresses the Hydroseal gasket and locks the band into place. Once secured, the only way to remove a SmartBand is to cut it.
Test data shows that properly installed SmartBands provide retention forces over 1,000 lbf, and remain stable under long-term exposure to heat, vibration, and environmental cycling. In fact, the bands are rated for decades of service, including in subsea and offshore environments where tension loss would be unacceptable.
Conclusion:
SmartBands are not simple plastic straps — they’re engineered tensioning components with a proven mechanical locking profile. When installed correctly, they will not loosen over time and are rated to last 20 to 30 years in service. Concerns about slippage are unfounded and not supported by product testing or field experience.
General Benefits of FRP in Pipe Supports
FRP’s performance goes beyond the absence of failure. Composite supports offer several inherent advantages over both steel and plastic-based alternatives:
Benefit | Description |
No Metal-to-Metal Contact | Prevents galvanic corrosion at contact points |
Non-Conductive | Safer in electrical or lightning-prone areas |
No Welding or Permits | Installs on live lines without shutdown |
UV & Chemical Resistant | Durable in outdoor and corrosive environments |
Vibration Damping | Reduces stress, movement fatigue, and operational noise |
No Epoxy Curing | Installs in minutes, no cure time, no bond failure |
Reusability | Can be unstrapped, inspected, and reinstalled |
Gasketed Moisture Seal | Closed-cell Hydroseal prevents crevice corrosion |
Final Thoughts
The myths surrounding FRP pipe supports often stem from outdated materials or misapplied assumptions — but modern engineered composites like those used in the SmartPad System have proven themselves in some of the harshest industrial environments on Earth. From high-temperature steam lines to salt-laden offshore platforms, SmartPads have consistently delivered long-term corrosion protection, structural integrity, and inspection flexibility where conventional welded or bonded supports fall short.
By eliminating metal-to-metal contact, providing watertight gasket compression, and enabling fast, epoxy-free installation, the SmartPad System redefines what pipe supports can achieve in both performance and cost of ownership. Backed by field testing, load validation, and more than a decade of composite engineering expertise, SmartPads are not just an alternative — they are the next evolution in CUPS protection.
For more information on SmartPads, technical specifications, installation guidance, or to request a quote, please contact us at Sales@SmartPadSystem.com or reach out to our engineering team at Cogbill Construction. We’re here to help you protect your assets, reduce maintenance costs, and ensure the long-term integrity of your piping infrastructure.