CORROSION

AND
CATHODIC PROTECTION
OF
CONCRETE STRUCTURES
FIGURE 1 – IDEAL POURBAIX DIAGRAM

PASSIVITY
CORROSION

IMMUNITY C

FIGURE 2 - PRACTICAL POURBAIX DIAGRAM

PITTING IMPERFECT
PASSIVITY

CORROSION PERFECT
PASSIVITY

IMMUNITY
 CORROSION OF STEEL IN
CONCRETE
• HOW STEEL IS PROTECTED FROM
CORROSION IN CONCRETE ???
– STEEL ENJOYS TO BE IN HIGH pH
– pH > 10 FORMS PROTECTIVE FILM ON
SURFACE
– STEEL IS MOVED TO PASSIVE ZONE IN
POURBAIX DIAGRAM
– STEEL IS SAID TO BE PASSIVATED
CORROSION OF STEEL IN CONCRETE
CAUSES:
–THE PASSIVE PROTECTION OF STEEL IS
DESTROYED BY:
• MOISTURE
• OXYGEN
• CHLORIDES
– OXIDATION (CORROSION) OF EMBEDDED
REINFORCEMENT
• UNIFORM ATTACK
• PITTING
RESULTS OF CORROSION
• DELAMINATION OF CONCRETE
• LOSS IN STRENGTH OF REINFORCING STEEL
• FAILURE OF HIGH STRENGTH COMPONENTS
WHAT CAN CORROSION CAUSE ?
Aggressive Environments:

• High levels of chlorides in native soils

• High levels of chlorides in the natural
waters
• High ambient temperatures, i.e. > 40 C
• High relative humidity, i.e. > 90%
• Atmospheres containing large amounts of
airborne salt and sulfur compounds
• Arabian Sea: one of the extremely
aggressive environments in the world
CLASSIFICATION IN MARINE
ENVIRONMENT
CORROSION PROTECTION OF
STEEL IN CONCRETE
• METHODS OF CORROSION CONTROL
REPAIR OR REPLACE CONTAMINATED CONCRETE,
INCREASE CONCRETE COVER
– PREVENT CONTACT BETWEEN REBAR AND CHLORIDE,
OXYGEN, AND WATER
• COAT REBAR (EPOXY OR GALVANIZED)
• MEMBRANES AND SEALANTS ON CONCRETE
– CORROSION INHIBITORS
• e.g., SODIUM NITRITE
– CATHODIC PROTECTION
 TYPICAL CORROSION CELL

-100 -300 -500 -300 -100

(1) (2) (3)

CATHODE ANODE

CATHODE ANOD
E

ANODE
CATHODE

IT CAN BE CLEARLY SEEN THAT A SPECIFIC SITE CANNOT BE DESCRIBED SOLELY

AS AN ANODE OR A CATHODE. THE EXACT STATUS DEPENDS ON THE LOCATION IT
IS COMPARED WITH.

HENCE ANY SITE MAY BECOME ANODIC OR CATHODIC IN THE FUTURE WITHOUT ANY
CHANGE IN POTENTIAL .

IN THE DIAGRAM ABOVE POINT 1 IS ALWAYS CATHODIC AND POINT 3 IS ALWAYS

ANODIC BUT POINT 2 CAN BE EITHER DEPENDENT UPON THE POINT OF
COMPARISON.
EFFECT OF LOCAL REPAIR ON CORROSION
REACTION

-100 -300 -500 -300 -100

PATCH

-100 -300 -100 -300 -100

SUMMARY

INITIAL CONDITION 1 CORRODING SITE

REPAIR CONDITION 2 CORRODING SITES

 TYPICAL CATHODIC PROTECTION CELL

-100 mV -300 mV -500 mV -300 mV -100 mV

ANODE
-1000 mV

POWER
SUPPLY

A CATHODIC PROTECTION SYSTEM OPERATES BY INTRODUCING INTO THE

SYSTEM A NEW ELEMENT WHICH HAS A MORE NEGATIVE POTENTIAL THAN ANY
OF THE ORIGINAL ANODIC OR CATHODIC SITES.
ONCE ENERGISED ALL ANODIC REACTIONS TRANSFER TO THIS NEW ELEMENT
ONLY.

THUS ALL AREAS OF THE REINFORCEMENT NOW BEHAVE ONLY IN A

CATHODIC MANNER.

HENCE THE NAME - CATHODIC PROTECTION

 Cathodic Protection of Existing
Structures
• Titanium anode mesh
with concrete overlay
• Titanium ribbon mesh
in slots
Titanium Ribbon Mesh Slotted System:

• Catalyzed Titanium Ribbon Anode

• Non-shrink cementations grout as the slot backfill
• Slot spacing typically 200-400 mm on center.
• Titanium current distributor bars provide continuity between the strips and
are spot-welded to the ribbon mesh in the transverse direction.

Slotted system installation

on a bridge
Titanium Anode Mesh with concrete Overlay (Shotcrete):

• Catalyzed Titanium Mesh Anode

• Mesh anodes shall be fastened with non metallic clips
• Cement shotcrete shall be sprayed to cover the anodes
 Cathodic Protection of New
Reinforced Concrete Structures
in Aggressive Environments
(Cathodic Prevention)
 Cathodic Prevention
• Corrosion control of
new reinforced
concrete structures
• Titanium ribbon mesh
cast in new concrete
• Applicable where long
life of 50 - 100 years
is required
 History

• Over 1,000 reinforced concrete structures

are cathodically protected worldwide

• CP has accrued a 25+ year performance

record as an effective, long-term solution
to control corrosion of reinforcing steel in
chloride contaminated concrete
Official FHWA Policy Statement

• Cathodic Protection is “….the only

rehabilitation technique that has proven to
stop corrosion in salt-contaminated bridge
decks regardless of the chloride content in
the concrete.”
 International Concrete CP
Specifications & Guides
• NACE RP0290-90 “Cathodic Protection of Reinforcing
Steel in Atmospherically Exposed Concrete Structures”
• AASHTO (The American Association of State Highway and Transportation Officials) MP5-95
“Standard Specification for Bridge Deck Cathodic
Protection”
• SHRP-S-372 “Cathodic Protection of Concrete Bridges:
A Manual of Practice”
• European Standard pr EN 12696-1.
• Concrete Society Technical Reports No.s 36 & 37
 Middle East Concrete CP
Specifications & Guides
• Saudi Aramco - SAES - X - 800
“Cathodic Protection for Existing
Reinforced Concrete Structures.”

• SABIC Standard B01-S03 “Cathodic

Protection for Existing / New
Atmospherically Exposed Reinforced
Concrete Structures.”
 CP of Reinforced Concrete:

• Shift of steel potential in negative

direction.
• Production of hydroxyl ions at steel -
increases alkalinity and helps build up
passive layer.
• Flow of chloride ions from cathode to
anode - reduction of chloride content at
steel surface.
Benefits of Titanium Based Anodes

• Life Expectancy > 75 years. Determined through

N.A.C.E. Standard TM0294-94.
• Significant track record in concrete structures.
• Dimensionally stable.
• FHWA design limit: 108-mA/m2
 Catalyzed Titanium Ribbon Mesh
for New Concrete Structures

• Light weight and easy to install

• Plastic rebar clips are used for attachment

• 200 - 400 mm anode spacing

• Ribbon anode facilitates monolithic pour

 Design Considerations

• Current distribution: Zone configuration

• Depth of penetration - up to 40 cm

• Current density -
–2.0 - 20.0 mA/m2 for Cathodic Protection
–0.2 - 2.0 mA/m2 for Cathodic Prevention
Cathodic Prevention

Cathodic Prevention
COMPONENTS:
SYSTEM NEGATIVE/ INSTRUMENT
REFERENCE ELECTRODE NEGATIVE CONNECTION:
MONITORING OF CORROSION IN CONCRETE

MULTI DEPTH SENSOR UNIT

 Economics of Cathodic
Prevention
• Since no chlorides are present in new
concrete, current requirement is 1/10 that
required for cathodic protection.
• CP installation is simultaneous with other
civil works, so there is no need for
separate manpower.
• When CP is used as the principal means
of corrosion control, the necessity to adopt
other methods of protection is not
required.
 Conclusions

• Concrete structures located in aggressive

environments are subject to premature
deterioration from corrosion of the
reinforcement.

• Traditional methods of corrosion protection

may not be sufficient to provide the level of
protection needed for the intended design
life.
 Conclusions

• The application of cathodic prevention

during new construction has significant
long-term benefits.

• Cathodic Prevention can be used in

concert with traditional methods of repair
or by itself at lower initial costs.
 Conclusions

• It has been shown that the current density

necessary to maintain a passive layer on
reinforcing steel before the concrete is
contaminated with chlorides is extremely
low (0.2 - 2.0 mA/m2) and that a protective
barrier to the chloride ion will form on the
steel surface.
 Conclusions

• Anode materials such as catalyzed

titanium ribbon which are embedded in
new concrete, can provide effective
corrosion control for the life of the
structure, i.e. > 75 years.
Titanium Ribbon Mesh Slotted
System:

• Catalyzed Titanium Ribbon Anode

• Non-shrink cementations grout as
the slot backfill
• Slot spacing typically 200-400 mm on
center.
• A typical concrete slot is 10-mm wide
by 25-mm deep for 13-mm wide anode
• Titanium current distributor bars
provide continuity between the strips
and are spot-welded to the ribbon
mesh in the transverse direction.
 QnA

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