Cathodic Protection Using Thermal Sprayed Zinc Anodes

Jorge Costa, P.E. Corrosion Restoration Technologies Division of Structural Group, Inc.

Outline
Corrosion of Steel in Concrete Cathodic Protection Metalized Anode CP Systems Equipment Economic Considerations Case Histories

Corrosion of Steel in Concrete

Corrosion Induced Deterioration Sequence

cover

oxygen, chlorides, moisture

Concrete as a Corrosion Environment

High Resistivity Low Porosity High Alkalinity (high pH)

Corrosion in Concrete
0.02

Corrosion Rate (inches per year)

0.01

0.005

0.002

0.001

0.0005 2 4 6 8 10 12 14

pH

Corrosion in Concrete

Corrosion Cell
Anode Cathode Electrical path between anode

and cathode
Electrolyte (Ionic Path)

Corrosion Cell
Current flow

A
Ionic flow

Corrosion Cells in Concrete

Corrosion Induced Cracking

Spalling and Delaminations

Corrosion Products

Structural Failures Caused by Corrosion

Time to failure Period 3

Time to cracking/spalling

Period 1

Period 2

Time to corrosion initiation

Corrosion Deterioration Versus Time

Level of Deterioration Cost of Repair Exponential Deterioration Curve
(100X)

(25X) (1X) (10X)

Time

Patches and Ring Effect

Patch

Anode

Anode
Cathode

REBAR

Ring Effect

Concrete Piles

Corrosion in Concrete Piles

Corrosion in Concrete Piles

Cathodic Protection

Cathodic Protection

Reduction or elimination of corrosion by making the metal the cathode in a corrosion cell. This is achieved by means of an impressed direct current or attachment to a sacrificial anode

Cathodic Protection
Delivers a small direct current through the

concrete to the steel. Current is discharged into the concrete from an anode. Previously corroding anodic areas receive current. Anodic areas are converted to cathodic areas. Corrosion is arrested.

CP System Types
Sacrificial or Galvanic Systems Impressed Current Systems

Sacrificial Cathodic Protection

New Anode Added

Impressed Current Cathodic Protection

Power Supply

Metalized Anodes for Cathodic Protection

Sacrificial Cathodic Protection System

Anode (zinc) is coated on concrete surface Anode is connected directly to steel Voltage difference generates protective current Zinc corrodes and steel does not

Impressed Current CP

Small Small direct direct current current is is passed passed from from a a permanent permanent anode anode External External power power supply supply connected connected between between anode anode and and steel steel Appropriate Appropriate polarity polarity and and voltage voltage to to stop stop corrosion corrosion process process Current Current can can be be adjusted adjusted for for zones zones according according to to exposure conditions and requirements exposure conditions and requirements

Thermal Sprayed Coatings

Metallized Coatings Process of spraying molten metal on to a surface to form a coating Feedstock material is brought to molten or near-molten state by a heat source. Atomized particles are propelled to a prepared surface with a gas. TS Coating is built up by proper application technique. Process is line-of-sight. Resulting coating has unique characteristics.

Metalized Coating

TS Coating Characteristics

Lamellar Structure Heterogeneous Composition Platelets Oxides Voids Un-melted particles

Zn Metalized Coating

Thermal Spray Processes

Flame / Gas Guns Wire Arc High Velocity Oxy Fuel Plasma Other Systems

Wire Arc Process

GENERATOR RECTIFIER WIRE METALIZING UNIT GUN
CONTACT TIPS

COMPRESSOR

WIRE

+ -

COATING COMPRESSED AIR

Metalizing Equipment

Wire Arc Equipment

Wire Arc Equipment

Wire Arc Equipment

Case Histories

Power Plant Cooling Tower

Power Plant Intake Structures

Parking Garage, PA

Coastal High Rise Buildings

Port of Corpus Christi

Wiloughbee Spit Bridge, VA

Marine Laboratory, FL

Metalized Anode Characteristics

Thickness : 15 -20 mils Porosity & Oxides < 6% Life expectancy:

y 13-15 years in galvanic mode y 20-25 years in impressed current mode

Special alloy composition (low Fe) Bond strength 100 250 p.s.i.

Metalized Anode Characteristics

Post application treatments

y Top coating y Humectant y y y y y y

Quality Control

Thickness Bond strength General Condition Safety Experience Training

Prequalification of Applicators