Zerust® Inhibitor Fusion (ZIF) Tape

The Problem

Corrosion Under Insulation (CUI) is one of the (petro) chemical processing industries worst problems and the costs associated to mitigating it are astronomical.

CUI is any type of corrosion that occurs due to a moisture buildup on the external surface of insulated equipment. If undetected, the results of CUI can lead to the shutdown of a process unit or an entire facility, and in rare cases it may lead to a process safety incident. While carbon and low- alloy steels operating between –45°C and 149°C are most at risk from CUI, the intermittent boiling and flashing that occurs above a metal temperature of 100°C (212°F) produces a fairly aggressive CUI environment. CUI is one of the most difficult processes to prevent. The reason for that is, by and large, no matter the precautions taken, water invariably seeps into the insulation and begins its dirty work—sometimes unseen until process leakage occurs

THE SOLUTION

ZERUST® Inhibitor Fusion (ZIF) Tape is a self-fusing, corrosion inhibiting silicone elastomer tape designed to protect pipes, flanges, valves, and other critical components from long-term corrosion, including Corrosion Under Insulation (CUI). It offers easy, cold application with durable bonding and resistance across a wide temperature range. ZIF Tape is a versatile solution that provides comprehensive corrosion protection in challenging environments

TYPICAL APPLICATIONS

• Pipelines and equipment under insulation
• High-temperature process piping
• Condensation-prone environments
• Oil & gas, chemical, and power industries
• Metal infrastructure

KEY ADVANTAGES

• Self-fusing: Forms a durable bond in ~30 seconds without heat or special tools
• CUI & Component Protection: Safeguards pipes, flanges, valves, and more by delivering inhibitors directly to the surface.
• Translucent & UV-Stable: Built for long-term durability and resilience.
• Elastic & Snug Fit: Minimizes moisture penetration.
• Wide Temperature Range: Effective from -49°F to 392°F (-45°C to 200°C).

Test Results

Control:

Pipe coated with red iron oxide primer with a 2 inch bare/uncoated section in the middle. Wrapped with 1 inch thick fiberglass insulation and tape.

Test Specimen:

Pipe coated with red iron oxide primer with a 2 inch bare/uncoated section in the middle. Wrapped with ZIF tape (~50% overlap on the wraps).
Wrapped with 1 inch thick fiberglass insulation and tape.

Test Conditions:

Step 1: Control and test specimens immersed in tap water for 8 hours
Step 2: Control and test specimens drained and placed in a convection oven at 80°C overnight Steps 1 and 2 carried out daily for 25 days

Results:

The ZIF tape significantly reduced the corrosion rate to both the bare and the coated sections even through the extreme test protocols. Substantial corrosion was seen in the control with blistering and delamination of the primer layer. The most effective method of preventing CUI is to keep water and electrolytes from coming into contact with the unprotected metal surface. However, while it’s nearly impossible to guarantee that the insulation or coating will not be breached – and none of the above mitigation practices guarantee the complete prevention of CUI – Zerust’s ZIF tape works with the assumption that there will be moisture ingress and actively inhibits corrosion.

Availability

Available in 36 ft. long, individual, whole rolls in 2”, 4”, 12” and 16” widths.

Part No.

• 02” ZIF Tape: 250-F-00105
• 04” ZIF Tape: 250-F-00108
• 12” ZIF Tape: 250-F-00106
• 16” ZIF Tape: 250-F-00107

ZIF Tape 36 ft. long

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