The Hidden Risk
Behind Corrosion Under Insulation on Offshore Platforms

  
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Corrosion Under Insulation (CUI) remains one of the most persistent and costly threats facing the offshore oil and gas industry. It has even caused explosions.  Each year, it accounts for vast maintenance bills, unexpected shutdowns and safety-critical failures. While water ingress often draws attention, a more subtle cause is often overlooked — vapour permeability.

Proper attention to preventing CUI’s can dramatically reduce maintenance costs and slash downtime. Versaperm’s vapour permeability measurement systems targets the root cause of hidden CUIs.

Versaperm, a leading authority in vapour permeability testing, is helping the industry tackle this issue with its advanced Mass Spectrometer-based testing solution. This technology is designed specifically to identify and quantify the vapour transmission properties of materials used on offshore platforms, from insulation and cladding to seals and protective coatings.

In marine environments where exposure to salt-laden air, high humidity and extreme temperature fluctuations is constant, even minor vapour ingress can lead to significant corrosion. Water vapour can migrate through insulation and cladding systems, condensing on colder pipework and structures. This moisture is often hidden and accumulates slowly over time, promoting corrosion beneath the insulation long before it becomes visible. The result is costly degradation of infrastructure, compromised safety and reduced asset lifespan.

Versaperm's latest system addresses this problem directly. Its Mass Spectrometer-based approach offers rapid and highly accurate measurement of vapour permeability, providing engineers with critical data that traditional gravimetric or cup methods cannot match. The system is capable of detecting extremely low levels of permeability and can analyse several different vapours and materials in a single test. Results that once took days can now be delivered in hours, providing faster and more reliable data to inform design and material selection.

By applying this testing early in the material selection process, offshore operators can make informed decisions that reduce long-term risk. They can choose materials with lower permeability, design insulation systems that resist vapour ingress and ensure long-term performance in demanding offshore conditions. In doing so, they avoid the hidden pathways that allow moisture to build up and corrosion to take hold.

Versaperm’s technology is already being used by major industry players who understand the importance of early intervention. Proactively testing materials before they are deployed is the most effective way to avoid the heavy cost of reactive maintenance and emergency repairs.

“Just because you can’t see doesn’t mean it won’t corrode,” says Chris Roberts, Technical Director of Versaperm. “Vapour permeability testing isn’t just a quality control step. It’s a front-line defence against failure offshore. Our Mass Spectrometer system gives engineers the confidence that their materials will perform as expected — before the platform goes live.”

Versaperm Ltd is based in the UK and brings over four decades of experience in vapour permeability measurement and control. It serves a wide range of sectors including energy, aerospace, packaging and pharmaceuticals, offering both testing services and precision instrumentation for critical applications.

ENDS

Please send any sales enquiries to Christopher Roberts, Versaperm Limited,,
10 Rawcliffe House, Howarth Road, Maidenhead, Berkshire, SL6 1AP, UK, Tel: +44 (0) 1628 777668,
e.mail info@versaperm.co.uk Web http://www.versaperm.co.uk

For further Press Information please contact Gerry Palmer @
T the Palmer & Rose Partnership.
Tel +44 (0) 1494 637499, e.mail gerry@palmer-rose.co.uk.