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If you have ever driven under the elevated portions of the Gardiner Expressway in Toronto, you probably noticed the litany of rust stains and exposed rebar visible on many of the expressway’s concrete support columns. These are the product of a structurally damaging process called corrosion.

Corrosion occurs when chlorides – primarily from de-icing salts in colder climates – penetrate concrete and reach the steel reinforcement causing it to rust. The volume of rust exceeds that of steel and over time, causes the surrounding concrete to crack and become damaged.

The safety implications of this process are apparent. You can google ‘concrete falls from Gardiner’ and find stories about chunks of concrete breaking off and falling on the roadways below. It’s easy to understand that this continuing deterioration is slowly compromising the integrity of the structure. To combat this problem, the City of Toronto has allocated $2.2 billion to fund the elevated expressway’s repair cycle over the next 10 years. This means that this cycle of repairs will cost 20 times what it cost to actually build the Gardiner in the first place.

So if corrosion jeopardizes safety, deteriorates structural integrity, and costs structure owners exorbitant repair costs, what is the solution?

Old Solutions versus New

For years, Calcium Nitrite-based admixtures have been the conventional concrete additive to accomplish this function. However, Calcium Nitrates have numerous drawbacks that forming contractors, ready-mix plants, and owners have worked around due to the simple fact that no viable alternative existed.

Here at Form and Build Supply, we constantly search for new, innovative products to bring to market. Products that perform better and solve problems. We’re proud to say that when it comes to corrosion-inhibiting technology we have found a superior alternative to Calcium Nitrites in the form of Cortec MCI® 2005 NS. This admixture product is integrated into concrete during the mixing stage and works to protect the embedded rebar from corrosive elements.

MCI® stands simply for Migrating Corrosion Inhibitors. This patented technology is incorporated into many of Cortec’s products and works by migrating through the concrete. When MCI® comes in contact with the embedded reinforcing steel, it has an ionic attraction and forms a protective molecular barrier around the steel. This barrier prevents corrosive elements from attacking the steel and greatly extends the concrete service life (see video for visual depiction of this process). Studies show that MCI® treated concretes have a corrosion rate that is 5 times lower than that of untreated concrete.


Benefits of Cortec MCI® 2005 NS versus Traditional Calcium Nitrites

For Calcium Nitrites to be effective, they require a large dosage rate to the concrete. This large dosage rate along with the nature of the product itself creates a number of problems for not only structure owners but concrete contractors as well. MCI® 2005 NS is the best solution to overcoming these challenges as illustrated below.

  1. Calcium Nitrites are Accelerators, Lower Air Content, and Increase Shrinkage Cracking: Due to their exceptionally high-dosage rates, Calcium Nitrites adversely affect concrete’s physical properties. Setting acceleration is one of these drawbacks and greatly reduces the amount of working time of the concrete. Forming contractors often experience quick or flash sets when using Calcium Nitrite dosed concrete in warmer weather. Calcium Nitrites also lower the air content in concrete which ultimately affects its durability. To offset these challenges, one must spend more money to add retarder and air-entrainment agents into the concrete mix. Additionally, Calcium Nitrates cause more concrete shrinkage which results in more cracking. This necessitates repairs on brand new structures. These headaches are avoided by simply switching to Cortec’s MCI® 2005 NS. It provides enhanced corrosion protection without affecting the set time or air content of your concrete.
  2. Calcium Nitrites require High Dosage Rates: For Calcium Nitrates to be effective they must be dosed at a substantially higher rate than Cortec MCI® 2005 NS. A lot of specifications provide for a Calcium Nitrate dosage rate of between 10 to 30 L/m3. In Ontario, there is a need for higher dose of Calcium Nitrites due to the above average presence of corrosive agents in the environment and extensive use of deicing salts in the winter. The higher dosage rate exacerbates problems previously mentioned. Cortec MCI® 2005 NS – on the other hand – is effective at a dosage rate as low as 1 L/m3 making it both more practical and cost effective.
  3. Calcium Nitrites Provide Inferior Long-Term Protection: MCI® stands for Migrating Corrosion Inhibitor. This describes how Cortec’s MCI® 2005 NS works. Its particles ‘migrate’ through the concrete structure and form a protective shield around concrete-embedded rebar. This shield protects the rebar from contaminants and reduces the corrosion rate by as much as 5 times versus untreated concrete. This ultimately extends the service life of the structure and reduces the number of required concrete repair cycles due to corrosion.

Already Enhancing Structures Worldwide

While MCI® 2005 NS and indeed, Cortec’s entire MCI®line of products are relatively new to the Ontario construction market, these products have been used in a number of high-profile jobs internationally. For instance, MCI® 2005 NS was used most notably in the podium substructure of the Burj Khalifa in Dubai – the tallest building in the world. The product was also used for a similar application in the Princess Towers also in Dubai.

MCI® 2005 NS’s use in this application represented 0.07% of the overall construction cost but effectively doubled the service life of the structure.
But the MCI® product line is effective in applications beyond towers and skyscrapers. Any civil application where the structural integrity of a concrete structure is vital can benefit from the use of the MCI® products. The Severn Bridge in the United Kingdom and the Cochrane Bridge in Alabama are two examples of where MCI® products were incorporated to protect the steel post-tensioned cables from corrosion.

Conclusion

Cortec’s line of MCI® products offer numerous benefits for anyone designing and building concrete structures. We’re proud at Form and Build to be the exclusive Ontario distributor for these products and look forward to talking with Engineers, structure owners, and concrete contractors about how this product line can enhance their structures and extend their service life.

To that end, we welcome anyone to reach out to us to schedule a lunch and learn or product demo. Please click here and enter your information and we will happily reach out to schedule a time to further discuss the benefits of our Cortec MCI® product line.

To our valued customers,
In our efforts to help protect yourselves and our employees amidst the COVID-19 situation, we are implementing the following protocols effective 10 am, March 24. We expect the Government of Ontario to release a list of businesses permitted to operate during the shut-down period. Once we have reviewed this list, we will adjust our plans to ensure we comply with province’s efforts to fight the virus.
Ordering:

  • Currently, we will remain open to fulfill orders. However, our showroom will be closed to practice and encourage social distancing. NOBODY will be permitted in our showrooms other than staff until further notice.
  • To place an order, please call or email your local branch at the contact information at the bottom of this advisory. If ordering by email, please specify your anticipated pick-up date and time or whether you are placing an order for delivery.
    Payment:
  • If you have an account with Form and Build, you can apply your order against your available credit as normal.
  • NO debit or cash will be accepted until further notice.
  • Credit card payments can be processed over the phone.
    Order Fulfillment:
  • For pick-up orders, please pull your vehicle to the yard/warehouse entrance at the branch. Our staff will load your vehicle with your order. Please stay inside your vehicle during this process. No signatures will be required at this time. We will take a picture of the order and write the receiving customers name on the packing slip.
  • For delivery orders, our drivers will comply with all job-site specific precautions.
    o If the customer is able to unload the delivered merchandise, our drivers will not leave their truck during this process. Once unloaded, they will take a picture of the delivered order and write the receiving customer’s name on the delivery slip. This will then be emailed to the customer.
    o If you require our driver to unload the order, please have your staff vacate the area in which the unloading is to occur. Our driver will then take a picture of the delivered order and write the receiving customer’s name on the delivery slip. This will then be emailed to the customer.
    We appreciate your patience and understanding in this time of uncertainty. We endeavor to continue to provide exceptional service to you while keeping our staff safe and complying with all government issued directives and guidelines.
    If you have any questions, please contact your local branch.
    Thank you.

March 18, 2020

To our valued customers,

Amid the COVID-19 pandemic, I want to assure you that we are taking the necessary precautions to keep our staff and customers safe while continuing to serve you. Currently, in accordance with Premier Doug Ford’s statement today, all Form and Build locations remain open and are adhering to our standard hours.
Please understand that the health and safety of our staff and yourselves are our highest priority. For this reason, we have taken the following steps in an effort to do our part to help mitigate the spread of this virus:

  1. Our employees have been instructed to employ the oft-cited common sense tactics to avoid virus transmission. This includes avoiding shaking hands, maintaining social distance, frequent hand-washing, and coughing and sneezing into their sleeves.
  2. We have redoubled our efforts to clean and sanitize our showrooms and offices. All locations are using an anti-bacterial solution to wipe down all high traffic areas including order desks, shelves, and office desks multiple times each day.
  3. We have made accommodations for any and all employees that are required to self-isolate. Our management staff has been instructed to immediately send home any employees exhibiting symptoms or who have had close contact with a person who has tested positive for COVID-19.
  4. We have required all travelling and outside sales staff to work remotely and avoid in-person meetings. Management has also identified other support functions that can be performed remotely and are currently putting in a plan to realize that remote work.
  5. Our management team has inquired our staff about any recent international trips. Based on the current guidelines, those who have recently returned from international travel have been asked to self-isolate.
    Please also note at this time that our inventory levels are robust and we are working with our supply chain to mitigate any disruptions. We endeavor to do all that we can to ensure we deliver the same quality service you’ve come to expect from us while keeping our staff and customers safe.
    As you can appreciate, this is a developing situation. We will continue to follow the most up-to-date guidelines and directives of our government and health officials. We currently remain open and will advise you if that changes.
    Thank you for your understanding.
    Sincerely,

William Ross
General Manager, Form and Build Supply Inc.

Greg Rea, General Manager

Concrete forming literally builds the foundations on which our homes and cities are constructed. For almost 45 years, Form and Build has been in the business of providing the highest-quality products to the forming industry. Our knowledgeable staff have advised customers on forms and forming accessories that help get the job done faster and with less hassle.

The cornerstone of our company’s forming offering for many years has been the Advance Panel System. This system has many advantages over its competitors in the market. However, over the years, contractors have looked past these attributes and begun to look at forming panels simply as commodity products.
In this article I’m going to show that nothing could be further from the truth. The right set of panels can save you time, money, and last for years when taken care of properly. Specifically, the Advance Panel System stands head-and-shoulders above its peers. So I think it’s time that General Contractors, Agricultural Contractors, Forming Companies, and Landscapers all take a serious second look at this simple yet versatile system.

Price and Value

Did you know that an Eight-Foot Four Bar Advance Form currently sells for the same price – roughly $110 a foot – as it did in 1981? Over that same time period, wood and steel prices have tripled, wages have steadily risen, and the price of a house – the very structure for which the panels were initially designed – have increased fivefold. If an Advance Panel System was a good investment in 1981, it’s clear that it has become an even better investment today.

While General Contractors (GC) might not consider it worth it to buy their own set of panels, I would suggest we consider that question in the context of the residential construction market of 2019. This year has been a busy one. And sure, it’s nice to see healthy demand in the market. But if a GC is busy, then so are the forming subcontractors on which they rely. And if forming subcontractors are busy trying to keep up with their work, a GC’s timelines become increasingly dependent on their schedules.

So when you consider the costs of scheduling uncertainty, changing timelines, and delays, a GC investing in a set of panels of their own looks ever more prudent. Because the Advance Panel System is so easy-to-use, a General Contractor can take care of simple forming jobs in-house without relying on the availability of their forming subcontractor.

And what if you’re a GC that does a lot of steel structures? The four or five foot Advance Panel System may be of particular interest. With this system, a GC can easily construct pilasters into the wall of a building by using a few system panels and inside and outside corner pieces. A system like this can be obtained for as little as $65 per foot.

Quality

You can rely on the Advance Panel System to provide you with hundreds of smooth walls over their lifecycle. That’s because Advance forms are the only system readily available in Canada with a high-density (120/120) extra heavy-duty overlay to counter the abrasive quality of concrete. This quality craftsmanship also contributes to Advance forms lasting 10-20% longer than other competing products. Longer lasting forms ultimately reduce your cost. For instance, if you get 100 pours out of a system that costs roughly $100 per foot, that equates to $1 per foot of wall built.

Convenience and Versatility

The wonderful thing about the Advance Panel System is that it’s easy-to-use and can be used to tackle a variety of projects in the residential, agricultural, and commercial markets. Also, all of the hardware to lock the panels into place are attached to each form and corner piece. This means there will be no running around on the job site looking for wedges or keys that tend to get lost on each project.

While the eight foot four-bar system was designed originally for residential basements, the eight foot six-bar system can be utilized in numerous commercial projects. Twelve and sixteen foot walls are routinely formed with ease. The system lends itself well to stacking and the extra ties included on the eight foot six-bar system have the added advantage of being able to increase your pour rates.

Did you also know that you can form up to two foot by two foot columns with only four panels and four corners? No other system can compete with the speed and ease that the Advance Panel System offers in constructing such columns. One needs to simply calculate the time it takes to do so using standard formply, snap ties, and walers. You’ll be surprised how much faster you can accomplish this task with the Advance Panel System.

Conclusion

So whatever market in which you do forming work, consider whether the Advance Panel System could save you time and money. The professionals at Form and Build Supply are more than prepared to answer any questions you may have provide you with the best options available. And remember the ease and versatility of the Advance Panel System will eliminate your need for a carpenter on your next forming job.

Devan Martel, Outside Sales Representative

We experience harsh winters in Canada. As the cold weather approaches, you may be thinking “I need to buy some salt”. For years, salt has been the go-to solution to combat ice build-up on our concrete sidewalks, patios, and driveways. However, de-icing salt can cause damage that lowers the value and aesthetic of your concrete investment.

So what if I told you there was an alternative?

Don’t Blame it all on the Salt
Strictly speaking, salt doesn’t react with cured concrete. However, it does lower the freezing point of water, attract moisture, and increase the presence of water within the slab. If your concrete has a weak surface, it can ‘pop-off’ when the water in the slab expands during the freezing process. This will leave you with a patchy mess come Springtime. Salt remnants can also migrate through your slab and corrode any reinforcing steel and cause problems for the structural integrity of your slab.

In these ways, excessive salting in the winter can diminish the value of your concrete flatwork.

Strategies to Keep your Investment Looking It’s Best
Let’s face it, Canada is a challenging environment for decorative concrete. The temperature change from season to season is dramatic. Despite the universal use of air-entrainment products to manage the freeze-thaw cycle, spalling is often times likely.

As we would always recommend, your first line of defence in this situation is to make sure you use a trusted professional for any concrete flatwork. Quality workmanship always goes a long way to the longevity of your concrete investment. In addition to this, products and techniques exist to further protect your investment. Assuming the installation of your slab was completed to the highest standards, the following strategies should help guard your concrete from the harsh winter elements.

Sealing Concrete Does More Than Make It Look Pretty
The easiest way to protect your concrete is by sealing it. By using a sealer, you’re creating a barrier between your concrete and moisture. This prevents water from penetrating into the slab thereby reducing the risk of pop-offs due to the freeze-thaw cycle.
With hundreds of sealers on the market all claiming to be the best, it can be difficult to find the right product for you. However, through our decades of experience, we are confident to present you with what we consider your best options below.

Topical Sealers
Topical sealers are a great option for protecting concrete surfaces. They’re available in water-based formulations for interior work and solvent-based formulations for exterior substrates. They work by creating a UV-stable film membrane on the surface. Although they can be slick when wet, they protect from abrasion, stains, chemicals, and moisture. Topical sealers have the added benefit of enhancing the look of your concrete by darkening accent tones which can really make the colours pop. They’re available in a low-gloss, matte finish, or a high-shine wet look finish.

Looking for a sealer that offers both high-shine and durability? We recommend using W.R. Meadows Hiac-Plus  with Shark-Grip  for added slip-resistance.

Penetrating Sealers
Penetrating sealers work differently. Rather than forming a film at the surface of the slab, these sealers are absorbed into the pores of the concrete. They react chemically with molecules naturally found in concrete to form a hydrophobic, water-repellent resin within the slab’s pores.

Although providing no visual enhancements, penetrating sealers work better than topical sealers at preventing the intrusion of moisture into the slab. This ensures complete protection from freeze-thaw cycles. Keep in mind, though, that penetrating sealers can ONLY be applied if there are no existing coatings or sealers already on the slab.

Penetrating sealers are available in various formulations depending on the porosity of your slab and the corresponding protection requirements. Greater porosity means you need a higher active solids content in the sealer to get the proper protection. Therefore, for a porous slab, we would likely recommend you purchase a penetrating sealer with 100% active solids content versus one with only 40%.

We are proud to carry W.R. Meadows Pentreat sealers among our line of penetrating sealers. This line of sealer comes in both a 100% and 40% active solids content formulation. For a list of all our sealers, click here. If you are unsure which sealer best suits your job, feel free to call any one of our five branches for advice.

Contractor’s Choice Ice Melter – Your Salt Alternative
We began this discussion on the corrosive aspects of salt. By now, it should be apparent that proper sealing techniques go a long way to protecting your concrete through the winter. But the problem of ice build-up – and how to get rid of it – remains.

To avoid the corrosive and damaging aspects of salt, we recommend you use Contractor’s Choice Ice Melter. Contractor’s Choice Ice Melter effectively melts ice even when the temperature drops to -25 Celsius. By contrast, salt melts ice down to -3 Celsius. Additionally, Contractor’s Choice Ice Melter’s composition does not have the corrosive elements of salt and will mitigate damage to your concrete.

Our Recommendation to You
In summary, by following the steps below, you should be able to keep your concrete sidewalks, patios, and driveways ice-free while protecting the quality of your investment:
1. Seal your sidewalk, patio, or driveway before the winter:
a. To enhance the look of your concrete, use a topical sealer.
b. If no coating or sealer has ever been applied before, use a penetrating sealer for enhanced protection.
2. Do your best to keep all walkways, driveways, and patios free of snow through regular shoveling or snow-blowing.
3. When ice builds up, use Contractor’s Choice Ice Melter to take care of the problem.

Still Have Questions? No problem!
We hope this article has been helpful and informed you on ways to reduce the risk of slip-and-falls in the winter while protecting your concrete. If you still have questions or require further assistance, feel free to give us a call at Form and Build. Our experienced sales team have been helping our valued customers battle Canadian Winters for 45 years. Call your local branch to have a member of our team put your mind at ease and keep your concrete looking brand new for years to come!

Devan Martel, Outside Sales Representative

Corrosion is one of the leading factors when it comes to the durability of materials and structures. By battling corrosion, we are able to prolong the life of existing structures and minimize corrosion damage in new construction. Many manufacturers have flooded the market with products claiming to be the next best thing since sliced bread, but not every corrosion inhibitor works the same. With so many options to choose from, it can be hard finding the right product for your application. That’s why we’ve gone ahead and found them for you.

Who is Cortec Corporation?
Cortec Corporation is the world leader in innovative corrosion protection solutions. The company has developed solutions to tackle corrosion problems in packaging, construction, oil and gas, and many other industries.  With over 400 products developed and 60 patents since 1977, it’s clear that Cortec Corporation are experts in what they specialize in – corrosion. Cortec MCI Cortec MCI is a division of Cortec Corporation that focuses on the construction industry. Cortec MCI products maintain structural integrity, rehabilitate vulnerable structures, and alleviate environmental concerns. Their product offering includes admixtures, surface treatments, rust converters, and more.

What Are Migrating Corrosion Inhibitors
Migrating corrosion inhibitors penetrate through the concrete to surround the structural steel, thus preventing corrosion. They work to penetrate the substrate in 3 ways;
• Capillary Action
• Vapor Phase
• Ionic Attraction

Once in contact with the embedded metals, a protective molecular layer is formed to stop corrosive elements dead in its tracks. Not only does it work to prevent corrosion, it also reduces existing corrosion rates as well.

Choosing the Right Product for The Job
With such an extensive product offering, choosing the right MCI product for your job may be a daunting task. Luckily for you, our sales team has undergone extensive training to help make your decision easier. Below we’ve taken the time to highlight 3 key products from their offering.

MCI-2005NS
MCI-2005NS is an organic corrosion inhibiting admixture that is added to the mix water of ready-mix concrete at the plant. It is effective at enhancing the durability and extending the service life of concrete structures. It is dosed at 1L/m3 – a huge benefit over other products that may be dosed as high as 30L/m3. While calcium nitrite based inhibitors will accelerate the set of the concrete, MCI-2005NS wont affect it at all. In fact, MCI-2005 may be used when a delayed set is required.
For more information on MCI 2005NS, click here.

MCI-2020
MCI-2020 is surface applied, migrating corrosion inhibitor that is capable of penetrating through concrete, mortar and limestone. It can be used in new or existing structures, such as highways, parking garages, and potable water structures. As a surface treatment, it’s crucial to know that MCI-2020 will not stain or discolor the existing concrete surface. It is easily applied using a brush, roller or sprayer.  For more information on MCI-2020, click here. 

MCI-2018
Much like MCI-2020, MCI-2018 is a surface applied product that migrates into even the densest of concrete. It is a 100% silane concrete sealer that provides water repellency by reacting with the substrate.  Once applied and cured, the treated substrate will become hydrophobic and retain its original appearance. Application is made easy through the use of a sprayer, roller or squeegee. For more information on MCI-2018, click here

Where Can I Buy MCI Products?
Cortec Corporation sells their products through distribution. This means that the general public cannot purchase their products directly from them but must do so through one of their distributing partners. At Form & Build, we pride ourselves on providing our customers with the best products in the market. That’s why we’re excited to hold exclusive rights to Cortec MCI products within Ontario.

Contact your local branch or sales rep today for all inquiries.