December 2025
Maintenance, Reliability and Inspection
Materials storage/corrosion/preservation technology and surplus materials utilization process
This article presents a comprehensive review of materials storage, corrosion challenges and preservation technologies. Additionally, it covers the utilization of surplus materials and the critical control processes needed to ensure quality and cost-effectiveness. Corrosion in industrial environments poses substantial risks to both material integrity and project budgets. The implementation of strategic preservation techniques and disciplined surplus materials management is essential for long-term sustainability.
Storage corrosion remains a critical concern in materials management, especially for long-term and mission-critical inventory. Inadequate storage conditions—such as exposure to moisture, salinity and fluctuating temperatures—can accelerate material degradation, leading to structural failures and increased lifecycle costs.
Proper preservation practices, including the use of protective blasting, coatings, desiccants, sealing, smart preservation monitoring tags [Internet of Things (IoT)-based] and vapor corrosion inhibitors (VCIs), are essential to mitigate these risks. Additionally, material-specific storage protocols and periodic inspection routines should be enforced to ensure stored items remain within serviceable condition.
In many industrial megaprojects, particularly those near coastal regions, materials are stored for extended durations under harsh environmental conditions. The eastern coast of Saudi Arabia, for example, features high humidity levels, saline dust and seasonal sandstorms—all of which contribute to accelerated corrosion of both ferrous and non-ferrous materials. These conditions demand a structured approach to material storage and preservation to maintain integrity, ensure operational readiness and control project costs.
Environmental context and area description. The environmental exposure in these areas includes humidity levels reaching up to 90%, saline airborne particles and extreme temperature fluctuations. Outdoor storage yards, often used due to space limitations, are especially vulnerable. Materials stored under such conditions without adequate protection degrade rapidly, leading to increased rejection rates during quality control inspections and higher rework costs. Effective mitigation begins with understanding the specific risks and implementing tailored storage and preservation practices.
Primary causes of corrosion. Corrosion in stored materials is primarily driven by five major factors:
- High humidity: Moisture in the air condenses on metal surfaces, initiating oxidation and corrosion, especially in carbon steels.
- Saline dust: Proximity to the coast results in salt particles settling on materials, exacerbating corrosion.
- Insufficient temporary protection: Materials stored without temporary covers or VCI wraps are highly susceptible.
- Poor ventilation: Enclosed storage without airflow fosters moisture accumulation.
- Improper sealing: Components not sealed correctly trap condensation inside, leading to internal corrosion.
Materials most affected by corrosion. Carbon-steel pipes and structural elements are particularly prone to corrosion due to their chemical composition and widespread use. When exposed to the elements without protective coatings or wraps, these materials experience pitting and surface degradation. Valves with carbon-steel trim suffer at their seals and moving parts, leading to operational failure. Bare electrical conduits and cable trays oxidize rapidly, resulting in unsafe installations. Non-coated fasteners and stud bolts lose structural integrity as corrosion damages threads and load-bearing surfaces. Rotating equipment like bearings and shafts are also highly sensitive to environmental exposure—corrosion on these components can render them unusable and cause mechanical failures (TABLE 1).
Consequences of inadequate preservation. The implications of poor preservation extend beyond physical degradation. Projects often face delays due to re-inspections, rework and part replacements. Maintenance costs increase post-commissioning as prematurely aged materials require early servicing. Improper storage can void vendor warranties, further adding to the financial burden. Corrosion-related failures pose safety hazards and increase the risk of operational shutdowns. Additionally, non-conforming materials lead to higher quality assurance/quality control (QA/QC) rejection rates, which disrupt supply chains and workforce scheduling.
Required preservation actions. To effectively preserve materials during storage, the following practices are critical:
- VCI wraps: Applying VCI wraps around metallic parts prevents moisture-induced degradation.
- Desiccant packaging: Electrical and electronic items must be stored in sealed, desiccant-lined packaging to prevent internal moisture damage.
- Climate-controlled indoor storage: Sensitive equipment should be stored indoors where humidity and temperature are regulated.
- Inspection and logs: Regular inspection routines and preservation logs ensure accountability and early detection of deterioration.
- Preservation teams: Designating dedicated preservation personnel within QA/QC teams ensures that standards are consistently met.
Time and cost implications. Various corrosion scenarios illustrate the financial and schedule impacts:
- Corroded pipes: Require blasting and recoating, resulting in moderate costs and delays of 2–3 weeks per batch.
- Damaged valves: May need full replacement due to internal corrosion, with very high cost and delays up to 6 weeks.
- Structural steel: If stored long-term without protection, replacement lead time can extend 6 mos–8 mos.
- Untracked surplus: Without proper documentation, surplus materials may be rendered unusable, leading to medium cost and unpredictable delays.
Storage requirements: Indoor vs. outdoor. Indoor storage must be humidity-controlled, particularly for electrical items, instruments and rotating machinery. Items should be stored off the ground using racks to prevent moisture contact, and access should be restricted and monitored via CCTV to maintain traceability.
For outdoor storage, materials should be placed on elevated platforms with effective drainage, and covered with full shrink-wrap or tarpaulin to prevent direct exposure. VCI emitters and desiccants must be included in packaging. Weekly visual inspections, supported by photographic evidence, are necessary to maintain optimal condition (FIG. 1).
FIG. 1. Many practices are critical to effectively preserve materials during storage.
Preservation technologies. Modern preservation technologies significantly reduce corrosion risks (TABLE 2). VCI wraps, papers and emitters provide passive protection. Desiccant systems help control internal humidity.
Smart preservation monitoring tags enable real-time condition monitoring using the IoT. Hydrophobic primers serve as a durable barrier on carbon steel. Containerized storage units with integrated dehumidifiers offer reusable and reliable options for long-term material protection.
Benefits of the solution process. The key outcomes of implementing structured preservation protocols include:
- Long-term material readiness and reduced deterioration
- Full compliance with original equipment manufacturer (OEM) and vendor preservation requirements
- Real-time monitoring and early failure prediction
- Significant cost savings by avoiding rework and replacements
- Adaptability to various storage durations and environmental conditions.
Challenges in implementation. Despite the benefits, challenges exist and can include:
- High upfront investment in advanced preservation systems
- Training requirements for personnel unfamiliar with protocols
- Occasional reliance on third-party service providers
- Need for precise inventory classification to manage discipline-based traceability.
Technology selection criteria. Choosing appropriate preservation technology depends on:
- Material criticality to the project
- Expected storage duration
- Environmental exposure intensity
- Comparative analysis of preservation cost vs. potential replacement costs.
Process performance metrics. Implementing this process has demonstrated measurable benefits:
- More than 60% reduction in corrosion-based non-conformance reports (NCRs)
- Improved material tracking using digital tagging
- Increased recovery and reuse of surplus materials
- Streamlined warehouse operations via structured classification.
Commercial impact. Preservation-driven material management leads to:
- Lower lifecycle costs and increased asset reliability
- Reduced procurement due to fewer replacements
- Improved vendor relationships through compliance
- Enhanced surplus inventory turnover and inter-project transfers.
Takeaways. Effective materials storage and preservation are essential to maintaining the integrity and availability of industrial assets, especially in challenging environments. This article demonstrates how a proactive, technologically advanced approach can safeguard material condition, reduce project risks and deliver long-term cost benefits. By integrating smart systems, disciplined processes and tailored storage solutions, project teams can ensure sustainable, high-quality material readiness throughout the lifecycle of any large-scale development.
Long-term storage in high-humidity environments, such as coastal or desert regions in the Middle East, requires additional layers of protection—including dehumidified storage shelters and controlled ventilation systems—to limit condensation and airborne salt deposition (ISO 9223, 2012). For electrical and instrumentation equipment, maintaining proper IP-rated sealing and avoiding UV degradation of polymer components is essential to prevent premature failure (IEC 60068-2-5, 2018).
A structured preservation inspection regime, typically implemented using a weekly or monthly checklist, ensures early identification of coating failures, mechanical damage, water ingress or missing protective materials. This systematic approach aligns with best practices recommended in major capital project execution frameworks (API RP 686, 2017) and supports extended storage periods without compromising equipment integrity.
REFERENCES
American Petroleum Institute (API) 571, “Damage mechanisms affecting fixed equipment in the refining industry,” 2011.
International Organization for Standardization (ISO) 12944-2, “Paints and varnishes—Corrosion protection of steel structures by protective paint systems,” 2017.
The Association of Materials Protection and Performance, (AMPP, formerly NACE) SP0208, “Managing atmospheric corrosion for storage and handling of materials,” 2021.
International Organization for Standardization (ISO) 9223, “Corrosion of metals and alloys—Corrosivity of atmospheres,” 2012.
International Electrotechnical Commission (IEC) 60068-2-5, “Environmental testing—Solar radiation,” 2018.
American Petroleum Institute (API) RP 686, “Recommended practice for machinery installation and installation design,” 2017.
“OEM Storage & Handling Manual,” various manufacturers, 2020.
The Author
Jeyhun Nasirov is a highly experienced professional with more than 22 yrs of progressive leadership in the oil and gas industry, specializing in PSCM, materials management, preservation, logistics, and supply chain operations. He has a strong record of accomplishment of optimizing material lifecycle processes, enhancing preservation strategies and ensuring the integrity and availability of critical equipment and spare parts across complex offshore and onshore projects. Nasirov has played key roles in major greenfield and brownfield developments around the world. His expertise includes the implementation of preservation programs, QA/QC inspection of incoming materials, and warehouse and laydown yard management aligned with international standards and project-specific requirements. Throughout his career, he has consistently driven improvements in materials management control, inventory accuracy, and preservation compliance, significantly reducing material degradation risks and supporting construction, commissioning, and operations readiness. Nasirov is also skilled in developing and reviewing procedures, technical documentation and flowcharts related to preservation and material workflows, ensuring alignment with HSE and risk management principles. He has a deep understanding of the challenges of maintaining equipment integrity across long-term projects and is committed to continuous improvement and reliability in materials and preservation management systems.
Comments