Surface applied corrosion inhibitor

Abstract

A sealer composition for a cementitious substrate, a cementitious structure sealed with the sealer composition, and a method of sealing a steel reinforced cementitious structure with the sealer composition. The sealer composition includes a substantially non- aqueous blend of a first silane, a second silane having a higher molecular weight than the first silane, and a corrosion inhibitor. The corrosion inhibitor is soluble in silane, soluble in solvent-diluted silane, and at least partially soluble in water. The cementitious structure includes a cementitious substrate and the sealer applied to the surface of the substrate and at least partially penetrating into the substrate. The method of sealing a steel reinforced cementitious structure from intrusion of corrosion-causing agents includes applying the sealer to the surface of a steel reinforced cementitious substrate and permitting the sealer composition to penetrate into the substrate to seal the substrate.

1 . A sealer composition for a cementitious substrate, comprising a substantially non-aqueous blend of:
 a first silane;   a second silane having a higher molecular weight than said first silane; and   at least one corrosion inhibitor,   
       wherein said corrosion inhibitor is soluble in silane, and soluble in solvent-diluted silane, and at least partially soluble in water; the molecular weight of said first silane is from about 100 g/mol to about 270 g/mol, and wherein the molecular weight of said second silane is from about 270 g/mol to about 576 g/mol. 
     
     
         2 . The sealer composition of  claim 1 , wherein the molecular weight of said first silane is from about 150 g/mol to about 250 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 400 g/mol. 
     
     
         3 . The sealer composition of  claim 1 , wherein the molecular weight of said first silane is from about 170 g/mol to about 240 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 300 g/mol. 
     
     
         4 . The sealer composition of  claim 1 , wherein said first silane is selected from the group consisting of alkyl trialkoxysilanes, dialkyl dialkoxysilanes, and trialkyl alkoxysilanes. 
     
     
         5 . The sealer composition of  claim 4 , wherein said first silane is selected from the group consisting of methyl trimethoxysilane, ethyl trimethoxysilane, n-butyl trimethoxysilane, isobutyl trimethoxysilane, methyl triethoxysilane, ethyl triethoxysilane, n-butyl triethoxysilane, and isobutyl triethoxysilane. 
     
     
         6 . The sealer composition of  claim 1 , wherein said second silane is selected from the group consisting of alkyl trialkoxysilanes, dialkyl dialkoxysilanes, and trialkyl alkoxysilanes. 
     
     
         7 . The sealer composition of  claim 6 , wherein said second silane is selected from the group consisting of n-octyl trimethoxysilane, isooctyl trimethoxysilane, dodecyl trimethoxysilane, hexadecyl trimethoxysilane, n-octyl triethoxysilane, isooctyl triethoxysilane, dodecyl triethoxysilane, and hexadecyl triethoxysilane. 
     
     
         8 . The sealer composition of  claim 1 , wherein said first silane comprises isobutyl triethoxysilane, and wherein said second silane comprises n-octyl triethoxysilane. 
     
     
         9 . The sealer composition of  claim 1 , wherein said corrosion inhibitor is selected from the group consisting of alkyl acetamides, alkyl carboxylic acids and salts thereof, alkoxy carboxylic acids and salts thereof, alkoxylates, phosphorus containing compounds, triazines, and mixtures thereof 
     
     
         10 . A cementitious structure comprising:
 a cementitious substrate; and   a penetrating sealer comprising a substantially non-aqueous blend of:
 a first silane; 
 a second silane having a higher molecular weight than said first silane, wherein the molecular weight of said first silane is from about 100 g/mol to about 270 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 576 g/mol; and 
 at least one corrosion inhibitor, wherein said corrosion inhibitor is soluble in 
 silane, and soluble in solvent-diluted silane, and at least partially soluble in water, 
   said sealer applied to the surface of said cementitious substrate and at least partially penetrating into said substrate.   
     
     
         11 . The cementitious structure of  claim 10 , wherein the molecular weight of said first silane is from about 150 g/mol to about 250 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 400 g/mol. 
     
     
         12 . The cementitious structure of  claim 10 , wherein the molecular weight of said first silane is from about 170 g/mol to about 240 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 300 g/mol. 
     
     
         13 . The cementitious structure of  claim 10 , wherein said first silane is selected from the group consisting of methyl trimethoxysilane, ethyl trimethoxysilane, n-butyl trimethoxysilane, isobutyl trimethoxysilane, methyl triethoxysilane, ethyl triethoxysilane, n-butyl triethoxysilane, and isobutyl triethoxysilane. 
     
     
         14 . The cementitious structure of  claim 10 , wherein said second silane is selected from the group consisting of n-octyl trimethoxysilane, isooctyl trimethoxysilane, dodecyl trimethoxysilane, hexadecyl trimethoxysilane, n-octyl triethoxysilane, isooctyl triethoxysilane, dodecyl triethoxysilane, and hexadecyl triethoxysilane. 
     
     
         15 . The cementitious structure of  claim 10 , wherein said corrosion inhibitor is selected from the group consisting of alkyl acetamides, alkyl carboxylic acids and salts thereof, alkoxy carboxylic acids and salts thereof, alkoxylates, phosphorus containing compounds, triazines, and mixtures thereof 
     
     
         16 . The cementitious structure of  claim 10 , wherein said corrosion inhibitor is selected from the group consisting of dimethyl acetamide, diethyl acetamide, disodium sebacate, iso-nonyl phenoxy acetic acid, ethynylcarbinolalkoxylate, octane phosphonic acid, mono-n-octyl phosphate ester, amine blocked C6-C10 alkyl phosphate monoester, triisobutyl phosphate, polyether phosphate, 1,3,5-Tris[3-(dimethylamino)propyl] hexahydro-1,3,5-triazine, and mixtures thereof. 
     
     
         17 . The cementitious structure of  claim 10 , wherein said corrosion inhibitor comprises a blend of dimethyl acetamide and triisobutyl phosphate. 
     
     
         18 . A method of sealing a steel reinforced cementitious structure from intrusion of corrosion-causing agents, comprising:
 applying to a surface of said structure to be sealed a penetrating sealer comprising a substantially non-aqueous blend of:
 a first silane; 
 a second silane having a higher molecular weight than said first silane, wherein the molecular weight of said first silane is from about 100 g/mol to about 270 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 576 g/mol; and 
 at least one corrosion inhibitor, wherein said corrosion inhibitor is soluble in 
 silane, and soluble in solvent-diluted silane, and at least partially soluble in water, 
   to the surface of a steel reinforced cementitious substrate and permitting the sealer composition to penetrate into the substrate.   
     
     
         19 . The method of  claim 18 , wherein the molecular weight of said first silane is from about 150 g/mol to about 250 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 400 g/mol. 
     
     
         20 . The method of  claim 18 , wherein the molecular weight of said first silane is from about 170 g/mol to about 240 g/mol, and the molecular weight of said second silane is from about 270 g/mol to about 300 g/mol.