Improved cathodic protection system

BY BARRY L. MARTIN ELGARD CORPORATION CHARDON, OHIO

hen concrete deteriorates because of rebar corrosion, repairs typically treat the symptoms instead of the cause. Patches, sealers, and membranes eventually fail because they dont halt the corrosion process. Cathodic protection (CP), though, is different. Even in salt-contaminated concrete, it stops corrosion and eliminates the need for periodic patching or deck replacement. Improved materials and methods have reduced costs and simplified installation of CP systems.

How cathodic protection works

Cathodic protection systems use electric current to combat corrosion. In concrete, metals separated by a salt solution generate current just as a battery does. Oxidation causes rust to form where the current originates (at the anode) but theres no damage where the currents journey ends (at the cathode). At the anode, rust occupies many times the volume of the original steel. This volume increase creates p re s s u res that crack the cove ri n g concrete allowing even more water and salts to reach the steel. Some cracks grow into delaminations that cause large spalls. To stop corrosion, a new anode is added. Its made of a metal that isnt damaged by oxidation. Connecting it to the positive terminal of a power supply and connecting all rebar to the negative terminal makes the entire rebar cage a cathode. Once the CP system is running, theres no further damage to rebars.

Workers can easily lay the flexible anode mesh used for this cathodic protection system. The mesh will be overlaid with concrete.

Improved anodes
Because anodes protect steel only up to about 6 inches away, anode material must be closely spaced over the entire area to be protected. An expanded metal mesh developed in 1985 offers several advantages: Light weight Suitable for protecting vertical surfaces and decks Needs only a thin concrete overlay (less dead load) The base material is thin titanium sheet expanded to form a diamondshaped mesh with 3x 13-inch openings. Its coated with mixed precious metal oxides so the anodic reaction produces only oxygen.

Anodic reactions may generate acid when some cathodic protection systems are used. Acid reacts with the alkaline concrete and may reduce bond strength at the anodeconcrete interface. To control this reaction, CP systems usually are designed to limit current density to 10 milliamperes per square foot of anode surface area. The coated titanium anodes, howe ve r, dont produce the same harmful effects. In tests, current densities up to 40 milliamperes per square foot caused no damage to the anode or surrounding concrete. The thin mesh is strong enough to resist rough handling but can be bent or curved to fit any shape. Overlay thickness can be as little as 1 inch. Mesh strands provide multiple current paths that maintain electri-

Figure 1. Multiple current paths in the mesh permit cutting it to fit around openings without losing electrical continuity. cal continuity. The system keeps running even if stresses in the structure break some strands or theyre cut during coring. A further advantage of the titanium mesh is thermal compatibility with concrete. Some systems use a conductive polymer made of carbon-filled resins. These have a much higher thermal coefficient of expansion than concrete. The difference can cause stresses as the polymer tries to expand or contract and is restrained by the concrete. Titanium, howe ve r, has a thermal expansion coefficient only slightly lower than that of concrete. St re s s e s caused by thermal movements are much smaller.

columns (Figure 1). Multiple current paths in the mesh permit this cutting without a loss of electrical continuity. Workers spot weld titanium conductor bars to the mesh (Figure 2). This forms metallurgical bonds that are stronger than mechanical connections and electrically superior. Then 14-inch-diameter holes are drilled into the deck to hold the plastic fasteners that keep the mesh firmly in place. After connecting the conductor bars to a DC power source, workers place the concrete overlay using normal placing or shotcreting proc e d u re s. The power source is activated and tests verify that the system works.

Large-scale project to be completed in 1988

Figure 2. Spot welding titanium conductor bars to the mesh produces electrically superior metallurgical bonds. ers must remove damaged concrete and prepare the surface for an overlay. They also may need to add wires that ensure electrical continuity of all reinforcement. Existing tie wire usually provides the needed continuity, but field measurements or a study of the rebar placing drawings may show that more electrical connections are needed. The mesh is unrolled from shipping spools onto the surface to be protected. Its cut with ordinary tinsnips to fit around drains, curbs, or In the summer of 1988 Baltimores Jones Falls Expressway will become the largest cathodically protected bridge project in the world. The anodic mesh system being used is expected to eliminate the need for periodic repair of corrosion damage. Costs of $3 per square foot for the CP system are expected to be returned manyfold as savings in repair costs over the life of the structure.

Installation methods
Before installing the mesh, work-

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Copyright 1989, The Aberdeen Group All rights reserved