Article: Corrosion Under Insulation (CUI) – How Coatings Technology is Tackling a Costly Industry Problem

A two-year breakthrough study estimates the annual direct cost of corrosion in the United States to be $276 billion. While this is a sizable number, larger than many of the world’s economies, it has been estimated that 25-30% of the total, or $70-80 billion, could be saved by using state-of-the-art corrosion management practices. In addition to the cost savings, corrosion can result in public and industrial safety issues.

CC Technologies (Dublin, Ohio) conducted the research in a cooperative effort with the U.S. Department of Transportation Federal Highway Administration (FHWA). NACE International – The Corrosion Society worked with Congressional representatives to secure $1 million in federal funding for the study.

The study identified the direct cost of corrosion in five major sectors of the economy – infrastructure, utilities, transportation, production & manufacturing, and government.

Corrosion Products

How Much is Corrosion Costing You?

RUSTGRIP - Corrosion = Protection

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Common Metal Roof Problems

Leaks most commonly occur at:

  • End Laps (Horizontal Seams)
  • Side Laps (Vertical Seams)
  • Valley Gutters
  • Ridge Caps and Ridge Ventilations
  • Flashings
  • Bad Fasteners (Screws)
  • Holes
  • Gutters
  • Skylights
  • Access Hatches

Most leaks result from or are worsened by:

  • Rusted Metal Panels
  • Roof Movement (expansion / contraction)
  • Overloading Roof With Equipment
  • Foot Traffic on Roof
  • Faulty, Clogged or Improperly Sized Gutter Systems
  • Faulty Construction / Poor Design
  • Old Age
  • Over Tightening Fasteners
  • Loose or Missing Fasteners

Rust generally occurs because of:

  • Exposure to the elements (Acid Rain, UV)
  • Corrosive substances in the air
  • Age of the building
  • Foot traffic which causes broken corrugations
  • Breakdown of factory coatings
  • Over tightening of fasteners during installation
  • Debris left on the roof
  • Building movement
  • Condensation on interior side

What to do when a metal roof begins to leak or rust: 

  • Call a licensed roofing consultant, architect or contractor and ask for a roof survey.
    (ie. Roofing Contractors Association of BC)
  • Determine exactly what the problems are.
  • Develop a repair or replacement strategy that not only solves today's problems but one that is also compatible with a long term maintenance plan.