Concrete is the world’s most widely used construction material—and also one of its greatest contributors to greenhouse gas. The root cause is cement production, which alone accounts for approximately 8% of global CO2 emissions. At this rate, successful strategies to lower concrete carbon output are especially significant. MCI® Technology is one of those simple but powerful strategies that helps the construction industry take a pivotal step toward a smaller carbon footprint.

Using MCI® Technology to Extend Concrete Service Life

How can MCI® Technology help lower carbon emissions? The answer lies in its ability to enhance concrete durability. Ashraf Hasania, Cortec’s MCI® Technical Sales and Product Manager, who holds degrees in civil and environmental engineering, explains the common-sense logic: “Increasing the service life of concrete structures using durable materials can reduce the need for demolishing old structures and building new ones. It can also lead to less need for major repairs. This lowers the carbon footprint of concrete structures and promotes sustainable practices.”

The way MCI® helps concrete structures last longer is by attacking one of the biggest enemies to concrete durability: corrosion of metal reinforcement. As rebar rusts due to carbonation, chloride exposure, and other environmental conditions, it expands and puts pressure on the concrete cover. This leads to cracking, spalling, and a vicious cycle of further exposure to corrosives and additional damage. Based on salts of amine carboxylates, MCI® Technology interrupts this process by migrating through the concrete pores to form a protective molecular layer on the rebar surface to delay and reduce corrosion. Service life models and lab and field studies have shown that MCI® can increase service life by three to four times. This translates into a comparable reduction in concrete’s carbon footprint.

When Can MCI® Be Used?

MCI® can be used at any stage in a structure’s lifecycle, but the best course to pursue is early treatment. “Sustainability in construction starts early in the process,” Hasania advises, “specifically in [the] design phase with careful selection of construction materials and concrete mixes.” Ideally, this includes the choice of MCI® concrete admixtures, which can be added to new concrete at the ready-mix plant or construction site. In contrast to calcium nitrite admixtures, MCI® admixtures have a low dose independent of chloride loading and do not negatively affect concrete mix properties. Existing structures can be treated with MCI® in the form of surface applied corrosion inhibitors (with or without water repellent) and repair mortars. Once applied, the MCI® molecules migrate through concrete pores to protect embedded rebar in sound concrete, or to even out corrosion potential and interrupt the problematic ring-anode/halo effect between new patch repairs and old concrete.

Other Sustainability Features

In addition to the main goal of helping concrete structures last longer, MCI® Technology offers other attractive features. For example, MCI®-2005 is a USDA Certified Biobased Product that contains 67% USDA certified biobased content. This use of renewable resources can help the project earn credits toward LEED certification while adding a more sustainable image to the structure and builder. Another attractive feature is the low toxicity of MCI®
products, many of which are certified to meet NSF Standard 61 for use in potable water structures.

Take a Step Toward Sustainable Construction

Considering the costs of construction and rebuilding alone, the benefits of extending concrete service life are clear. Add to it the ripple effect of decreasing the amount of new cement needed to repair and replace old structures, and the advantages of MCI® Technology go even further—helping the construction industry take major steps toward a smaller carbon footprint and a more sustainable future. Learn more about sustainability with Cortec® MCI® today: https://www.cortecmci.com/sustainability/

Keywords: concrete greenhouse gas emissions, sustainable construction, carbon footprint, CO2 emissions, concrete admixtures, Cortec, MCI, Migrating Corrosion Inhibitors, LEED certification, From Grey to Green

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Cortec® is pleased to announce its newest US patent for corrosion mitigation inside dry sprinkler systems!
While sprinklers are designed to fight fire, they themselves are at elevated risk for corrosion during their service life. Sprinkler corrosion problems are serious enough that National Fire Protection Agency (NFPA) standards for sprinklers call for corrosion risk evaluation at installation and periodic corrosion monitoring thereafter.* Cortec® has developed its patented sprinkler protection process as a simple, cost-effective solution to this problem.

A Practical Solution for Hard-to-Reach Void Spaces
Cortec’s patent covers a comprehensive system of protection that relies on Vapor phase Corrosion Inhibitors (VpCI® or VCI). This technology does not require the direct application of the corrosion inhibitors to every metal surface that needs protection. Rather, the vapor pressure of the corrosion inhibitors, delivered in powder or fluid form, will allow them to vaporize and disperse throughout the piping voids to access even difficult to reach spaces. Vapor phase Corrosion Inhibitors are attracted to metal surfaces, where they adsorb in a protective layer that interferes with the normal corrosion reaction fostered by the presence of oxygen and an electrolyte (e.g., residual water). These Vapor phase Corrosion Inhibitors are able to work in both the liquid phase and the vapor phase, allowing them to protect both wet and dry surfaces within the pipe.

Customizable Application Options
At least two methods of Vapor phase Corrosion Inhibitor application exist. One option is to use VpCI® fogging fluid to deliver the corrosion inhibitors immediately through the dry pipes. The other employs more gradual vapor dispersion by placing dry Vapor phase Corrosion Inhibitors in a housing connected to a pressurized air system that constantly circulates the protective vapors through the piping. This comprehensive system also includes efficacy monitoring methods such as corrosion coupons or sensors.

Benefits of Cortec® Patented Fire Sprinkler Protection
The primary benefit of Cortec’s fire sprinkler protection system is the mitigation of corrosion inside dry sprinkler pipes, helping the sprinklers last longer with less likelihood of failure. This significantly reduces the risk of leakage and clogging due to corrosion, in turn reducing the need for expensive and time-consuming repairs or pipe replacements. At the same time, the system is easy to install, requires little to no maintenance, and is economical and effective. These benefits are a huge advantage over traditional nitrogen purge, which can be expensive and difficult to maintain, and for which failure is not uncommon.

Another Example of Corrosion Technology Leadership
Cortec® strives to be a leader in developing practical solutions for corrosion needs in all industries. This fire sprinkler corrosion mitigation system is an excellent example of how Cortec® has provided a cost-effective, comprehensive, groundbreaking solution that departs from the status quo. It is an important technology to consider as an effective alternative to traditional protection processes that can easily fail or be difficult to maintain. Contact Cortec® to learn more about this exciting cost-effective sprinkler maintenance technology: https://www.cortecvci.com/contact-us/

Keywords: fire sprinkler corrosion, US patents, Cortec, corrosion mitigation, fire sprinklers, fire sprinkler protection, NFPA, National Fire Protection Agency, fire sprinkler maintenance, nitrogen purge alternatives

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Ranking among the most demanding bridges in the world—not only in terms of complexity of construction but also in a complex design—2,404-m (7,887.14-ft) long, Peljesac bridge is one of the most important and largest infrastructure project in Europe. Connecting Croatia’s Peljesac peninsula with the mainland to bypass a short stretch of the Bosnia and Herzegovina coastline started three years ago.

The project is worth 550 Million Euros, although most of the funding came from the European Union. ln order to meet the main criteria of quality design, such as stability, durability, economy, and integration into the environment, the inventive design proposed the construction of an extra dosed bridge with an integrated hybrid structure comprising of five central spans, each 285-m long, and six low pylons. Especially careful approach was taken to ensure durability for the extended lifespan of over 130 years.

Cortec’s MCI® 2018 was specified on this project during the design phase as a silane-based impregnation with a migrating inhibitor property to protect against the harmful effects of corrosion, thus extending the service life of the bridge. MCI® 2018 is a 100% silane-based concrete sealer containing migrating corrosion inhibitors that allows deep penetration into concrete and provides water repellence by chemically reacting with the cementitious
substrate. It seals surface pores, preventing the intrusion of chlorides, reduces carbonation, and protects from the ingress of wind-driven rain. Treated concrete surfaces are fully breathable and their natural moisture-vapor transmission is not affected. After repair of surface damage and cleaning of discolorations and other surface defects, the concrete surface of the pylons needed to be protected with a colorless silane coating to improve durability and increase the resistance of the concrete surface to long-term external influences. MCI®-2018 carries CE certification that indicates conformity with health, safety and environmental protection standards for products sold within the European Economic Area (EEA).

Application of MCI®-2018

A combination of AC coatings, cathodic protection of steel reinforcement in piles and pile heads, a concrete cover of 65– 85 mm stainless steel reinforcement and impregnation of all concrete surfaces with MCI®-2018 was chosen as the strategy to help the bridge achieve a 130-year service life. MCI®-2018 was applied on the entire substructure of the bridge. All concrete parts were coated with MCI®-2018 by a spraying technique. The work was performed in accordance with the project requirements and after surface preparation to full functionality. This included:

•  Access to pylons
•  Rehabilitation of the concrete surface of the pylons
•  Cleaning the concrete surface of the pylon (washing the pillars with water)
•  Impregnation of the concrete surface of the pylon with MCI®-2018.

MCI®-2018 contains time-proven Migrating Corrosion Inhibitors (MCI®). The silane component provides water repellency by chemically reacting with the cementitious substrate under proper application, decreasing the ingress of aggressive materials. The product penetrates deep into concrete, providing corrosion protection to reinforcing steel from existing water and chloride ions, or other contaminants. For the Peljesac bridge, continuous monitoring of the condition of the structure at one central place will be done during the construction phase and the exploitation phase to examine parameters of structural behavior, time, seismic activity, and structural durability. The designer of the bridge specified corrosion protection for all concrete segments in order to achieve a 130-year service life. After completion, the Peljesac Bridge will be ranked among the five largest and most attractive European bridges, constructed at the beginning of 21st century. This important new structure is connecting two separate parts of Croatia and bypassing border crossings at the short coastal strip near Neum in Bosnia and Herzegovina. 

Cortec’s CEO, Boris Miksic, Croatian-American businessman is proud that his patented technology was used on this historic project to connect two parts of his country. “Our MCI® technology is used in largest construction projects throughout the globe. I dedicated more than forty years of my life in
developing most advanced, environmentally safe corrosion protection solutions. Witnessing its application in my home country on this monumental bridge structure is truly a special feeling. Croatia has gone through some tough times, having to fight its independence in a war 30 years ago. Seeing it
prosper and develop in of the most desirable countries in Europe feels just about right and completion of Peljesac bridge is huge step forward for all of us.”

You can learn more about Migrating Corrosion Inhibitors (MCI®) here: https://www.cortecmci.com/

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October 27, 2021

For better or worse, winter is on its way to the Northern Hemisphere. It will soon be time to pull out warmer coats, hats, and boots and rev up the snowblower. On the jobsite, it will be time to face inconvenient winter construction delays, including grouting delays for PT (ing) projects as the temperatures drop too low. Since state and federal requirements typically call for corrosion inhibitor application if the waiting period is two weeks or longer, it is important to be ready with the best option on the market for PT grouting delays: MCI®-309!

Efficient Protection for PT Tendons
MCI®-309 from Cortec® Corporation is an extremely efficient method of protecting metals within an enclosed space. It comes in dry powder form and can easily be fogged through PT ducts with a low-pressure air hose before the duct is capped. Once applied, MCI®-309 vaporizes and travels throughout the PT duct, forming a protective molecular layer on the metal surfaces of the PT strands. This layer is self-replenishing if disturbed, as new protective vapor continuously redeposits on the surface. MCI®-309 is considered an ambiodic (mixed) inhibitor that protects at both the anode and cathode of a corrosion cell.

Why Choose MCI®-309?
There are several reasons MCI®-309 is ideal for PT grouting delays:
1) It reduces corrosion on PT tendons during a vulnerable pre-grouting period.
2) It is easy to apply. Little to no surface prep is required.
3) It protects hard to reach areas through vapor action.
4) It typically does not need to be flushed out prior to grouting, unlike oil-based inhibitors.

Another positive feature of MCI®-309 is that it does not contain silicates, phosphates, nitrites, or heavy metals. It does not increase the risk of hydrogen embrittlement for high tensile strength steel. Neither does it affect physical properties of concrete and grout (set time, strengths, etc.). Testing performed by American Engineering and Testing, Inc., confirmed that MCI®-309 does not affect strand pull-out strength compared to a control. Furthermore, an approximately year long test at the Pennsylvania State University Grouting Laboratory showed a positive reduction in corrosion on prestressing strands placed in PVC pipes containing a saltwater solution and treated with MCI®-309 (a worst-case scenario compared to dry conditions recommended for MCI®-309 PT duct application).

Recent Examples of MCI®-309
MCI®-309 has been used for winter grouting delays in recent bridge projects of note. The St. Croix River Crossing was a monumental bridge opened in 2017 to alleviate constricted traffic flow between Minnesota and Wisconsin. Due to its unique location in the St. Croix National Scenic Riverway, the bridge was made with a special extradosed design (combination box girder and cable stay bridge) to minimize the visual impact on the landscape. The pre-cast boxlike segments were connected by PT cables, which required corrosion protection during grouting delays in the notoriously harsh winter environment. MCI®-309 was chosen for the job.

MCI®-309 was also used during construction of the Samuel De Champlain Bridge, the world’s widest twoplane cable stay bridge and one of the largest infrastructure projects in North America to date. MCI®-309 was chosen for winter PT grouting delays on the main structure and has seen continued use in the Réseau Express Métropolitain light rail system segment of the project.

Do the Possible!
While it is impossible to stop the inevitable approach of winter and grouting delays, it is possible to minimize the negative effects by selecting an efficient method of corrosion protection. Contact Cortec® today to discuss MCI®-309 for easy PT strand protection in your next construction project:
https://www.cortecmci.com/contact-us/

Learn more about MCI®-309 here: https://www.cortecmci.com/product/mci-309/

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