Common Corrosion Protection Methods for Pipe Supports and Hangers

Pipe supports and hangers are often exposed to harsh environmental conditions such as humidity, chemicals, salt spray, or extreme temperatures. Over time, these factors can lead to corrosion, which weakens structural integrity, compromises load-bearing performance, and reduces system reliability. To ensure long-term service life and operational safety, appropriate anti-corrosion treatments must be applied during manufacturing or prior to installation.

Below are the most commonly used corrosion protection methods for pipe supports and hangers.

1. Hot-Dip Galvanizing (HDG)

Process:
Steel components are immersed in molten zinc at approximately 450°C (842°F), forming a metallurgically bonded zinc coating.

Advantages:

Excellent protection in outdoor and industrial environments

Long-lasting, typically 20+ years in moderate environments

Uniform coating even on complex geometries

Best Applications:

Power plants, refineries, and chemical processing plants

Outdoor piping systems

Coastal or high-humidity areas

2. Electro-Galvanizing (Cold Galvanizing)

Process:
A thin layer of zinc is electrochemically plated onto the surface of the metal.

Advantages:

Smooth and aesthetic surface finish

Suitable for indoor applications

Cost-effective for small components

Limitations:

Lower corrosion resistance than HDG

Not recommended for outdoor or marine use

Best Applications:

HVAC piping, cleanrooms, or indoor mechanical systems

3. Powder Coating

Process:
Dry powder (typically polyester, epoxy, or hybrid) is electrostatically applied to the metal surface and then cured under heat to form a hard finish.

Advantages:

Excellent resistance to chipping, UV, and chemical exposure

Available in a wide range of colors for identification or branding

Environmentally friendly (low VOC emissions)

Limitations:

Requires proper surface preparation

Not self-healing if the coating is scratched

Best Applications:

Architectural piping, food & beverage industries, chemical plants

4. Epoxy and Polyurethane Paint Systems

Process:
Multi-layer coating systems using primers, epoxy mid-coats, and polyurethane topcoats.

Advantages:

High chemical and abrasion resistance

Excellent adhesion to metal surfaces

Customizable thickness and color

Limitations:

More labor-intensive

Requires strict curing conditions

Best Applications:

Offshore platforms, petrochemical plants, or buried supports

5. Stainless Steel Components

Approach:
Use of stainless steel (e.g., 304, 316) for entire support assemblies.

Advantages:

Inherent corrosion resistance without the need for coatings

Long service life in aggressive environments

Low maintenance

Limitations:

Higher initial cost

Not always necessary for standard applications

Best Applications:

Cleanrooms, pharmaceutical and food processing facilities

Marine and offshore piping systems

6. Rubber or Plastic Coating (Encapsulation)

Process:
Pipe contact areas are covered with rubber or plastic sleeves or dipped in coating material.

Advantages:

Prevents metal-to-metal contact

Reduces vibration and noise

Protects insulation and pipe coatings

Limitations:

Typically used in combination with other methods

Not suitable as a standalone protection in outdoor environments

Best Applications:

Noise-sensitive buildings, thermal insulation zones

7. Bitumen or Asphalt Coating (for Underground Supports)

Process:
A thick, tar-like layer is applied to the support to provide a moisture barrier.

Advantages:

Effective for buried or wet environments

Low-cost moisture barrier

Limitations:

Aesthetic limitations

Not suitable for exposed pipe supports

Best Applications:

Underground piping supports, soil-contact systems

Conclusion

Selecting the right corrosion protection method depends on several factors, including environmental exposure, material compatibility, budget, and required service life. In many cases, a combination of base material selection and surface treatments yields the best results. For critical infrastructure or severe environments, investing in high-performance coatings or stainless steel components can prevent costly failures and extend operational life.