The need for concrete repairs is inevitable in a world where concrete is the most widely used construction material. This is especially true in corrosive environments where concrete deterioration accelerates due to seawater or heavy use of deicing salts. Since concrete repairs are time and labor-intensive, it is important to do them in a way that will extend structural service life as much as possible. Cortec’s MCI-2039 High-Performance Horizontal Repair Mortar was designed to help contractors reach that goal.
MCI-2039 is a single-component, fast-setting, high-strength, cement-based repair mortar enhanced with Migrating Corrosion Inhibitors (MCI). These inhibitors form a molecular protective layer on the surfaces of rebar, increasing the quality and extending the service life of the repair and surrounding structure. Once applied and hardened, MCI-2039 provides a high level of adhesion and durability, as well as resistance to water and carbonation attack. High early strength allows for fast repairs and quick return of traffic. MCI-2039 can be applied indoors or outdoors in a wide temperature range, from 20-100° F. The mortar can be extended up to 60% by weight for repairs greater than 2-in. deep.
One major problem with concrete repairs is the insidious ring-anode/halo effect. MCI-2039 can minimize the ring-anode/halo effect as Migrating Corrosion Inhibitors in the repair mortar travel to adjacent concrete to even out the corrosion potential and help the repair last longer.
What is the Ring-Anode/Halo Effect?
This occurs when the higher pH and resistivity of the patch material creates a difference in corrosion potential between new and old concrete. As a result, corrosion activity may accelerate in the concrete surrounding the patch. What was intended to fix the problem inadvertently shifts the corrosion process to another area.
Implement a High-Performance Repair System
MCI-2039 is part of Cortec’s MCI High Performance Repair System (HPRS), which outlines five steps to achieve long-lasting concrete repairs.
- Prepare the substrate following ICRI Guideline No. 310.2R-2013 (or a similar engineering guide).
- Rusty rebar should either be blasted to bright metal or coated with CorrVerter MCI Rust Primer to passivate the rust.
- Apply MCI-2039 for horizontal repairs.
- After the repair mortar has cured, a surface applied corrosion inhibitor (SACI) such as MCI-2020 (or a water-repellent MCI SACI) should be used on the entire concrete surface.
- A final coat of MCI EcoRainbow Architectural Coating protects against water intrusion and carbonation and provides a finished look. This step is optional.
By following these guidelines, concrete contractors can maximize the durability of the patch and thus delay time to the next repair, substituting MCI-2039 for standard repair mortar to enhance protection wherever a horizontal concrete repair is needed:
- Bridge decks, parking decks, and ramps
- Highway repairs and overlays
- Slabs below grade, on grade, or above grade
- Loading docks
- Airport runways
- Industrial and commercial structures
MCI-2039 is a convenient way to add corrosion protection directly into the repair process. Combined with the entire MCI HPRS, it is a powerful antidote to corrosion decay in reinforced concrete.
