Corrosion is an expensive and persistent problem that must be carefully handled in a step-by-step process. Most metals become extremely contaminated with heavy rust, scale and hydrocarbon deposits. These contaminants must be removed before further processing will be effective. Surface preparation is the first and very important stage in corrosion protection process. This essential step is conducted before the application of corrosion protection coatings. In fact, one of the main causes of corrosion related problems is poor surface preparation. This is because anti corrosion coating is directly affected by the surface that it is applied to.

If the surface has not been properly prepared, the coating will not stick properly and this will result in lower effectiveness and longevity of the corrosion protection coating. Surface preparation is most often used for steel, aluminum and concrete materials. Cortec’s environmentally friendly products make it easy to clean multi-metals, remove rust, condition and prepare metal for temporary or permanent coatings and packaging. Cortec’s surface preparation products also add patented VpCI® corrosion protection. One of Cortec’s bestsellers is VpCI® 414 Cleaner Degreaser, non-toxic, water-soluble, biodegradable cleaner. Designed as a special heavy-duty temporary coating and wax remover from metal and painted surfaces, VpCI® 414 concentrate is extremely effective in the removal of dirt, oils and greases or other cosmoline-like products. As a viscous liquid, market leading VpCI-®414 is ideal for underhanging and vertical applications. It provides multimetal corrosion protection even after parts have been cleaned, up to 48 hours. VpCI® 414 cleaner enables cost effective way to remove rust effectively, easily and safely while adding corrosion protection. It is also effective for light oils and greases and will not affect painted surfaces. VpCI®- 414 can be applied at full strength or diluted. It provides strong corrosion protection after parts have been cleaned.

Non flammable – VpCI 414®, does not affect painted surfaces and remains active even if left to dry. It is mostly used at room temperature, thus reducing energy consumption but it can also be used in a heated bath for heavy hydrocarbons. Viscous liquid will cling to ceilings and vertical surfaces in a ready-to-use formulation. The product is highly effective at low concentrations, diluted as low as 1% for concentrate (by volume) and higher. It is easily applied and no special protective equipment is needed. Metals protected are carbon, stainless and galvanized steel, cast iron, copper and brass. VpCI® 414 is used in cleaning and corrosion prevention applications by global companies worldwide like General Motors as well as the United States Air Force, who used VpCI® 414 as part of the Cortec’s “Clean, Protect, Preserve” program and achieved high performance, cost effective and easy method of cleaning the surfaces.

Lower Cost, Improved Cleaning Solution for Parts Washing Machine
Plant located in India manufactures a wide range of excavators. Before assembling the gearboxes, they were cleaning the parts in the washing machine using alkaline industrial cleaner at 5-6% concentration, maintaining the temperature at 65- 70 ° C (149-158 ° F). Sump life of this cleaner was 30-45 days. After washing the parts, oil remained on the surface. This was unacceptable to the customer. They were searching for a cleaner with good cleaning ability, short term rust protection, and an economical cost. Since they did not want to make many changes in the existing process, they introduced Cortec® VpCI®-414 to the washing machine at 0.5% and maintained the temperature at 65-70 ° C (149-158 ° F). The problem was solved at a lower cost without making any changes in the existing process. VpCI®- 414 is user friendly, and the cleaning quality is better than with other cleaners on the market even at very low dosages. The customer no longer faces cleaning issues and oil carryover on the surface due to the excellent properties of VpCI®-414. Indian manufacturer has implemented VpCI®-414 in the parts washing machine and started ordering it regularly. They are also planning to install one more washing machine in which they will use Cortec® VpCI®-414, as well. 

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September 1, 2022

The ubiquitous problem of rebar rust is hard to escape in the construction industry, but there is a practical answer. As part of Cortec’s High Performance Repair System (HPRS^®), CorrVerter^® MCI^® Rust Primer simplifies surface prep by passivating corrosion on steel surfaces. It is an exciting tool to help the construction industry tackle a recurring challenge.

The Problem of Rebar Rust
Rebar and other reinforcing metals play an integral role in providing the strength necessary to make concrete a viable building material. It is also one of the major causes of concrete deterioration. Although the high initial pH of concrete creates a naturally passive environment that protects metal reinforcement in new concrete, carbonation and cracking can lead to the formation of corrosion products on embedded reinforcement. As rebar rusts, it expands, putting pressure on the concrete cover. This causes more cracking and concrete spalling, deteriorating the structure and eventually requiring repair.

Effective Concrete Repair
For a repair to be effective, exposed reinforcement is typically sandblasted to remove corrosion and promote good surface adhesion to the new repair material. The ICRI 310.1R-2008 “Guide for Surface Preparation for Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion,” states that exposed reinforcing steel should be free of any materials such as concrete, dirt, and corrosion products that could interfere with repair material adhesion, although tightly bonded light rust is usually not detrimental to the bond of patch materials. This opens the door to a completely different level of surface prep convenience using CorrVerter^® MCI^® Rust Primer.

How CorrVerter^® MCI^® Works
CorrVerter^® MCI^® is a unique formulation of chelating agents combined with a high-solids waterborne latex with extremely low water vapor permeability. This fast drying, single-component primer converts surface rust into a hydrophobic passive layer and offers excellent protection against re-rusting of metal surfaces. These characteristics are ideal for repairs, making surface prep extremely simple. When using CorrVerter^® MCI, the first step is to wire brush loose rust off the metal surface. This requires much less labor than blasting and no special equipment. The next step is to remove the excess salt, dust, and contamination by rinsing with water. CorrVerter^® MCI^® can then be applied by spray or brush and left to cure for 12 hours before applying repair products. CorrVerter^® will turn visibly black by the time it dries to touch in about two to three hours.

A Convenient Solution for the Construction Industry
CorrVerter^® MCI^® is an exciting labor- and time-saving tool for contractors and engineers to be aware of. In addition to increasing the convenience of concrete repairs, CorrVerter^® MCI^® is also useful for construction delays where some concrete was already poured, leaving rebar partially exposed to the elements until the project can resume. When the project starts again, CorrVerter^® MCI^® is a good way to passivate any rust that has begun in the meantime, thus forestalling additional corrosion problems that could develop as a result. Contact Cortec^® to learn more about these great alternatives to sandblasting during concrete repair and rusty surface prep: https://www.cortecmci.com/contact-us/

Keywords: rusted rebar in concrete, surface prep, rebar rust, construction industry, concrete deterioration, concrete repair, Cortec, MCI, concrete spalling, alternative to sandblasting

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Traditional rust preventatives present two major challenges. One is the issue of environmental and worker hazards from using hazardous mineral oils and flammable solvents. The other is the lack of cleanliness and workability involved in applying and removing greasy rust preventatives. Ready to meet this need is BioCorr® HP, the newest generation of Cortec® Corporation’s game-changing biobased, dry-film rust preventative! First released in 2021, BioCorr® HP is worth taking another look at for advantages that go beyond environmental benefits.

Streamline the Rust Preventative Process

BioCorr® HP is a water-based, biobased rust preventative designed to preserve metals in storage and during transportation. Unlike rust preventative oils, this product leaves a dry, virtually undetectable film on the metal surface. The film displaces water and oils and also actively inhibits corrosion. BioCorr® HP helps promote a cleaner workplace and prevent material waste. It also streamlines processes because it does not require removal by the end user in most cases. This ready-to-use formulation can protect multi-metals for up to two years of indoor storage (or during shipment when combined with VpCI® packaging materials).

One Dry Film, Many Possibilities

Because BioCorr® HP is so thin and undetectable, it can also be used in areas where there are tight tolerances. One great example is the protection of threaded mating surfaces on equipment where temporary rust prevention is needed, but where a thick greasy substance is not practical. BioCorr® HP is able to provide this interim protection without being noticed or requiring cleaning later. Since BioCorr® HP does not interfere with automatic transmission fluids, it can be used to protect transmissions as they await installation or assembly. There are countless other applications where it can be used, as well:

• Automotive components
• Pipes, flanges, and gears
• Sheets, coils, and castings
• Valve stems
• Equipment internals
• Various other manufactured components

Avoid the Hassle of Greasy Rust Preventatives

Whatever the application happens to be, BioCorr® HP is an excellent way to provide interim corrosion protection in an unobtrusive way without the mess and hassle of greasy rust preventatives. Contact Cortec® to discuss your application in detail: https://www.cortecvci.com/contact-us/

Keywords: biobased rust preventative, rust preventatives, preserve metals, inhibit corrosion, Cortec, BioCorr, alternative to greasy rust preventatives, corrosion protection, USDA certified biobased product, alternative to petroleum-based products

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Corrosion is an irreversible process that costs industries time and money to deal with the effects. Corrosion prevention is therefore in the best interest of manufacturers and asset owners responsible for covering losses from deteriorating assets. While protective VCI packaging solves many metal shipping and storage needs, it is not always the optimal choice for certain metal shapes or storage/transit settings. When this is the case, Cortec’s VpCI^®-391 is an excellent removable coating to consider for temporary or even long-term corrosion protection.

Unnoticeable Dry Film Rust Preventative Coating

VpCI^®-391 is a fast-drying water-based temporary coating that dries to a thin, clear, virtually unnoticeable non-tacky film. It is perfect for protecting bare metal surfaces from corrosion in transit or temporary storage but can also be applied directly over painted surfaces. VpCI^®-391 provides protection indoors and outdoors and is easy to remove with an alkaline cleaner if desired. These features have made it a popular temporary rust preventative coating that displaces traditional greasy, oily rust preventatives with an unnoticeable temporary protective coating that is drastically more convenient.

Clean, Convenient Corrosion Protection

There are many advantages to using VpCI^®-391. In addition to its corrosion protection, the dry, non-tacky surface finish stays much cleaner than traditional oily/greasy rust preventatives that tend to collect insects, dust, and other contaminants on their sticky surfaces. It also weathers much better in outdoor applications. Furthermore, testing has found that VpCI^®-391 does not negatively impact weld geometry or mechanical properties of the weld, allowing welders to easily keep surfaces corrosion-free prior to welding without extensive surface-prep hassle.

When and Where to Use VpCI^®-391

The possibilities for using VpCI^®-391 are endless. Examples include the following:

• Heavy Equipment
• Machinery
• Vehicles
• Piping
• Structural Steel

Transit is one period in which VpCI^®-391 is beneficial for safeguarding brand-new metal components—whether fire trucks, valves, or front-end loaders—from unpredictable exposure to harsh weather conditions on land and sea. It can be sprayed over unpainted bolts and metal tubes as well as metal wheel rims or entire painted vehicles. Since VpCI^®-391 is relatively unnoticeable, distributors often leave it on new equipment until resale.

VpCI^®-391 is also great for storage and layup. For example, VpCI^®-391 can be applied right over painted railings and equipment on offshore platforms for extra corrosion protection during rig-stacking. Pipeline segments stored in laydown yards may be coated with VpCI^®-391 to protect weld ends from rusting. At the time of assembly or installation, the welder can simply clean off the coating or weld directly over it, instead of spending extra time grinding away opportunistic rust that could otherwise set in.

A third purpose for VpCI^®-391 is preventative maintenance. For instance, one company that uses front-end loaders to move high volumes of deicing salts or fertilizers has adopted VpCI^®-391 as part of their annual preventative maintenance routine. By applying VpCI^®-391 over the vehicles once a year during the slow season, the equipment lasts longer and does not look 10 years old after just one year of use.

Effective, Easy, and Inconspicuous

Anyone who needs a dry temporary corrosion protection coating should consider VpCI^®-391 as an easy, effective, versatile, and inconspicuous option. It looks good and performs well even in outdoor environments, allowing users the advantage of unobtrusive corrosion protection during the transit, storage, or maintenance phase. Contact Cortec^® today to learn more about using VpCI^®-391:

https://www.corteccoatings.com/contact-us-2/

Keywords: rust preventative coating, VCI packaging, corrosion prevention, metal shipping and storage needs, removable coating, keep weld surfaces corrosion free, preventative maintenance, Cortec, Cortec Coatings, transit coatings

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Good adhesion is critical to the success of a coatings system, especially when painting metal to protect it from corrosion. Although many of Cortec’s Micro-Corrosion Inhibiting Coatings™ are designed to be applied direct to metal (DTM coatings), a primer is often recommended for improved adhesion. Extra care must be taken for galvanized steel, aluminum, and other metals where adhesion is more difficult. Cortec’s VpCI®-373 serves this purpose as an excellent wash primer for creating a strong bond between metal surfaces and the paint that protects them.

Common Methods for Improving Coating Adhesion
Common methods for improving adhesion on galvanized steel and aluminum include the following:

• Chromate pretreatment/conversion coatings for unpainted aluminum
• Lead and zinc chromate primers for galvanized steel
• Acid etching on galvanized steel
• Applying a wash primer

The first three options have obvious downfalls due to the use of heavy metals and harsh acids that could be harmful for workers. The fourth is an excellent way to keep paint application simple. Wash primers typically are very thin yet promote good adhesion between the metal surface and the chosen topcoat. This can help the protective coating last longer instead of failing prematurely. Without good adhesion, the coating is destined to peel or flake early, giving corrosives free access to the metal surfaces.

VpCI®-373 Wash Primer
VpCI®-373 is a water-based wash primer that creates a good bond on metal surfaces such as galvanized steel or aluminum where adhesion is difficult. VpCI®-373 can be applied at an extremely thin DFT (dry film thickness) of 0.5-1.0 mils (12.5-25 µm) and top-coated with a wide range of water-based or solvent-based Cortec® MicroCorrosion Inhibiting Coatings™ for corrosion protection. It creates a strong bond between the metal and its protective coating to enhance durability and longevity. It can replace chromate treatments and conversion coatings and is an excellent alternative to acid etching in terms of both safety and convenience.

Coating Galvanized Roofing Sheets
VpCI®-373 was used to answer the adhesion question when painting a galvanized roof over a liquid nitrogen loading dock at an industrial site in the Philippines. Lead and zinc chromate based primers had not been enough to avoid adhesion problems, and etching of the galvanized coating with phosphoric acid was expected to lead to coatings failure within a year. This time, the customer chose to clean the new roofing material and apply VpCI®– 373 as a primer, followed by a topcoat of VpCI®-386. VpCI®-373 worked better than standard red lead or zinc chromate primers and was found to fully adhere to galvanized iron roofing sheets.

Good Adhesion or Failed Protection
Corrosion inhibitor coatings lose their value as soon as they begin to peel off the metal they are designed to protect. When special alloys such as galvanized steel or aluminum make adhesion more difficult than normal, VpCI®-373 steps in to provide a proper bond between the metal and the chosen paint, uniting them in a powerful anticorrosion coatings system to make protection more effective. Contact Cortec® to learn more about VpCI®-373 and the means of achieving good coating adhesion: https://www.corteccoatings.com/contact-us-2/

Keywords: wash primer, good coatings adhesion, painting metal, corrosion, corrosion inhibiting coatings, Cortec, direct to metal coatings, corrosion protection, improving coating adhesion, coating galvanized roofing sheets

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No one wants to apply a paint or anticorrosion coating only to come back later and find that it has dried to look like cracked mud. Not only does the texture look bad, but it also leaves behind cracks that go down to the metal surface, making it more susceptible to corrosion. While the problem of mud cracking can only be resolved by removing and reapplying the coating, it is very easy to prevent by following the guidelines below!

Why Does Mud Cracking Happen?

No matter how good a coating is, mud cracking can occur when the coating is applied too thickly. This is because solvents and water evaporate out of the paint at a certain rate as the coating dries. If the coating is too thick, the surface of the coating dries more quickly than the volatiles underneath can evaporate. Once the surface dries, the volatiles are trapped below, and the only way they can escape is by cracking the dry surface layer to get out. While mud cracking can happen with either solvent-based or water-based coatings, it is more common in water-based coatings because water evaporates more slowly.

How Can You Prevent Mud Cracking?

The solution for preventing mud cracking is extremely simple: follow the manufacturer’s recommendations for coating thickness. The coating manufacturer already knows how the coating will behave and usually provides both a wet film thickness (WFT) and a dry film thickness (DFT) recommendation on the product data sheet. To avoid mud cracking, the coating applicator simply needs to apply the recommended WFT, measuring coating thickness with a WFT gauge to make sure it is correct.

If only the DFT is listed, the painter can figure out the proper WFT based on the recommended DFT and the percent volume of solids. This percentage tells how much of the coating will remain after the volatiles have evaporated. For example, an approximately 50% volume solids coating such as VpCI®-395 will lose about half of its WFT by the time it dries. To get 3 mils (75 µm) DFT, the coating will need to be applied at 6 mils (150 µm) WFT. A coating such as EcoShield® VpCI®-386 with a 31% volume of solids will lose a little more than two-thirds of WFT by the time it dries, meaning 9.6 mils (240 µm) WFT are needed to achieve 3 mils (75 µm) DFT.

What If You Need a Thicker Coating?

Sometimes, it is necessary to apply a thicker coating than normal. If this is the case, the painter can avoid mud cracking by applying the paint in multiple coats and allowing them to dry in between each application.

Remember to Follow Instructions!

Often the best way to achieve success is right in front of us. By following WFT recommendations on a coating’s technical data sheet, painters can avoid unnecessary problems and rework caused by mud cracking. Contact Cortec® for more coating application tips and advice on selecting an anticorrosion coating for your specific application: https://www.corteccoatings.com/contact-us-2/

Keywords: Cortec, Cortec coatings, anticorrosion coatings, mud cracking, how to avoid mud cracking, measuring coating thickness, water-based coatings, solvent-based coatings, coating application tips, measuring WFT

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When choosing a coating, painters typically want one with good adhesion that will not peel quickly. But in some cases, a peelable, strippable coating is exactly what users need for a temporary coating application. Factor in corrosion protection, and manufacturers and maintenance crews have VpCI®-372, a flexible option for removable metal coatings applications.

How VpCI®-372 Works

VpCI®-372 from Cortec® Corporation is a fast-drying, water-based, low VOC acrylic peelable coating that provides corrosion protection in sheltered applications. It can be applied to metal surfaces by spray, brush, or dip. It dries quickly to a clear coat or can be tinted to match some existing color schemes or to provide easy identification of parts. When protection is no longer needed, the user can peel the coating off by hand and discard it as solid waste. This is an exceptional advantage, allowing workers to keep the metal clean, dry, and protected without having to expose themselves to solvents and paint removers.

When to Use VpCI®-372

VpCI®-372 should be used when packaging and other rust preventative coatings are not optimal. The following questions can be helpful in guiding the decision:

• Does the shape of the metal make packaging difficult?
• Would packaging removal at the end of preservation interrupt the workflow?
• Do I need temporary protection rather than a permanent topcoat?
• Do I want to be able to remove the coating without solvents or cleaners?
• Will my component be exposed to light physical abrasion (e.g., gravel bouncing off the road)?
• Do I have metal parts that need to be masked off?

If the answer to any of these questions is “yes,” the application is a good candidate for VpCI®-372 corrosion protection.

Where to Use VpCI®-372

VpCI®-372 peelable coating can be used on equipment in transit, in storage, and sometimes even in operation. For example, instead of applying a greasy rust preventative to new parts being shipped to the assembly plant, a manufacturer can spray the bare metal components with VpCI®-372, which can be peeled off clean and dry when the end user is ready to assemble the parts. Other applications include:

• Threads, Splines, and Dynamic Profiles – VpCI®-372E is an extra thick version of Cortec’s coating that can be painted on to protect threads, splines, machined areas, or other metal surfaces with dynamic profiles.
• Winter Equipment Storage –Maintenance crews putting away metal boats or other equipment for the winter can spray metal surfaces with VpCI®-372 and simply peel it off in the spring.
• Component Masking – Coating applicators in a paint booth can mask off specific areas of a part with VpCI®-372 before spraying the rest of the component with a permanent coat. The VpCI®-372 collects the overspray and can be peeled off to reveal a clean, bare metal surface after the paint application.
• Heavy Equipment Storage – VpCI®-372 can even be sprayed on dump truck beds, forklift tines, or grader blades of heavy equipment that has to sit in storage for extended timeframes. The equipment will be protected but ready to drive off at a moment’s notice, with or without removing the coating.

Give Peelable Coatings a Try

Peelable coatings work better in some applications than in others. The key is to determine what factors are at play for a particular preservation need. If your application calls for temporary corrosion protection and is not suited to packaging, it may be time to put peelable, strippable coating to work by ordering a sample of VpCI®-372 or VpCI®-372E. Contact Cortec® for advice today: https://www.corteccoatings.com/contact-us-2/

Keywords: corrosion protection, peelable coating, strippable coating, low VOC coating, transit coating, heavy equipment storage, winter equipment storage, Cortec, Cortec coating, metal coatings

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Cortec® Corporation is pleased to announce the receipt of a Concrete Contractor 2022 Top Products award for CorrVerter® MCI® Rust Primer! Concrete Contractor uses these awards to recognize innovative industry products that have captured the attention of construction professionals who read their magazine or website. In an announcement listing this year’s award winners, the editor of Concrete Contractor explained, “These solutions were designed to not only help overcome the challenges contractors face on a daily basis but do so with innovative ideas and the ingenuity for them to be successful in the years to come.” Here is how CorrVerter® MCI® Rust Primer does that for the concrete industry.

Making Life Easier for Concrete Repair Contractors

CorrVerter® MCI® Rust Primer makes life easier for contractors performing concrete repairs by providing an alternative to grinding and abrasive blasting of rusty rebar. In order to ensure the soundness of a concrete repair, the contractor must make sure that the exposed reinforcing metal will bond properly to the new concrete patch material. The ICRI 310.1R-2008 “Guideline for Surface Preparation for the Repair of Deteriorated Concrete Resulting from Reinforcing Steel Corrosion” calls for a clean metal surface with no concrete, dirt, or corrosion products that could interfere with adhesion, noting that a layer of tightly bonded light rust is usually not a problem. CorrVerter® MCI® Rust Primer falls within these guidelines and circumvents the need for labor-intensive blasting by passivating the rust with rust converting primer.

How CorrVerter® Works on Rusty Rebar

CorrVerter® MCI® is a single component, fast-drying, water-based primer that converts rusted surfaces to a passive layer. It contains a unique formulation of
chelating agents combined with a high solids waterborne latex with extremely low water vapor permeability. The combination of these materials converts the surface rust into a hydrophobic passive layer with excellent protection against re-rusting. This is perfect for concrete repair applications where rusty steel reinforcement has been exposed, where further corrosion protection is required, and where good surface prep is difficult to achieve. CorrVerter® is a low-labor alternative to sandblasting and is easy to paint onto corroded rebar after loose rust has been removed with a wire brush. When properly applied, it shows bond strength similar to that of uncoated rebar.

Implementing a High Performance Repair System (HPRS®)

CorrVerter® is an important part of Cortec’s five-step MCI® High Performance Repair System (HPRS®):

1. Prepare the Substrate
2. Treat and Clean Rusted Rebars (e.g., apply CorrVerter®)
3. Apply Repair Materials
4. Apply Surface Applied Corrosion Inhibitors (SACIs)
5. Apply Final Coating (optional)

The MCI® HPRS® is designed to help concrete repairs last longer by incorporating Migrating Corrosion Inhibitors that slow the progression of corrosion and the ring-anode/halo effect. CorrVerter® is a low-labor surface prep option that makes it much easier to get the repair off to a good start.

Honored and Eager to Get Effective Solutions into the Hands of Concrete Contractors

Cortec® is eager to get effective, easy-to-use concrete corrosion protection solutions into the hands of contractors and building owners around the world to extend the service life of reinforced concrete structures. Cortec® is especially honored to be recognized for CorrVerter® MCI® Rust Primer by the Concrete Contractor 2022 Top Products awards and looks forward to continuing to make life easier for concrete contractors with this simple and effective method of rebar surface prep! Learn more about CorrVerter®MCI® Rust Primer here: https://www.cortecmci.com/product/mci-corrverter/

Keywords: CorrVerter, MCI, From Grey to Green, Concrete Contractor 2022 top products, concrete repair, alternative to sandblasting, surface applied corrosion inhibitors, corrosion protection, extend service life, rebar surface prep

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