Insulated pipe comprises some of the most widespread and costly corrosion issues we document.  Not only are the piping layouts complex and extensive, they are typically enclosed behind walls and in ceilings.  While primarily related to chill water and dual temperature systems, it is also common for condenser water and other insulated pipe in exposed outdoor environments.  Fundamentally, any corrosion occurring to the exterior of the pipe is the fault of inadequate insulation thickness, the wrong insulation type, the lack of an effective moisture barrier or outer protection, having been poorly installed, or it being trampled on for years by workers and not maintained.

The common misconception that insulation alone will prevent any corrosion to the pipe surface is one major cause of the problem; with the very simple 1st step of coating the pipe with a rust preventative never even considered.  A 2nd misconception is that the outer paper covering of typical fiberglass insulation provides a barrier to moisture migration.  As an inevitable result, moisture migrates through the insulation to produce varying degrees of deterioration from mild cosmetic surface rust all the way to total pipe destruction.  Most conditions remain hidden from view until a failure occurs, with exploratory investigation to a potential insulation problem almost never performed.

This series of Photo Galleries presents examples showing the consequences of improperly selected, poorly installed, inadequately selected, and/or poorly maintained insulation in its various forms.