Cortec MCI® Corshield

Introduction

Cortec MCI® CorShield is a revolutionary corrosion inhibitor that utilises Migrating Corrosion Inhibitor (MCI) technology and advanced corrosion inhibitors to provide comprehensive protection against the ravages of corrosion. This innovative product is designed for effective corrosion control, safeguarding a wide range of materials, from steel and concrete to aluminium and copper, ensuring the longevity and integrity of critical infrastructure, industrial equipment, and valuable assets.

Product Specifications (.PDF)

Cortec MCI® CorShield

The Importance of Corrosion Protection

Corrosion is a ubiquitous problem that affects industries and communities worldwide. It is estimated that the global cost of corrosion exceeds $2.5 trillion annually, a staggering figure that underscores the urgent need for effective corrosion mitigation strategies. Beyond the financial burden, uncontrolled corrosion can also lead to structural failures, environmental damage, and even loss of life in extreme cases. Effective corrosion management is essential to address these challenges comprehensively.

Understanding Corrosion and Its Impact

Corrosion is a natural electrochemical corrosion process that occurs when metals and other materials interact with their surrounding environment. This interaction can be accelerated by factors such as moisture, chemicals, and environmental pollutants, leading to the gradual deterioration of the affected materials.

The Pervasive Nature of Corrosion

Corrosion can manifest in a wide range of industries and applications, from the construction of buildings and bridges to the maintenance of industrial machinery and marine vessels. It is a persistent challenge that affects everything from the steel reinforcements in concrete to the critical components of power generation equipment, presenting significant corrosion challenges across various sectors.

The Consequences of Unchecked Corrosion

Corrosion damage can have severe consequences, both in terms of financial and safety implications. Structural failures, equipment breakdowns, and the need for frequent repairs and replacements can all contribute to significant economic losses. Moreover, the potential for catastrophic incidents, such as pipeline ruptures or bridge collapses, underscores the importance of proactive corrosion prevention measures.

The Science Behind Cortec MCI® CorShield

Cortec MCI® CorShield is a cutting-edge product that harnesses the power of corrosion inhibitors and Migrating Corrosion Inhibitor (MCI) technology. This innovative approach allows the inhibitor to migrate through porous materials, such as concrete and masonry, to reach and protect the reinforcing steel or other embedded metals.

Cortec MCI® CorShield has also been tested for reinforcing steel bond strength in accordance with ASTM A944-99, ensuring excellent performance in both storage and embedding applications. The product’s performance meets the standards outlined in ASTM A944-99, confirming its compliance and effectiveness.

The Migrating Corrosion Inhibitor (MCI) Corrosion Inhibitors Technology

The MCI technology employed in Cortec MCI® CorShield works by forming a protective molecular layer on the surface of the metal, creating a barrier that prevents the electrochemical reactions that lead to corrosion. This self-replenishing layer, known for its corrosion resistance, is able to migrate to areas that are difficult to access, ensuring comprehensive protection even in hard-to-reach locations.

How Cortec MCI® CorShield Works

Cortec MCI® CorShield is designed to be applied to the surface of the material, where it can then penetrate and migrate to the reinforcing steel or other embedded metals. Once in place, the inhibitor forms a protective barrier that neutralises the corrosive elements, preventing the onset of rust and other forms of deterioration. Additionally, Cortec MCI® CorShield does not need to be removed prior to embedding in concrete, providing effective corrosion prevention.

Applications of Cortec MCI® CorShield

Cortec MCI® CorShield is a versatile corrosion protection product that can be utilised in a wide range of industries and applications, from construction and infrastructure to marine environments and industrial settings.

Construction and Infrastructure Protection

In the construction industry, Cortec MCI® CorShield is widely used to protect reinforcing metals in reinforced concrete structures, such as bridges, buildings, and parking garages. It is also suitable for short to medium-term unsheltered outdoor protection, providing effective corrosion resistance in various environments. By safeguarding the steel reinforcements, the product helps to extend the lifespan of these critical assets, reducing the need for costly repairs and replacements.

Marine and Coastal Applications

Cortec MCI® CorShield is also highly effective in marine environments, where corrosion control is crucial due to the combination of saltwater, humidity, and harsh weather conditions that can accelerate the corrosion process. The product is commonly used to protect ships, offshore platforms, and coastal infrastructure, ensuring their long-term integrity and performance.

Industrial Corrosion Prevention

Beyond the construction and marine sectors, Cortec MCI® CorShield, known for its effective corrosion inhibitors, finds applications in a variety of industrial settings, including power generation, manufacturing, and chemical processing. By protecting the critical components and equipment in these environments, the product helps to minimise downtime, reduce maintenance costs, and improve overall operational efficiency.

Benefits of Using Cortec MCI® CorShield

Cortec MCI® CorShield offers a comprehensive suite of benefits in corrosion protection, making it a compelling choice for organisations seeking to safeguard their assets and infrastructure.

Long-term Protection

One of the key advantages of Cortec MCI® CorShield is its corrosion resistance, providing long-lasting protection against corrosion. The product initially cures to a soft, non-tacky film but eventually hardens, ensuring long-lasting durability and effectiveness. The self-replenishing nature of the MCI technology ensures that the protective barrier remains effective for extended periods, reducing the need for frequent reapplication or replacement. Additionally, Cortec MCI® CorShield provides long-term indoor protection.

Cost-effectiveness

By extending the lifespan of critical assets and infrastructure through effective corrosion control, Cortec MCI® CorShield can help organisations save significantly on maintenance and repair costs. The product’s ease of application and low-maintenance requirements further contribute to its cost-effectiveness.

Environmental Considerations

Cortec MCI® CorShield is formulated with corrosion inhibitors and environmental sustainability in mind. The product is non-toxic, biodegradable, and does not contain volatile organic compounds (VOCs), making it a responsible choice for organisations committed to reducing their environmental impact.

Ease of Application

Applying Cortec MCI® CorShield for corrosion protection is an excellent choice due to its straightforward process, requiring minimal surface preparation and specialised equipment. This simplicity of application allows for efficient deployment, reducing downtime and disruption to ongoing operations. Cortec MCI® CorShield forms a soft non-tacky film, providing effective corrosion resistance for reinforcing metals both in storage and when embedded in concrete.

Case Studies and Success Stories

Cortec MCI® CorShield has been successfully deployed in a wide range of projects, showcasing its effectiveness in corrosion control and protecting critical infrastructure and assets.

The Restoration of the Mackinac Bridge

One notable case study involves the restoration of the Mackinac Bridge in Michigan, USA, which had been plagued by corrosion damage for years. The bridge, which spans the Straits of Mackinac, required frequent and costly repairs. By applying Cortec MCI® CorShield to the bridge’s concrete and steel components, the project team was able to significantly extend the structure’s lifespan, saving millions in maintenance costs.

Protecting Offshore Oil Platforms

In the offshore oil and gas industry, Cortec MCI® CorShield has been instrumental in safeguarding critical infrastructure, such as offshore oil platforms, due to its exceptional corrosion resistance. By applying the product to the platforms’ steel components, operators have been able to minimise the impact of corrosion, reducing the need for costly repairs and ensuring the continued safe operation of these vital assets.

Comparison with Other Corrosion Protection Methods

Corrosion inhibitors, while traditional corrosion protection methods such as coatings and cathodic protection have their merits, Cortec MCI® CorShield offers several distinct advantages that set it apart.

Advantages of Cortec MCI® CorShield

The MCI technology employed in Cortec MCI® CorShield allows for deeper penetration and more comprehensive protection compared to surface-applied coatings. Additionally, the product’s ability to self-replenish and migrate to hard-to-reach areas makes it a more effective and long-lasting solution than traditional methods. Cortec MCI® CorShield also offers excellent corrosion resistance.

Limitations of Traditional Corrosion Protection

Corrosion control methods, such as traditional paints and sealants, can be labor-intensive to apply and often require regular maintenance and reapplication. Moreover, these methods may not be effective in protecting embedded metals or addressing corrosion in hard-to-access areas, leaving critical components vulnerable to deterioration.

Best Practices for Applying Cortec MCI® CorShield

To ensure the optimal performance and corrosion protection of Cortec MCI® CorShield, it is essential to follow best practices for surface preparation and application.

Surface Preparation

Proper surface preparation, including the use of corrosion inhibitors, is key to the success of any corrosion protection system. Before applying Cortec MCI® CorShield, the surface should be clean, dry, and free of any contaminants or existing coatings that could interfere with the product’s ability to penetrate and migrate.

Application Techniques

Cortec MCI® CorShield can be easily applied using a variety of corrosion control methods, including spraying, brushing, or dipping. The specific application technique will depend on the size and complexity of the project, as well as the accessibility of the target surfaces. Additionally, Cortec MCI® CorShield is water-based, making it environmentally friendly and easy to use.

Safety Considerations

As with any construction or industrial product, it is important to follow all safety protocols and guidelines, including corrosion protection, when working with Cortec MCI® CorShield. This includes the use of appropriate personal protective equipment (PPE) and adherence to any applicable environmental regulations.

Maintenance and Long-term Care

Maintaining the effectiveness and corrosion resistance of Cortec MCI® CorShield over the long term is essential to ensuring the continued protection of critical assets and infrastructure.

Inspection Schedules

Corrosion control through regular inspections of the treated surfaces can help identify any areas that may require additional application or maintenance. Establishing a consistent inspection schedule is crucial to the longevity of the corrosion protection system.

Reapplication Guidelines

In some cases, reapplication of Cortec MCI® CorShield, which includes corrosion inhibitors, may be necessary to replenish the protective barrier and maintain optimal performance. The product’s manufacturer can provide guidance on the appropriate reapplication intervals based on the specific application and environmental conditions. Results confirmed the effectiveness of Cortec MCI® CorShield.

Future Developments in Corrosion Protection

As the global demand for effective corrosion protection solutions with enhanced corrosion resistance continues to grow, Cortec Corporation is committed to driving innovation and advancing the capabilities of its MCI technology.

Ongoing Research and Development

Cortec’s team of researchers and engineers are continuously exploring new ways to enhance the performance and versatility of Cortec MCI® CorShield, including the use of corrosion inhibitors. This includes investigating the potential for incorporating additional corrosion-inhibiting compounds, as well as exploring the application of the technology in emerging industries and applications.

Potential New Applications

As the world becomes increasingly interconnected and reliant on critical infrastructure, the need for robust corrosion control and protection solutions will only continue to grow. Cortec MCI® CorShield is well-positioned to address these evolving challenges, with the potential for new applications in areas such as renewable energy, transportation, and smart city development.

Conclusion

Cortec MCI® CorShield represents a game-changing advancement in the field of corrosion protection. By harnessing the power of Migrating Corrosion Inhibitor (MCI) technology, this innovative product offers comprehensive, long-lasting protection for a wide range of materials and applications.