Repair System Method Statement

1. Preparation of The Base:

1.1. Carefully Scarify and remove all spalled, loose and deteriorated concrete.
1.2. Where rebar is exposed, assess its integrity. If deemed sound, undercut by 1-2 cm. if
corroded and more than ¼ of its diameter is compromised, provide additional bars.
Anchor additional reinforcement to the existing concrete. Please seek advise from
structural consultant.
1.3. Using adequate shear connectors, waterjet concrete surface to achieve clean surface with
open pores.

2. Corroded Steel Reinforcement Treatment:

2.1. Clean the exposed rebars from loose rust and other contaminants such as soil, mud and
dirt using suitable manual, power tools or water jetting.
2.2. Allow to dry thoroughly before applying CorrVerter that can be applied on marginally
prepared surfaces.
2.3. Brush apply CorrVerter with no surface show-through.
2.4. For badly corroded surfaces, a second coat of CorrVerter should be applied.
2.5. Allow to air dry before repair mortar application.
2.6. Apply repair mortar within 2 weeks of CorrVerter application. If that proves to be
difficult, apply CorShield to the treated steel to keep it protected until repair mortar
application. CorShield ensures protection of treated exposed steel for up to 24 months in
unsheltered outdoors.

3. Corrosion Inhibitor to Repair Mortar Treatment:

3.1. Removal of all deteriorated or cracked concrete to sound concrete is recommended.

3.2. All concrete repairs mortar shall contain Migrating Corrosion Inhibitor Mini Grenades.
Repairs should be allowed to cure before coating for best results. A 28 days cure for new
concrete is preferred.
3.3. The Mini Grenades, corrosion inhibitors shall be added to the repair mortar mix at the rate
of 1 grenade per 0.015 cubic meters of repair mortar.
3.4. On the job site, add the Grenades in the portable mixer along with the water prior to the
addition of the repair mortar. Allow the bag and the powder to dissolve prior to addition of
the other components. Mix mortar until uniform.
 4. Surface-Applied Migrating Corrosion Inhibitor:

4.1. Surface should be free of standing water, dirt, dust, oils, grease, curing compounds,
efflorescence, laitance, and other contaminants.
4.2. Stir MCI 2020 or MCI 2020 V/O thoroughly before use.
4.3. Apply MCI 2020 using airless sprayer, brush, or roller to horizontal surfaces in a single coat
at a rate of (3.68 m2/L) or in two coats at (7.36 m2/L) in case of extremely dense concrete
surface.
4.4. In case of applying more than one coat to achieve the best results, we recommend
allowing the surface to dry enough between applications

5. Corrosion Inhibition Admixture for New Concrete:

5.1. In case of casting new concrete, add MCI 2005 at a fixed rate of (0.6 L/m3) to the
concrete mix.
5.2. Allow MCI 2005 to be mixed thoroughly before casting the concrete.
5.3. For optimal protection of bottom steel reinforcement, add MCI 2005 at a fixed dosage
of (0.6 L/m3) to the grouting mix before injecting.

6. Areas where Surface Corrosion Treatments cannot be Used

6.1. Drill holes to the level of the targeted steel reinforcement with a minimum depth of 2”
(51 mm) for a 1” (25 mm) fill or 3” (76 mm) for a 2” (51 mm) fill.

6.2. Center the application area such that the maximum distance from the edge of the
protected area is 9” (230 mm). Clean the holes with oil-free compressed air for a
minimum of 2 seconds to prepare the hole for injection.
6.3. MCI®-2020 Gel is injected into the predrilled holes by a handheld caulk gun or piston
pump, filling to the specified depth. After injection, cut off a length of closed cell backer
rod sized for hole diameter, filling space between MCI®-2020 Gel and the top of the
hole. Leave at least ½” (12.5 mm) at the top for proper patching. Fill the remainder of
the hole with a class R3 or R4 repair mortar (per ASTM C928)