Category: News Alert

June 2, 2021

There are always plenty of reasons and opportunities to remove gas and oil stains from concrete. For instance, concrete driveways, garages, and bridges are often the victims of vehicle gas and oil leaks. In addition to dealing with the bad appearance, contractors must make sure concrete surfaces are thoroughly clean and free of all contaminants before applying a waterproofing membrane. A recent test demonstrates MCI®-2061 in action under the microscope and builds confidence in this “green” cleaning product for concrete oil stains.

How Green Cleaners Work

MCI®-2061 works by a dual mechanism. Biodegradable surfactants disperse oil droplets and perform the initial cleaning. If properly applied, MCI®-2061 spores then germinate into active microorganisms and perform secondary cleaning by actually digesting hydrocarbons. This activity increases as time goes on. In fact, spores that remain in the substrate after rinsing may continue to degrade residual hydrocarbons that were not removed in the initial cleaning process.

MCI®-2061 Efficacy Demonstration

To demonstrate surfactants and microorganisms at work in MCI®-2061, the product is typically applied to a small area, and before-and-after results are compared to validate the cleaning efficacy. However, the easiest and fastest way to show decomposition of organic matter is to measure COD (chemical oxygen demand) reduction in a sample. To demonstrate this, three samples of MCI®-2061 were prepared for testing of biodiesel digestion. All samples were diluted with water at a ratio of 1:100 and were also examined under the microscope.

Sample #1 (control) – MCI®-2061 without bacteria or biodiesel
Sample #2 (control) – MCI®-2061 without bacteria but with biodiesel added
Sample #3 – MCI®-2061 with bacteria and biodiesel

COD, a measure of contaminants in the solution, dropped by 36.12% over this timeframe, while COD increased slightly in the two control samples not seeded with bacteria.

For a PDF version please click here.

The fertilizer industry would be one of the finalists if awards were given to the most corrosive industries. Although fertilizer makes a huge difference for agricultural productivity, it has a negative effect when it comes to vehicles and structures, sometimes eating through eight inches (20 cm) of concrete in just five years and deteriorating fertilizer spreader trucks in a few short months. Cortec® is looking at ways to help the fertilizer industry pull out of this vicious cycle of equipment degradation through the strategic use of Cortec® Coatings.

Fighting an Uphill Battle Against Corrosion

Without special protection, trucks that spread fertilizer are destined to rust. Fertilizer blends made of ammonia nitrate, nitrogen, phosphate, and potash enrich the soil but take their toll on the trucks that spread them on fields for just a few summer months. In fact, fertilizers tend to be more corrosive than deicing salts used in harsh winter environments. Fertilizer corrodes practically any metal it touches: dump truck beds, brace bars, spreader pans, lines and pumps under the truck, and air intake filters. The economic cost is that fertilizer trucks often have to be ripped down to the frame and rebuilt every two years—a high price tag for these expensive assets.

Implementing a Preventative Maintenance Plan

In the past, fertilizer truck owners have taken it as a matter of course that their equipment will rust and need to be rebuilt or replaced every few years. However, for some, a new realization is dawning that it does not have to be this way. Cortec® Coatings offer an excellent preventative maintenance plan that can extend the service life of fertilizer equipment. A small annual investment can have a potentially huge savings that could have benefits for years to come.

VpCI®-391 is a water-based removable coating that dries to a clear non-tacky film. It is great for spraying over painted surfaces without significantly changing the appearance of the equipment. It has a low VOC of 0.4 lbs/gal (48 g/L) and is easy to work with. Although it is considered a removable coating that can be washed off relatively easily with an alkaline cleaner, users often leave it on for ongoing corrosion protection because it is so inconspicuous. VpCI®-391 can be sprayed over both painted and unpainted metal surfaces on fertilizer trucks. For the underbody, a tough coating of VpCI®-398 Undercoat is recommended. VpCI®-398 dries to a soft, non-brittle black film that helps protect against cracking and coating damage from the impact of gravel or debris.

Revolutionary Solution for Front-End Loaders

Over 10 years ago, a barge loading company discovered the benefits of VpCI®-391 when it started applying this removable coating for annual preventative maintenance on front-end loaders used to move large volumes of deicing salts and/or fertilizers at ports. The harsh exposure typically made the loaders look 10 years old in just one year, requiring replacement every two or three years. The equipment started lasting much longer when the company started applying VpCI®-391 over the top, bottom, front, and back—all accessible metal—of the loaders. The company loved the coating and has continued to apply it as part of annual preventative maintenance for many years.

Fight Corrosion, Cut Costs

Fertilizer is a formidable but not impossible corrosion challenge to tackle. With simple preventative fleet maintenance using Cortec® Coatings, fertilizer companies can help their trucks and equipment last longer, saving huge costs with just a small annual investment. Contact Cortec® to learn more about developing a solution for your fertilizer equipment: https://www.cortecvci.com/contact-us/

Keywords: fight corrosion on fertilizer trucks, Cortec Coatings, fertilizer corrosion, preventative maintenance, extend service life, underbody coating, low VOC coating, fleet maintenance, Cortec, most corrosive industries

For a PDF version please click here.

August 17, 2022

Water and wastewater treatment facilities are part of the critical infrastructure that makes our lives better on a daily basis, but often does not get a second thought. Nevertheless, the longevity of these structures not only impacts our municipal budgets but can also affect our long-term carbon footprint, since concrete production is among the largest contributors to anthropogenic greenhouse gas emissions. Specifying Migrating Corrosion Inhibitors (MCI®) into the concrete structural design can promote a more sustainable future by reducing the need for early replacement of high carbon-cost, energy-intensive reinforced concrete in drinking water reservoirs, desalination plants, and wastewater facilities.

Drinking Water Reservoirs and Pumping Systems

The first of these environments is the least corrosive. However, concrete drinking water reservoirs, piping, or pumping stations can still experience challenges from high exposure to moisture or due to long-term carbonation. One water consortium in Europe knew from experience that their structures were prone to corrosion and took care to minimize future damage by incorporating MCI®-2005 admixture into a new reservoir and water regulating tank. This concrete admixture is certified to meet ANSI/NSF Standard 61 for use in large potable water structures and so was a great corrosion inhibiting alternative to calcium nitrites, which are not certified in this way. Another product certified to meet NSF Standard 61 is MCI®-2020, which can be used for maintenance and corrosion mitigation on existing drinking water structures where carbonation may have set in.

Desalination Plants

Desalination plants are much more corrosive due to inevitable exposure to saltwater and brine. This is a built-in recipe for corrosion disaster. It is therefore imperative for desalination engineers to specify corrosion protection into the system in order to fight this ever-present challenge. The Sorek Desalination Plant is a great example of how and where MCI® can be used to fight desalination plant corrosion. MCI®-2005 was added along with a waterproofing admixture to both filtration bins and prefab concrete pipe segments. MCI®-2005 was also admixed into brine water reservoirs, where water likely reaches its peak chloride concentration. Furthermore, MCI®-2020 surface applied corrosion inhibitor (SACI) was used to compensate for low concrete cover in some desalinated water reservoirs. At least seven years later, no corrosion related issues had been reported.

Wastewater Treatment Plants and Pumping Stations

Last, but not least, wastewater treatment plants are among the most corrosive of these environments due to the high concentration of H2S and other contaminants present in the waste materials. Clarifiers, aeration tanks, secondary treatment bins, walkways, and pumping stations are often made of reinforced concrete and exposed to corrosive chemicals. The best plan is to specify MCI®-2005 or MCI®-2005 NS as a corrosion inhibiting admixture when the tanks or facilities are first poured. MCI®-2026 can be topically applied at any stage as a tough barrier in tanks or high traffic areas because of its outstanding resistance to chemicals and abrasion.

Promote Economic and Environmental Sustainability The presence of water, chlorides, and/or chemicals naturally adds to the risk of reinforced concrete corrosion. By taking advantage of a few key MCI® materials, facility designers and owners can raise the probability of extending service life for greater economic and environmental sustainability. Contact Cortec® for advice on your facility:
https://www.cortecmci.com/contact-us/

Keywords: sustainability, MCI, From Grey to Green, corrosion protection, concrete corrosion, concrete admixtures, carbon footprint, contributors to greenhouse gas emissions, wastewater treatment, extending service life