This paper presents research on coatings designed to combat severe Corrosion Under Insulation (CUI) scenarios, marking a significant milestone in the coatings industry. The development of these coatings involved extensive research and formulation investigations. The revisiting of a 20-year CUI case study reveals the remarkable link of real-world observations with coatings development. For the first time, a discussion is had on the evolution and understanding of aluminum as vital pigment choice for CUI protection and its emergence across the Oil & Gas industry. While recent industry discussions have focused on binder resin systems (AMPP SP0198), this paper expands the conversation to include the critical role of pigments. Extensive testing has been conducted to evaluate the performance of aluminum in various temperature and operational conditions. We also explore other pigments and review different approaches to CUI protection. The testing methodologies include accelerated CUI tests, electrochemical techniques, and industry-standard tests to ensure coatings are fit for purpose. This latest research is highly relevant to the Oil and Gas sector, offering a new perspective on CUI protection. It underscores the importance of considering pigments as well as binders for their crucial impact in coating to offer extended lifetimes.
