Rock wool is widely used in industrial piping systems for its excellent thermal insulation properties, but its porous structure allows water infiltration that can lead to corrosion under insulation (CUI) on metal pipe surfaces. In order to investigate how water infiltration into the insulated pipeline system creates a corrosive environment, a study on the flow behavior of fluids in porous media was conducted. Experiments were performed to measure the flow velocity and pressure drop along three principal directions—axial, radial, and circumferential. These measurements enabled the derivation of specific viscous and inertial resistance coefficients, which characterize the flow through the rock wool structure. The results indicated that the flow parameters of rock wool change over time and with repeated use, particularly after dry–wet cycles. The experimentally derived parameters were incorporated into both small-scale and large-scale three-dimensional computational fluid dynamics (CFD) models to simulate water transport within the rock wool insulation layer. Validation experiments performed on a real rock wool-insulated pipeline system confirmed the predictive accuracy of the CFD simulations in capturing water movement through the insulation. The large-scale model further analyzed the influence of inlet velocity, rock wool aging, and pipeline inclination on the development of environmental conditions for CUI.

The corrosion of steel reinforcements substantially degrades the longevity of reinforced concrete structures, particularly in marine settings. This investigation introduces a comprehensive model that simulates the processes involved in moisture and chloride ion transport, rebar corrosion, and the consequent cracking of concrete. The model reveals that the transport dynamics of chloride ions are primarily dictated by their penetration rates through the solution. The sensitivity of the steel to corrosion is a function of the concentrations of water and chloride ions, whereas the rate of corrosion predominantly depends on the availability of oxygen at the corrosive site. Oxygen diffusion is the rate-limiting step in the entire process of the electrochemical reactions of the rebar. And the peak corrosion rates are observed at the interface between the solution and the gas phase. The model calculates the stress and strain in the concrete resulting from volumetric expansion due to oxidization of the steel bars. By accurately reproducing the progression of corrosion-related damage, this model provides crucial insights for predicting the service life of offshore concrete structures and enhancing durability against aggressive environmental conditions.