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What Materials Keep Critical Industrial Infrastructure Reliable?

Critical infrastructure relies on materials chosen for specific pressures, loads and exposures—and on protection, inspection and maintenance that keep degradation manageable.
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No single material keeps critical infrastructure from failing. Reliability depends on matching materials to pressure, loads, temperature, chemicals, moisture, radiation and electrical demands—and on whether the asset can be inspected, maintained and repaired over time. In pipelines and long-lived power plants, steel, concrete, polymers and composites each have important roles and distinct failure risks.

Which materials are used in critical infrastructure?

Steel, concrete, polymers and polymer composites are common material classes across infrastructure-related manufacturing, construction and transportation, according to the U.S. National Institute of Standards and Technology (NIST). They are not interchangeable: engineers select materials for the job and the conditions around them, then plan how to protect and monitor them.

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Material family Typical infrastructure roles Key considerations
Steel and other metals Structural members, pressure pipelines, equipment and reactor components Steel can support high-pressure pipeline service, but corrosion protection and monitoring are important. Risks such as bare, uncoated steel and older iron alloys or joints apply to particular assets, not all modern metal systems.
Concrete and cementitious materials Civil structures, foundations and power-plant structures Long-term service life can be difficult to predict. Concrete aging is a distinct area of work in the U.S. Department of Energy’s nuclear materials pathway.
Polymers and polymer composites Plastic distribution pipe, cable insulation, coatings, adhesives, seals and composite components Some polymers resist corrosion, but their strength and performance depend on the application and formulation. NIST notes that laboratory performance may differ from real-world performance as exposure conditions and degradation rates vary.
Electrical cable insulation Insulation for cables in power plants and other electrical systems Cross-linked polyethylene (XLPE) and ethylene propylene rubber (EPR) can age under heat and radiation; moisture can also change dielectric performance. Monitoring and material-specific aging studies help assess condition.

Materials also appear in combinations. NIST notes that coatings help prevent corrosion and structural adhesives can be important in repairing existing infrastructure. A material’s performance in a laboratory test alone does not establish how long a component will last in a particular operating environment.

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How does material choice affect pipelines?

Pipeline selection makes the trade-offs especially clear. The U.S. Government Accountability Office (GAO), drawing on interviews and analysis, reports that steel can handle higher operating pressures than plastics, but it needs corrosion protection and costs more than plastic pipe. Plastics and emerging composites generally resist corrosion, but do not have the strength for high-pressure applications described in GAO’s analysis.

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That comparison does not mean one material is universally safer or more economical. The appropriate choice depends on required pressure and strength, the environment, installation constraints, inspection access and long-term maintenance. A lower purchase price does not by itself establish lower lifecycle cost.

Age and material history matter, too. PHMSA records show that cast or wrought iron was used in gas distribution through the 1940s, steel use became extensive beginning in the 1950s, and plastic became prevalent in distribution from the early 1970s. The agency flags age and bare steel without protective coating as risk indicators. It also notes historical brittle failures in some plastic pipes manufactured in the early 1970s, while saying modern plastic pipe is manufactured to resist brittle failure. These historical observations should not be generalized to all current steel or plastic pipe.

What does corrosion do to infrastructure?

Corrosion is an electrochemical process that oxidizes steel and removes metal. On pipelines, that loss can thin the pipe wall and lead to leaks or, less commonly, rupture if it is not mitigated. PHMSA describes corrosion as a time-dependent threat: it can grow or worsen when left unmanaged.

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External corrosion can result from exposure to soil, air or water. Internal corrosion may follow exposure to transported products or contaminants such as water, hydrogen sulfide or carbon dioxide. Other pipeline degradation mechanisms include stress corrosion cracking, microbiologically influenced corrosion, stray-current interference and selective seam corrosion.

PHMSA’s reported incident figures are historical and apply to different pipeline categories and periods:

Pipeline category Reported incidents attributed to corrosion Period and source
Gas transmission, gas gathering and hazardous-liquid pipelines About 17% 2013–2017; PHMSA
Natural-gas distribution pipelines About 1% 2013–2017; PHMSA
Pipeline incidents overall, on average About 18% 1998–2017; PHMSA

These figures are not current incident rates and should not be treated as estimates for every pipeline or for infrastructure in general. The categories and time windows differ, so the percentages are not directly interchangeable.

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How are pipelines protected from corrosion?

Protection is a system rather than a one-time material choice. PHMSA identifies material selection, protective coatings, cathodic protection, corrosion inhibitors and line cleaning as prevention methods. Operators also use inspection, testing and assessment to identify problems and plan timely repairs or replacement.

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  • Coatings provide a barrier between steel and the surrounding environment, but coatings can degrade and need attention.
  • Cathodic protection helps control corrosion on buried or submerged metal, but requires ongoing maintenance and electricity across long distances.
  • Inhibitors and cleaning can help address corrosion risks associated with pipeline contents and internal conditions.
  • Inspection and integrity management help operators assess condition and decide when repair or replacement is needed.

Because protective measures have their own upkeep requirements, an engineering decision should account for the whole operating and maintenance system—not only the pipe material or its initial cost.

What materials age in long-lived power plants?

In nuclear power plants, aging management extends beyond reactor metals. DOE organizes its materials-aging work around reactor metals, concrete, cables, buried piping and mitigation. The condition of electrical cable insulation is particularly important because heat, radiation and moisture can affect its performance, and aging assumptions may not fit every insulation formulation or operating history.

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A 2026 review by Pacific Northwest National Laboratory (PNNL) discusses XLPE and EPR insulation, thermal and radiation aging, and moisture-related dielectric changes. Its authors identify monitoring, targeted studies of material aging and predictive simulation as ways to improve confidence in assessments. They describe a testing-based approach as promising for future cable aging management in light-water reactors; this is not a guarantee that every cable’s condition can be inferred from a single test or model.

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Why do supply risks matter in material decisions?

Infrastructure materials must be available not just for initial construction but also for maintenance, replacement and upgrades. DOE’s 2023 assessment considered 38 materials used by eight major technologies and evaluated 23 materials for criticality after screening. It assessed criticality using two factors: importance to the energy sector and supply risk.

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This makes supply availability another design consideration alongside strength, corrosion resistance, exposure conditions, inspection access and maintenance needs. The assessment is an energy-sector analysis, not a complete inventory of supply risks for every type of infrastructure.

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How should infrastructure materials be compared?

A useful comparison starts with the asset’s operating conditions and continues through its expected service life. For a pipeline, that means checking pressure and strength requirements alongside corrosion controls. For a power plant, it includes the materials’ exposure to heat, radiation or moisture and whether inspection methods can provide meaningful information about aging.

  • Operating demands: What pressure, structural load, temperature or electrical function must the component handle?
  • Exposure: Will it contact soil, water, chemicals, transported products, radiation or other damaging conditions?
  • Protection and maintenance: What coatings, monitoring, cleaning, testing or repairs are needed, and can they be sustained?
  • Inspection and repair access: Can operators detect degradation early and reach the component when work is required?
  • Lifecycle and uncertainty: What is known about long-term performance in the actual environment, and what remains difficult to predict?
  • Supply: Are the materials needed for construction, maintenance or replacement exposed to meaningful supply risk?

For these reasons, reliability comes from matching materials to their duties and managing their degradation—not from choosing a single supposedly strongest material.

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