Technology Brief

V.08.13

ekkomaxx Cement Concrete Demonstrates Inherent Immunity to

Microbiologically Induced Corrosion (MIC)
Microbiologically Induced Corrosion (MIC), a well-known and widespread problem, is responsible for
premature deterioration of portland cement concretes subjected to wastewater exposure. This technology brief
is intended to provide the reader with an understanding of the unique attributes of CeraTech USAs (C-USA)
non-portland cement and its inherently higher corrosion resistance.
Much has been written about MIC in wastewater systems. A summary of the process is outlined in the following
steps:
1. Anaerobic, sulfate reducing bacteria in the sewage and sludge consume the readily available sulfate, and
produces hydrogen sulfide (H2S). Turbulence within sewage flow, temperature, and sewage itself impacts the
aggressiveness of this condition.
2. Sulfur Oxidizing Bacteria (SOB) (Thiobacillus) in the tidal zone oxidizes the H2S, effectively producing
sulfuric acid at levels up to 7% concentration.
3. The sulfuric acid attacks Portland Cement Concrete (PCC), reacting with the abundant Calcium Hydroxide
(Ca(OH)2) and Calcium Silicate Hydrate (CSH) gel in the PCC forming Calcium Sulfate (gypsum). Further
reactions with Tricalcium Aluminate (C3A) form ettringite, and subsequently leads to a breakdown of the
cement hydrate structure. The exposed concrete effectively turns to a pasty mush with no structural integrity.

Th e MIC
C o rro s io n P rocess

Hydrogen Sulfide Gas

Is Absorbed By Moisture
on Concrete Face

Resultant Sulfuric
Acid Reacts with Calcium
Hydroxide Within Cement
Paste Forming A Soluble
Material (Gypsum)

Sulfate Reducing
Bacteria

H 2S
Hydrogen Sulfide Gas

Concrete Wall

1500 N. Beauregard St. Suite 320 Alexandria, VA 22311 888-341-2600 www.ceratechusa.com

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Technology Brief
V.08.13

THERE ARE THREE PRIMARY APPROACHES FOR ADDRESSING THE ISSUE OF MIC IN CONCRETE
1. Inhibit the growth of bacteria. Inhibiting bacteria growth would ensure H2S would not be converted
to sulphuric acid, and as a result the concrete would be free from acid attack. Special admixtures, at an
additional cost, are available and have shown effectiveness at inhibiting growth of bacteria on PCC.
2. Apply an acid resistant protective coating. A variety of acid resistant coatings are available for the
protection of concrete. However, coatings incur significant additional cost (in material, labor, construction
and maintenance), and have shown high degrees of variability in durability and effectiveness - often related
to installation issues.
3. Produce a concrete that is resistant to attack from sulfuric acid concentrations of up to 7%.
In this case, even though the bacteria would be present, the concrete would be impervious to acid attack.
Required enhancements to PCC do not result in a significant increase in acid resistance. Existing concrete
technologies (prior to ekkomaxx) that do demonstrate the required acid resistance are very costly and not
economically viable for the wastewater industry.
Within this discussion, we examine ekkomaxx, a CERATECH Cement concrete manufactured by C-USA. The
ekkomaxx cement system utilizes a process to effectively combine fly ash with proprietary liquid additives,
sand, aggregates, and water to produce a dense concrete that is many times more durable than traditional
portland cement concretes.
CERATECH Cement forms a very stable Calcium Aluminum Silica Hydrate (CASH) crystalline structure
(rather than the CSH gel structure of PCC). In addition to the favorable chemical structure, ekkomaxx offers
the following benefits:
1. Low Water to Cement (W/C) ratio creates a dense, very low chloride permeability matrix with a discontinuous
capillary system.
2. ekkomaxx has no excess Ca(OH)2 available to react with the sulfuric acid present in wastewater
environments.
3. ekkomaxx has no C3A available to fuel the development of ettringite.
Based on the chemical composition alone, ekkomaxx is inherently resistant to sulfuric acid attack. To validate
performance, ekkomaxx was tested per ASTM C 267.

ekkomaxx RESISTANCE TO SULFURIC ACID ATTACK TEST PROCEDURE:

Testing was performed per ASTM C267 Method C, Standard Test Methods for Chemical Resistance of Mortars,
Grouts, and Monolithic Surfacings and Polymer Concretes.
Concrete specimens were cast using sulfuric acid resistant aggregates to isolate any chemical attack to the binder.
The fine aggregate used was a quartz-based C33 sand.
The coarse aggregates used were #57 granite.
The test method required all test specimens to be conditioned for 28 days prior to exposure.
Portland cement concrete specimens were prepared as controls and cured for 28 days in lime water, per
ASTM testing procedures.

1500 N. Beauregard St. Suite 320 Alexandria, VA 22311 888-341-2600 www.ceratechusa.com

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Technology Brief
V.08.13

Per CeraTechs recommendation, the ekkomaxx specimens were air cured in their molds. Once the 28-day
curing period was complete, the specimens were weighed and immersed in separate containers containing
acid solutions. The specimens were removed at the following ages of exposure: 1, 7, 14, 28, 56, and 84 days.
Following the immersion test period, specimens were rinsed to remove any loose material, blotted dry, and
weighed prior to compressive strength testing per ASTM C39.
Weight Changes were calculated as follows:
Weight change, % = [(W C)/C] X 100

Where: C = conditioned weight of the specimen

W = weight of specimen after immersion
Compressive Strengths were calculated as follows:
Change in compressive strength, % = [(S2 S1)/S1] X 100

Where: S1 = average compressive strength of specimens following the conditioning period.

S2 = average compressive strength of specimens following the immersion test period.
ASTM C267 makes a significant statement regarding the interpretation of results. In Section 12.1: Because of
the chemical nature of certain types of materials, the rate of weight, and compressive strength change
with time is of more significance than the actual value at any one time. A plot of the test results will
indicate whether a particular material will approach constant weight in time or continue to change in weight (or
compressive strength) as the test progresses.

TEST RESULTS FROM EXPOSURE TO 7% SULFURIC ACID:

The PCC specimens exhibited noticeable surface attack within four weeks, as demonstrated by the exposure
of coarse aggregate particles due to surface paste loss (Figure 1 ). Ekkomaxx cement concrete exhibits no
noticeable surface attack even after 112 days of exposure (Figure 2). The percent of weight loss of the PCC was
about 8% at 28 days. After 28 days, the PCC specimens gained weight due to absorption of the acid and the
formation of gypsum, which is soft and not abrasion resistant (Figure 3 ). To summarize, at 168 days the PCC
samples were acid soaked and in the process of catastrophic internal deterioration.

Figure 1. portland concrete

@ 28 days in 7% H2SO4

Figure 2. ekkomaxx concrete

@ 112 days in 7% H2SO4

1500 N. Beauregard St. Suite 320 Alexandria, VA 22311 888-341-2600 www.ceratechusa.com

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Technology Brief
V.08.13

It should be noted that the specimens were immersed in a tank of sulfuric acid with no fluid motion. In a real
world wastewater environment, the fluid motion would create erosion conditions that would continually remove
deteriorating surface material, eventually leading to structural failure.

ekkomaxx w/ granite aggregates

portland w/ granite aggregates

Figure 3

ekkomaxx w/ granite aggregates

portland w/ granite aggregates

Figure 4

When comparing ekkomaxx samples to PCC samples (Figure 4) it is significant to note that in contrast to the
PCC samples, the strength of ekkomaxx concrete actually improved over the same 168 day period (gaining
over 30% in compressive strength).
The ekkomaxx specimens are relatively unaffected by constant immersion in 7% sulfuric acid. Over 168 days,
there was a minimal 1% increase in weight due to absorption while the compressive strength of the ekkomaxx
specimens continued to increase over the entire 6 month period (gaining about 35% strength over the initial
value). After 168 days exposure the ekkomaxx samples exhibited only trace amounts of paste loss (Figure 2).

1500 N. Beauregard St. Suite 320 Alexandria, VA 22311 888-341-2600 www.ceratechusa.com

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Technology Brief
V.08.13

CONCLUSIONS
ekkomaxx cement chemistry provides exceptional durability in MIC environments. The results of the ASTM
C267 tests demonstrate;
1. ekkomaxx has an inherent resistance to 7% sulfuric acid without the addition of admixtures or coatings.
2. ekkomaxx is effectively immune to the impact of colonization by Thiobacillus bacteria. When utilized in
a wastewater environment, ekkomaxx does not require additional protection from liners or acid resistant
coatings to provide a durable, long life concrete structure.
Aggressive laboratory testing validates ekkomaxx as an ideal choice to provide extended lifecycle for concrete
structure, subject to MIC in the wastewater environment.
ekkomaxx carbon neutral cement concrete demonstrates superior sustainability benefits with market leading
reduction in CO2 emissions (near 100%), water savings of approx. 50%, and multiple times greater durability.
ekkomaxx is commercially available today with lifecycle costs well below PCC.
With Americas wastewater infrastructure in need of repair or replacement, ekkomaxx provides an
environmentally beneficial and cost effective solution.

1500 N. Beauregard St. Suite 320 Alexandria, VA 22311 888-341-2600 www.ceratechusa.com

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