Materials, surface treatment, science & engineering
Combatting Corrosion Under Insulation (CUI): Engineering an Award-Winning Barrier with Rockwool
IPU: R&D’s Strongest Ally
A Model for Agile Collaboration
IPU: R&D’s Strongest Ally
IPU: R&D’s Strongest Ally
Client
Rockwool
Rockwool Technical Insulation faced a critical challenge in the North American market. While stone wool is a superior insulator, customers were increasingly concerned about Corrosion Under Insulation, a hidden, aggressive localized form of corrosion with peak corrosion rates that can exceed 3 mm per year on hot insulated steel pipes Responding to input from the industry and customers Rockwool identified an idea to improve their already water repellent insulation material WR-TechTM with an added layer of corrosion protection.. They needed an integrated chemical defense system (a corrosion inhibitor system) that could survive extreme temperatures of 250°C without compromising safety or environmental standards.
IPU’s Approach
Partnership in Practice IPU acted as the technical bridge from the initial brainstorm to the factory floor. Our role was multifaceted, combining chemistry, simulation, and industrial design. 1. Agile R&D & Iterative Testing: We bypassed slow, traditional development cycles by building quick but scientifically sound test rigs. Using simple test-rigs inspired from industry standards, we rapidly screened inhibitors to find a formula that remained stable at 250°C and was non-toxic. 2. The "Hydrophobic" Paradox: A major hurdle was getting a water-soluble inhibitor into Rockwool’s water-repellent fibers. We developed a proprietary coating process, to ensure the inhibitor could be applied to the inner surface of the pipe sections. Exactly where the protection of the corrosioninhibitor is needed the most. 3. Physics-Based Scaling: To move from small lab samples to cover Rockwools full product program ranging from 2,5 cm to massive 90cm diameter pipe sections, we built mathematical models to simulate drying times and heat flow. By calibrating these models with data from a minimum viable production process prototype (a cost-effective, functional rig), we provided the precise dimensioning data - airflows, temperatures, and cycle times - needed for dimensioning and building full-scale production machines.
Delivering Results
Delivering Results, Building Confidence The collaboration delivered Corrosion Resistance Technology, a new high-performance insulation. 1. Industrial Integration: IPU helped oversee the commissioning ,run inand training of three automated production lines in Grand Forks, British Columbia, ensuring the chemical mixing, spraying, and drying processes worked seamlessly within the existing factory footprint. 2. Market Leadership: The resulting product doesn't just match the competition; it outperforms it. Rockwool’s CR-Tech recently won the prestigious AMPP (formerly NACE) product award, solidifying their position as the premium choice for technical insulation.
A Model for Agile Collaboration
A Model for Agile Collaboration
A Model for Agile Collaboration
This project bypassed the usual corporate bottlenecks. IPU worked directly with Rockwool’s Technical Insulation division (RTI), acting as the lead corrions and process experts. We collaborated with machine builders and chemical plant specialists to ensure that the "why" behind the chemistry wasn't lost in the "how" of the machinery.
Our presence on the factory floor during commissioning allowed for real-time troubleshooting operator training and knowledge transfer, smoothing the transition for the local workforce.
Looking Ahead
With the Canadian lines fully operational and the product winning awards, the focus shifts to the next generation of global manufacturing.
Why IPU?
Rockwool chose IPU because they needed a partner who could handle the "messy" reality of innovation. We provided the technical courage to say, "We haven't tried this before, but we will find a way."
From the first chemical testin the lab to the first shipping container leaving the factory, IPU remained R&D’s strongest ally, turning a competitive threat into a global success story.