Category: PRESS RELEASE

March 22, 2024

For more than four decades, VpCI^®-368 has been Cortec’s toughest removable coating for corrosion protection on metal parts. Today, it continues to be widely used in preservation and shipping applications. Anyone interested in taking advantage of this rust preventative standby for corrosive conditions can rise to the occasion by understanding what the removable coating is like and how it can be used.

Temporary Waxlike Coating

VpCI^®-368 is a solvent-based temporary waxlike coating that provides protection in harsh, unsheltered environments. It dries quickly to a slightly brown finish and protects at 2-3 mils (50-75 µm) DFT (dry film thickness). It can be removed with an alkaline cleaner such as VpCI®-414 or another flash rust inhibiting cleaner from the VpCI^®-41x Series.

Layup of Stationary Surfaces

VpCI^®-368 can be applied to new equipment in transit or use equipment that needs to be laid up, for applications such as rig stacking or other large preservation projects. Whereas VpCI^®– 369 is a go-to for corrosion protection on moving parts during layup, VpCI^®-368 is often the default coating for stationary surfaces.

Flange Face Protection

Another common use for VpCI^®-368 is protection of valve or pipe flanges in extreme environments. By applying a temporary coating, manufacturers or inventory managers can protect the sensitive flange face from corrosion that could otherwise delay startup especially in the case of gramophone raised faces, which may need to be resurfaced if damaged.

Protection of Wind Components

One manufacturer of wind turbine shafts, rings, and hubs has made use of VpCI^®-368 D to protect their most sensitive metal surfaces during shipping and storage. The components are exported around the world and stored indoors or outdoors for two to five years. Past corrosion problems inspired the manufacturer to explore and adopt a Cortec^® corrosion solution that consists of the following:

• Clean components with a dilution of VpCI^®-415 and dry.
• Apply VpCI^®-368 D by roller to designated areas.
• Shrink wrap components in VpCI^®-126 HP UV Shrink Film or MilCorr^® VpCI^® Shrink Film (these offer UV resistance and extra corrosion protection for potential outdoor storage).
• Send VpCI^®-414 along as part of the kit so the end user can remove VpCI^®-368 D when needed.

Rise to the Occasion with Removable Coatings

In industry, many occasions arise for the use of a temporary rust preventative coating. When the harshest conditions exist, a removable coating such as VpCI^®-368 is an excellent choice for interim corrosion protection during shipping and layup, whether for a one-time preservation project or as part of routine shipping procedures. Contact Cortec^® to learn more about this and other removable coating options.

Keywords: Cortec removable coating, corrosive conditions, coating for corrosive conditions, waxlike coating, alternative to Cosmoline, corrosion protection, equipment layup, offshore layup, corrosion solution, shipping solutions

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Water repellents play an important role in concrete maintenance and corrosion protection by blocking out certain corrosives and keeping in Migrating Corrosion Inhibitors. Because water repellents are sometimes applied alone or in conjunction with other concrete surface treatments, Cortec^® has recently expanded its MCI^® portfolio to include MCI^®-2018 X, a 100% silane penetrating water repellent for concrete surfaces.

Water Repellent for Concrete

MCI^®-2018 X is MCI^®-2018 minus the Migrating Corrosion Inhibitors. Its primary function is to line concrete substrate pores with a hydrophobic layer that reduces the ingress of moisture, chlorides, and carbonation, thus extending the service life of the structure. If applied after a penetrating SACI (surface applied corrosion inhibitor), MCI^®-2018 X prolongs the protection period of the corrosion inhibitor. MCI^®-2018 X allows the surface to stay fully breathable and retain its original appearance.

Solving the SACI/Water Repellent Dilemma

In the past, MCI^® customers sometimes faced the dilemma of whether to apply MCI^®-2020 to get the highest concentration of MCI^® SACIs on the market or whether to take advantage of the benefits of the two-in-one MCI^®– 2018 water repellent with a lower concentration of Migrating Corrosion Inhibitors. While an even better option was to apply MCI^®-2018 on top of MCI^®-2020 for maximum protection, this could easily fall outside the project scope and budget. Now, if MCI^® users want the high concentration of MCI^®-2020 with only a water repellent on top, they can order MCI^®-2018 X along with MCI^®-2020 and be done with their search for a supplementary product.

When and Where to Use MCI®-2018 X

MCI^®-2018 X can be used for routine maintenance every 5-10 years or used as part of the finishing touches to a concrete repair. Because it does not change the substrate’s appearance, MCI^®-2018 X is a great option for historical restorations. As a silane water repellent, MCI^®-2018 X has smaller molecules and adsorbs better into concrete than siloxane blends that can cause puddling, making MCI^®-2018 X better for areas where slippage is a concern (e.g., steps, parking garage floors, and bridge decks). Other target applications include commercial buildings, tunnels, jetties/piers, and offshore oil platforms (non-submerged applications). MCI®-2018 X is also a good option for contractors who do not want to or need to pay extra for a corrosion inhibitor because their only purpose is to repel water on brick or stone surfaces that do not have underlying metal reinforcement.

How to Apply MCI^®-2018 X

MCI^®-2018 X can be applied by spray, roll, or brush to a clean concrete surface with a CSP 1-3 surface profile (per ICRI guidelines). As noted, MCI^®-2020 may be applied first for additional corrosion protection. After a repair, fresh concrete should be allowed to cure 28 days before application of MCI^®-2018 X. A dry surface is preferred for maximum penetration, although the second coat of MCI^®-2018 X should be applied wet-on-wet over the first coat for best results.

A Customized Approach to Concrete Protection

The addition of MCI^®-2018 X to the Cortec^® portfolio helps contractors take a more customized approach to their selection of MCI^® concrete surface treatments by adding a stand-alone water repellent to their concrete maintenance/repair kit. Used alone or in conjunction with MCI^®-2020, MCI^®-2018 X may be the logical choice to meet certain project protection and budget parameters. Contact Cortec^® if you need more help deciding which concrete surface treatment combination is best for your next job.

Keywords: concrete maintenance, concrete repair, Migrating Corrosion Inhibitors, From Grey to Green, concrete water repellent, surface applied corrosion inhibitors, Cortec MCI, historical restoration, concrete protection, concrete breathability 

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Years ago, the only way to remove paint from machine tools, workbenches, pipes, railcars and other surfaces was to use a fast-working chemical strippers containing methylene chloride. Unfortunately, due to their high toxicity, these strippers were restricted to outdoor use or well-ventilated areas.

This is because of their harsh fumes and high VOC content. Today, demand for chemical strippers using safer ingredients is growing rapidly and they are more popular than ever. Thanks to its long term expertise, Cortec^® designed green, environmentally friendly paint strippers with superior effectiveness. EcoClean^® VpCI^®-434G & VpCI^®-434L are rapidly biodegradable, non-corrosive, low-toxicity, eco-friendly paint and graffiti strippers that are designed for a wide range of industrial paint removal applications, as well as being efficient gasket remover. EcoClean^® VpCI^®-434G & L are formulated using environmentally safe benzyl alcohol to replace toxic methylene chloride type paint removers. They can effectively remove architectural, industrial, and lead based paints. This paint remover contains special blend of environmental friendly, low VOC solvents that replace hazardous toxic type paint cleaners. 

EcoClean^® VpCI^®-434G is formulated to be an exceptionally smooth flowing gel that provides vertical cling to surfaces for the toughest stripping projects while EcoClean^® VpCI^®-434L is a liquid solution. The stripper uses special wetting agents to penetrate deep into coatings, breaking them down and softening for easy removal of inks, acrylics, 2k & 1k urethanes, alkyds, lacquers, varnishes, and adhesives.

FEATURES

•  Low VOC
• Biodegradable
• HAPs Free
• Environmentally Friendly
• Low Odor
• Low Flammability

EcoClean^® VpCI^®-434G & L are effective on metal tanks, metal pipes, spray booths, structural supports, spray equipment, machine tools, workbenches, pipes, railcars, vehicles, airplanes, buildings, floors, stairways, pavements, road surfaces and many more.

Keywords: VpCI, sustainability, green inhibitors, corrosion protection, paint strippers, paint remover, coatings, environmentally friendly

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Manufacturers of metal parts and equipment need to find ways to make their mass production a efficient as possible while still delivering the level of quality that the end user desires. When it comes to painting each part, that means finding the right protective coating for metal with the most efficient method of application. Cortec^® offers the following suggestions for making the most of Cortec’s Micro-Corrosion Inhibiting Coatings™ in the context of a dip tank application.

Benefits of a Dip Tank

In large scale manufacturing operations, dip tanks often have the advantage of more efficient and uniform coating applications. Cortec^® Technical Service Manager, Rick Shannon, who has several decades of experience in coatings and related industries, recently shared the following key benefits of setting up a dip tank:

1. Dip tanks are highly efficient with minimal waste; dip lines can be set up for excess paint to drip back into the tank.
2. Dip tanks can provide complete coverage for geometries that are difficult for spray applications to cover in a uniform manner.
3. Parts that have a lot of open space (e.g., screens) are often coated using dip tanks. Spraying this type of product would be highly inefficient and would generate a lot of waste.

Dip Tank Maintenance Best Practices

However, simply having a dip tank is not the end all of efficient coatings application. For manufacturers to make the most of their dip tank, it is necessary to regularly monitor the tank to make sure the coating does not go bad. Shannon recommended creating a chart with the follow in items to be checked daily, weekly, or monthly.

• Viscosity (check daily, at minimum)
• pH (for water-based systems, check daily)
• Solids (check monthly)

The chart should also note the size of the tank, any additions made to the tank, and the date each physical property was checked or new paint was added. Shannon notes that these are only general suggestions, and if manufacturers notice that they are going through a large volume of coating because of high production levels, they may want to increase monitoring frequency. “By keeping track of the physical properties in your tank on a regular basis there will be less chance [that] the tank goes bad and you have to scrap the material and start over,” Shannon explained.

Cortec^® Coatings Benefits

One advantage of using a Cortec^® Coating in a dip tank is that Cortec^® offers a variety of water-based, corrosion inhibiting options that can be matched to most custom colors. Depending on the coating choice, these water-based paints can reduce VOC levels and eliminate unpleasant solvent-based paint odors, creating a more worker-friendly environment. Of special note for manufacturers, EcoShield^® 386 FD is a great option for fast-paced lines with force-dry applications that need good hot-hardness. Better yet, it contains only 0.04 lbs/gal (5 g/L) of VOCs.

Get Started with Your Dip Tank Application!

Manufacturers need to think of many different things, not least of which is finding the right coating and application method to paint their metal components. Using Cortec^® Coatings in a dip tank application and following the recommended dip tank maintenance procedures is a great way to get the protective benefits of a Cortec^® Coating while making the most efficient use of the product in certain situations. Contact Cortec^® for help selecting a protective coating for metal and setting up a efficient dip tank application.

Keywords: dip tank best practices, metal manufacturers, best practices for metal manufacturers, Cortec Coatings, coatings for metal, how to apply paint efficiently, dip tank maintenance, water-based paints, worker friendly coatings, anti-rust coatings 

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Are you getting ready to paint a new industrial facility for the first time or touch up an aging plant? Cortec^® Corp. shares several coatings ideas for protecting concrete and metal surfaces inside your buildings.

Protecting Concrete Floors

When painting concrete floors, it is important to have a coating that will stand up to both traffic and any chemicals that might be used in the facility. In many cases, MCI^®-2026 Floor Coating is an excellent choice as a 100% solids, 2-component novolac epoxy coating with a high degree of chemical and abrasion resistance. The coating is rated to hold up very well against a variety of acids, solvents, alkalis, salts, and even some miscellaneous food items such as peanut butter and fruit/vegetable juices. MCI^®-2026 Floor Coating can be used in areas with strict VOC limits and meets all of the USDA/FDA guidelines for use in federally inspected facilities.

Protecting Structural Steel

Metal walkways, railings, and stairways inside industrial facilities often need some extra corrosion protection— especially in a high moisture processing environment. Cortec^® suggests the following direct to metal (DTM) corrosion inhibiting coatings:

• CorrVerter^® Rust Converter Primer
CorrVerter^® is a low VOC water-based rust converting primer that can be used on previously rusted surfaces where sandblasting or grinding is not a good
option. When properly applied, it passivates the surface rust and protects against further rusting. It dries black and can be coated with a water-based or solvent-based topcoat.

• Water-Based 2K Epoxy Primer
VpCI^®-395 is an excellent primer for many metal surfaces, serving as a strong base for topcoats. As a two-component (2K) system, it offers the inherent durability advantages of cross-linking alongside the worker advantages of a water-based, low VOC coating. It can also be used as its own topcoat indoors, away from UV light.

• Solvent-Based One-Coat System
VpCI^®-396 is another primer option that may be preferred by workers who want to avoid the hassle of mixing a 2K system. It is a fast-drying solvent-based moisture cure urethane and can be matched to a variety of custom colors if desired for a topcoat.

• Water-Based Acrylic Topcoat
VpCI^®-395 and VpCI^®-396 can each be top-coated with EcoShield^® VpCI^®-386, one of Cortec’s top performing water-based acrylic Micro-Corrosion Inhibiting Coatings™ that can be applied clear or matched to many custom colors.

Choosing a Color Scheme

While most factories are not rated for their beauty, choosing a paint color scheme for metal surfaces can still be important, creating a clean, uniform, or even cheerful environment. Sometimes safety colors are needed to identify a trip hazard or other danger area. In other cases, color-coding may be needed to identify different types of valves or piping. Often, Cortec® can adjust its protective coating tints accordingly with its color-matching services.

Get Help from Cortec^® Coatings

Next time you need to apply a fresh coat of paint to concrete or metal inside your plant, make your selection based on the features and benefits your facility and workers need most. Contact Cortec^® for further help with coatings selection and color matching.

Keywords: paint for concrete floors, coating metal stairs, coating metal railings, corrosion inhibiting coatings, protective coatings for metal, concrete floor coating, Cortec color matching, chemical resistant coating, Cortec, VpCI

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It is fairly safe to say that every industrial facility has at least a few rusty parts—whether they be a handful of nuts and bolts that have corroded over time or an entire warehouse inventory of valves, gears, and other spares that have never been properly preserved. Rather than letting these parts go to scrap, a powerful—yet simple—solution is to restore parts by setting up a rust removal station with Cortec^® VpCI^®-422, a USDA Certified Biobased Product. Cortec^® shares tips on why and how that can be done.

Reasons for Rust Removal

There are two types of companies that will typically benefit most from setting up a VpCI^®-422 rust removal station:

• Those that provide services to heavy industry (entire companies can be based on rust removal).
• Those that want to make better use of maintenance budgets by in-house chemical rust removal instead of more labor-intensive options.

Purposes for rust removal include everything from touching up the occasional rusty part that maintenance teams encounter around the plant, to reclaiming millions of dollars’ worth of inventory that has been sitting in poor storage conditions at an oil and gas facility. In each case, the underlying goal is to preserve the value of the component and extend its service life by restoring it to usable condition. 

Choosing Rust Removal Equipment and Location

Rust removal setups range from simple to complex depending on the size of the components and the length of the job. For example, a one-time job to clean up a handful of rusty parts around the facility may only mean that maintenance needs three dishpans and a mesh steamer basket to dip and remove very small items such as nuts and bolts. Another option for sporadic rust removal is to place the rust removal solutions in portable self-contained units that can be moved from one part of the plant to another without spilling concerns. If rust removal is a recurring activity, workers may want to install permanent tubs in a designated area. In some cases, tubs will need to be large enough to hold a giant gear or valve, and cranes may be needed to raise and lower the part. If desired, bubblers and heaters can be added to speed up the rust removal action of VpCI^®-422.

Identifying the Stages of Rust Removal

Before setting up a VpCI^®-422 rust removal station, workers should identify how many stages of the process are needed. At minimum, there should be three: VpCI^®-422, rinsewater, and an alkaline cleaning fluid (e.g., VpCI^®– 41x Series). However, workers should first ask if the parts are dirty or greasy, in which case a precleaning stage is needed to degrease and rinse the parts before dipping them in VpCI^®-422 (which removes rust but not dirt or grease). Following rust removal, a preservation step is often critical to preserve what was restored.

How to Remove Rust

• Once the stations are set up, rust removal proceeds as follows:
• Clean and degrease the part if needed.
• Immerse the part in VpCI^®-422 for one hour to 24 hours depending on the severity of the rust. Workers may check the components periodically to see how rust removal is proceeding.
• Dip the parts in plain water to rinse away any residual VpCI^®-422 and corrosion products so as not to contaminate the final neutralizing bath. At this stage, the worker can proceed to the final rinse or perform another round of rust removal.
• Dip satisfactory parts in an alkaline cleaner such as VpCI^®-414, which neutralizes the acid and inhibits flash rust.
• Dry the parts and preserve them against further rusting in storage or transit. This step can take a variety of forms, including dipping the part into a bath of VpCI^®-377 or BioCorr^® water-based rust preventatives or simply enclosing the dry part in VpCI^® Film and Bags or other VpCI^® packaging materials. 

Ready, Set, Remove Rust!

Rust removal with VpCI®-422 can make a major difference in a firm’s inventory value. By understanding the steps and equipment involved, companies can save asset value with a very simple process. Contact Cortec® to learn more about setting up a rust removal station at your facility!

Keywords: rust removal, biobased rust remover, rusty parts, preserving oil and gas inventory, USDA Certified Biobased Product, Cortec, VpCI, flash rust inhibitor, flash rust inhibiting cleaners, how to remove rust

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Although sustainability is a major buzzword in society and corporate sustainability initiatives are encouraged, many uncertainties surround the switch from petroleum- or solvent-based products to their water-based or biobased alternatives. However, BioCorr^® HP is one example of a USDA Certified Biobased Product that offers many practical advantages to companies who take the biobased route.

The Basics of BioCorr® HP

BioCorr^® HP is Cortec’s latest generation of BioCorr^® water-based/biobased rust preventatives, bringing together some of the favorite features of Cortec’s previous versions. Unlike rust preventative oils, this ready-to-use product leaves a dry, virtually undetectable film on metal surfaces. BioCorr^® HP can be used to protect a variety of components during the manufacturing process or in storage. It is especially relevant to the auto industry but also may be used in coil processing, casting, and many other segments of metal manufacturing.

Practical Advantages

The main advantages of BioCorr^® HP come from its thin, dry-film forming characteristics. This means it does not attract dust and other debris that normally stick to greasy surfaces. It can also be used for components with tight tolerances, such as auto parts or threaded mating surfaces on heavy equipment. In many cases, the film does not have to be removed, reducing work time and streamlining the WIP cycle between different stages of the manufacturing process. Overall, these qualities make BioCorr^® HP inherently easier to work with than traditional oil- or solvent-based rust preventatives and leave behind a cleaner work environment.

Making Sustainability Work

In addition to its practical benefits, BioCorr^® HP offers a more sustainable approach to rust prevention. As a product that contains 54% USDA certified biobased content and carries no hazard symbols for its ready-to-use form, BioCorr^® HP is an outstanding replacement to hazardous mineral oils and flammable solvents. However, Cortec^® Technical Service Engineer Luke Stone does point out one potential challenge and how BioCorr^® HP overcomes it. “[W]ith many of the lighter water-based RP’s [rust preventatives] it can be difficult to visually inspect parts for coverage,” Stone explained. “Using a product like BioCorr^® HP with a UV tracer allows you to easily inspect parts by shining an ultraviolet light, allowing you to have peace of mind that your process is effectively protecting your parts.” 

Ensuring Compatibility

Another important step in choosing a new rust preventative is ensuring compatibility with the components themselves, the manufacturing process, and other fluids that will touch the rust preventative. BioCorr^® HP scores well in several areas that are of importance, primarily in the auto industry:

1. It does not interfere with transmission fluids.
2. It can be applied by dip or spray, robotically or by hand.
3. It has good emulsion stability in storage, so it is unlikely to separate inside application equipment.
4. It is compatible with yellow metals.

Making the Leap to Biobased

Whether you need to protect gears, transmission components, pipes, flanges, valve stems, or threaded mating surfaces, BioCorr^® HP is a good rust preventative option to consider when seeking more sustainable options or simply looking for a product that is easier to use. Contact Cortec^® to discuss whether BioCorr HP is the right biobased rust preventative for your metal protection needs.

Keywords: biobased rust preventative, biobased rust prevention, sustainability, USDA Certified Biobased Product, water based rust preventative, dry film rust preventatives, alternatives to oils and solvents, automotive rust preventatives, transmission rust preventatives, Cortec

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Tanks and tank farms are everywhere in the industrial world. Many tanks are used to store liquids. Others are used for mixing, dipping, or cleaning. Coatings are typically needed to protect the metal surfaces from rusting and provide a good appearance. Some environments demand more protection than others. It is therefore imperative to select the appropriate coatings system for specific tank conditions. The following examples provide guidelines for users of Cortec^® Coatings.

Coating Outdoor Tanks

Surface prep prior to coating is imperative for any tank, especially those with rusty or dirty surfaces. Painters can either sandblast rusty surfaces to white metal or (in situations where this method is not preferred or allowed) remove loose rust and scale and then apply CorrVerter^®, a water-based primer that converts the rust into a passive layer. Outdoor tanks usually need the most external protection because of exposure to rain, sun, and other harsh weather conditions. For tanks in these environments, Cortec^® recommends priming tank exteriors with VpCI^®-396 corrosion inhibiting primer followed by VpCI^®-384 2K corrosion inhibiting topcoat. Using two coatings of VpCI^®-396 primer instead of just one will add greater longevity to the system if the user has the time and budget to do so. 

Storage tank internals have different requirements as they will not be exposed to much, if any, UV light, but they will be exposed to liquids. VpCI^®-395 is a good choice for priming the interior walls and floors of many such storage tanks. This 2K epoxy coating brings corrosion inhibitors close to the metal surface and is good for immersion conditions. A nice advantage for workers applying VpCI^®-395 in a semi-confined space is that it is water-based and has a low VOC of 0.2 lbs/gal (24 g/L). If desired, VpCI^®-395 can be used as its own topcoat for extra durability since tank internals are typically not exposed to UV light. The recommended dry-film thickness (DFT) is 1.5-3.0 mils (37.5-75 µm) per coat.

Another important consideration for tank internals is the filling procedure. In many tanks, liquids are pumped in from the top. If the tank is large, the force of a liquid falling—for instance—50 feet (15 m) could chip the paint off the tank floor. Therefore, it is sometimes necessary to apply an 11.0-13.0 mil (275-325 µm) coat of VpCI^®– 2026 over VpCI^®-395 on the tank bottom for better impact resistance.

Coating Indoor Tanks

Indoor tanks are a different story because they are not exposed to sun or outdoor weather and often serve a different function than storage. Milder conditions make it easier to opt for a full water based-system, such as VpCI^®-395 and EcoShield^® VpCI^®-386 for tank exteriors. As with outdoor tanks, adding a double coat of primer will help the coating system last longer and likely increase time between routine painting jobs. Mixing tanks at a manufacturing plant are often not coated internally; however, tanks that hold strong chemicals such as sulfuric acid may require a strong chemical resistant system such as VpCI^®-395 and VpCI^®-2026.

Ongoing Tank Maintenance

As with almost any industrial asset and fixture, tanks need special attention to keep them in good condition and protect them against sometimes harsh conditions. External and internal coating can be an important part of that routine maintenance both for appearance and metal preservation. Coating needs can vary from tank to tank, so be sure to contact Cortec^® for specific recommendations on your application!

Keywords: tank coatings, corrosion protection, metal preservation, Cortec Coatings, tank maintenance, internal tank coatings, external tank coatings, rusty tank surface prep, chemical resistant coating, water-based coatings

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