ZERUST® Inhibitor Fusion (ZIF) Tape

The Problem

Corrosion in industrial environments often occurs in areas that are difficult to inspect and maintain.

• Corrosion Under Insulation (CUI): Moisture intrusion beneath insulation creates a hidden, aggressive corrosion environment that can go undetected until failure occurs
• Flange Corrosion: Crevice corrosion at flange interfaces can lead to seized bolts, leaks, and costly maintenance

If left unaddressed, these issues can result in unplanned downtime, safety risks, and significant repair costs.

THE SOLUTION

ZERUST^® Inhibitor Fusion (ZIF) Tape is a self-fusing, corrosion-inhibiting tape designed to protect metal surfaces from corrosion in both exposed and insulated environments.

Made from a silicone elastomer with embedded corrosion inhibitors, ZIF Tape:

• Forms a tight, conforming barrier around complex geometries
• Delivers corrosion-inhibiting protection directly to the metal surface
• Adheres to itself (not the substrate), allowing for clean removal
• Can be applied quickly without heat or special tools

ZIF Tape works on bare or coated steel and does not interfere with existing cathodic protection systems.

For some applications, ZERUST^® ZIF Guard, a non-inhibiting holding tape, may be used at terminating ends or abrasion-prone areas to help secure the ZIF Tape during installation.

TYPICAL APPLICATIONS

• Pipelines and piping systems under insulation
• Flanges, valves, and bolted connections
• High-temperature process piping
• Field welds and repair areas
• Condensation-prone and corrosive environments
• Offshore, marine, chemical, oil & gas, and power facilities
• Metal infrastructure and industrial assets

KEY ADVANTAGES

• Corrosion Protection: Helps protect pipes, flanges, valves, and other components by delivering inhibitors directly to the metal surface. 
• Embedded corrosion inhibitors provide effective, long-term protection
• Self-fusing design creates a secure, continuous barrier without heat
• Cold-applied with minimal surface preparation (SSPC-SP2 recommended)
• Wide temperature range: -49°F to 392°F (-45°C to 200°C)
• UV-resistant for outdoor durability
• Translucent design allows visual inspection without removal
• Adapts to complex shapes and irregular surfaces
• Preserves existing coatings and removes cleanly without residue
• Long service life: 10+ years under normal conditions

corrosion under insulation (cui) protection

CUI is one of the most difficult forms of corrosion to prevent due to unavoidable moisture ingress beneath insulation systems.

ZIF Tape helps mitigate CUI by providing both a protective barrier and active corrosion inhibition directly at the pipe surface.

When applied prior to insulation, ZIF Tape:

• Creates a self-fused, continuous layer that minimizes moisture intrusion
• Conforms tightly to welds, bends, and irregular surfaces
• Maintains protection across a wide temperature range
• Enables assets to be reinsulated and returned to service quickly

Field applications show ZIF Tape installed on piping, covered with insulation and cladding, and placed back into operation with long-term protection.

Laboratory testing using cyclic CUI conditions demonstrated no rusting or coating degradation after exposure, supporting its performance in aggressive environments.

flange corrosion control

Flange interfaces are particularly vulnerable to corrosion due to crevice conditions and environmental exposure.

ZERUST^® ZIF Tape provides active corrosion protection that helps maintain flange integrity and keep assets operational.

Why ZIF Tape for Flanges

• Provides active corrosion protection at flange interfaces, not just a passive barrier
• Helps keep bolting serviceable, reducing the need for cutting or replacement
• Cold-applied and can be installed during operation without hot work permits
• Forms a tight, self-fused seal that limits moisture ingress
• Minimal surface preparation required (SSPC-SP2 recommended)
• Removes cleanly without damaging coatings or leaving residue
• Proven long-term performance in field and offshore environments

Flange Protection APPLICATION

• ZERUST^® Inhibitor Fusion (ZIF) Tape: primary corrosion protection layer
• ZERUST^® ICT^® Tube Strip Pro: inhibitor delivery within flange gap
• ZERUST^® ZIF Guard: non-inhibiting holding tape used to help secure terminating ends during installation

This combined approach protects both external surfaces and internal flange interfaces for more complete corrosion control.

zif tape for flange & asset protection - download Brochure

operating summary

• Ensure the equipment, pipe, flange, or surface to be protected is clean, dry, and at ambient temperature during installation.

• Wrap ZERUST^® Inhibitor Fusion (ZIF) Tape over the area to be protected (over existing coating, if applicable) prior to installing insulation.

• Remove the backing while applying the tape and maintain tension to ensure a tight, conforming fit. Overlap the tape during application to allow it to self-fuse into a continuous protective layer.

• Apply pressure to the wrapped surface for approximately 30 seconds to initiate bonding and ensure proper fusion.

• Apply ZERUST^® ZIF Guard over terminating ends as needed to help secure the ZIF Tape during installation and minimize unraveling.

• Inspect the application to confirm the area is fully encapsulated and sealed.

• To remove, cut the ZIF Tape with scissors or a knife and peel away. No heat or chemicals are required.

Typical Properties

Typical values are not meant to be a specification.

Availability

Contact a ZERUST^® representative for ordering information.

Product sold in US customary units. Metric units approximate.

Storage

Store in original packaging in a cool, dry place away from sunlight.
Optimal storage conditions: below 76°F (24°C) and ≤ 50% RH.