Developments in Cathodic Protection

of Steel in Concrete
CONCRETE BRIDGE
DEVELOPMENT GROUP
Eurocodes and Innovation
2nd July 2009: St Hughs College
Oxford
BRIAN WYATT
Eur Ing, BSc (Hons), C Eng, MIM, FICorr, FIHT, FCS

CORROSION CONTROL
CORROSION CONTROL Affiliates Ltd
3 Ivy Court, Acton Trussell, Staffordshire ST17 0SN
www.controlcorrosion.co.uk
CORROSION CONTROL
 Developments in Cathodic Protection of
Steel in Concrete

PAPER SUMMARY

Concrete Durability
Corrosion of Steel in Concrete
Cathodic Protection of Steel in Concrete
Criteria of Protection
System Development
Standards
Applications
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 Developments in Cathodic Protection of
Steel in Concrete

CONCRETE DURABILITY
Steel in concrete is normally durable

Cement paste pH 11-13: steel is passive

Chlorides or acid gasses disrupt passivity
Concrete designed for durability: with low
water cement ratio, with cement replacements
(silica fume, gbbs or pfa) the pore structure is
improved and concrete is more impermeable to
corrodants

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 Developments in Cathodic Protection of
Steel in Concrete

CONCRETE DURABILITY
Why steel corrodes in concrete
Chlorides disrupt passive film on steel surface
and allows pitting corrosion
Present from sea dredged aggregates, marine
exposure, de-icing salts or chemical
contamination
Diffuse to level of steel: Critical Level:
0.2% Cl - by weight of cement post-hydration
Cl - ion/OH - ion ratio 0.6 better criterion
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Developments in Cathodic Protection of
Steel in Concrete

Reinforcement Corrosion: Spalling of

Concrete: Chlorides from Groundwater

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Developments in Cathodic Protection of
Steel in Concrete

Marine contamination c. 10 year old

high quality pre-cast beams

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 Developments in Cathodic Protection of
Steel in Concrete

CONCRETE DURABILITY
Carbonation
Acidification (neutralisation) of cement paste
pore water by acid gases, CO2 NOx SO3 etc
Carbonation front generally quite uniform
Corrosion more generally over steel surface
due to widespread loss of passivity as pH drops
below c. pH 9
Seldom problem on civil structures due to
better quality concrete & better cover
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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection

Reinforced concrete pipelines protected with

CP in 1950s
Trials of CP to atmospherically exposed
reinforced concrete bridge beams and then deck
units in 1958-1974
Criteria for CP of steel in alkaline concrete
differ from those for steel in neutral soils or
waters
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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection Criteria

for steel in concrete: to re-establish or

maintain passivity by raising pH and shifting
potential into passive region of Pourbaix
diagram. 150mV decay or -0.720V wrt
Ag/AgCl/0.5M KCl: Current Density 2-20mA/m2
for steel in soils or waters: to render immune
by depressing the potential into the immune
region. -0.800V wrt Ag/AgCl/0.5M KCl: Current
Density 20-250mA/m2
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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection Criteria

for steel in new concrete, or before the [Cl-] is

sufficient to initiate corrosion: to maintain
passivity by maintaining/raising pH irrespective
of eventual [Cl-]. 150mV decay or -0.720V wrt
Ag/AgCl/0.5M KCl: Current Density 0.2-2mA/m2
Also termed cathodic prevention

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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection Criteria

These Criteria are applicable to steel in

concrete:
Irrespective of chloride concentration or
carbonation level
To atmospherically exposed, buried and
immersed reinforced concrete
Oxygen flux will determine current density and
if potential decay or absolute potential criteria
will be most applicable

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Developments in Cathodic Protection of
Steel in Concrete
SYSTEM DEVELOPMENT: Impressed Current
Monitoring
System

Anode
+
Power
Supply Current Flow from Anode
Reference
- Electrodes
Cl- Cl-
Cl-
Current Cl-
Cl-
Flow
Reinforcing Steel

Concrete

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 Developments in Cathodic
Protection of Steel in Concrete
SYSTEM DEVELOPMENT: Galvanic

Galvanic Anode (usually Zn based)

+
+

+
+

+
Current Flow

Current Flow

- - - - - - - - -

Concrete

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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection System Development

often applied as part of concrete repair

element must be structurally sound: corroded
bars may need replacement; cause of distress
must be assessed
cracking, spalling and other concrete defects
must be repaired
chloride contaminated but not damaged
concrete does not need to be removed: COST
SAVING
2-20mA/m2 of steel subject to [Cl-] and O2 flux
0.2-2mA/m2 for cathodic prevention
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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection: Anode Types

MMO/Ti (activated Ti) Mesh, Ribbon, Strip etc
anode embedded into or onto concrete

The most reliable anode material, flexible forms,

high current density products available.

If applied to existing structure extra weight of

concrete overlay or complexity of slots/chases

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 Developments in Cathodic Protection
of Steel in Concrete

MMO/Ti Ribbon anode applied

to reinforcement in bridge deck
reconstruction: Corrpro USA

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 Developments in Cathodic Protection of
Steel in Concrete
MMO/Ti Ribbon Anode installed on reinforcement of
new construction bridge pier: CCSL Bahrain: 2002

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 Developments in Cathodic Protection of
Steel in Concrete
MMO/Ti Ribbon Anode installed on reinforcement of
new construction Floating Jetty:
Corrosion Control Associates Detail Designer: 2007

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 Developments in Cathodic Protection of
Steel in Concrete
MMO/Ti mesh anode to repaired beam showing
anode/cable connection, before 25mm concrete
overlay: Abu Dhabi: Tarmac & Corrosion Control
c. 1988

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 Developments in Cathodic Protection of
Steel in Concrete
Permanent reference electrode being installed in
original concrete in repaired beam with MMO/Ti
mesh anode, before 25mm concrete overlay

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Developments in Cathodic Protection of
Steel in Concrete
Manama Sitra Causeway Deck Repair: Concrete
Removed exposing Corroding Reinforcement:
Bahrain: Tarmac & Corrosion Control c. 1990

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 Developments in Cathodic Protection of
Steel in Concrete
MMO/Ti Mesh cathodic protection system to
Manama Sitra Causeway: Laid on wet pavement
concrete and overlaid within 30 minutes

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 Developments in Cathodic Protection of
Steel in Concrete
Cathodic Protection: Anode Types
Conductive Coatings

Coating containing conductive pigment

(normally graphite) applied to concrete surface
primary anode of Pt/Nb/Cu or MMO/Ti wire or
strip to facilitate cable connection and to
distribute current
Advantages, light weight, low cost, if fails blows
away.
Not very durable, low current limit
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 Developments in Cathodic Protection of
Steel in Concrete

Conductive Coating CP system on Midlands Links

Motorway support structures: Tarmac &
Corrosion Control c. 1990

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 Developments in Cathodic Protection of
Steel in Concrete

Cathodic Protection: Anode Types

Discrete Anodes
MMO/Ti tubes
Titania (Ebonex) tubes
MMO/Ti wire in carbon loaded gel

Advantages for current distribution into

complex areas, if well designed
Disadvantages of holes and high current density
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Cathodic Protection of Steel in Concrete: 20 Years
of Progress

System Developments

European & Canadian Practice:

Detailed design featuring LOCAL current
demand determination and anode provision
Remote monitoring and control

USA Practice
Generalist design often current provision
based on m2 of concrete
Low technology power supplies & minimal
monitoring
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Cathodic Protection of Steel in Concrete: 20 Years
of Progress

Standards

Well Established Standards for Cathodic Protection of

Steel in Concrete
BS EN 12696: 2000 Cathodic Protection of Steel in
Concrete
HA BA 83/02 Cathodic Protection for use in Reinforced
Concrete Highway Structures: Main UK user Advice
Note
HA Specification for Cathodic Protection Drafted &
awaiting approval
1989 Concrete Society TR 36 and TR 37 being Revised

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 Cathodic Protection of Steel in Concrete: 20 Years
of Progress
Standards

COSTS from HA BA (year 2002, broad brush):

Conductive coating: 20 - 40/m2

Sprayed Zn: 60 - 100/m2
MMO/Ti mesh & overlay: 60 - 100/m2
Discrete anodes: 40 - 100/m2
Conductive cementitious overlay: 30 - 60/m2

BUTdue to avoidance of removal of sound but Cl-

contaminated concrete SAVINGS to as little as 1/8
the costs of alternative long term repairs
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Developments in Cathodic Protection of
Steel in Concrete

RECENT APPLICATIONS

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Developments in Cathodic Protection of
Steel in Concrete

Khalifa Bridge
Bahrain
CCSL:
c. 2002
MMO/Ti Ribbon cast
into New
Construction
for 50 Year
Durability in
hot, saline marine
environment

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Developments in Cathodic Protection of
Steel in Concrete

MMO/Ti Ribbon mounted

on plastic spacer rails to
facilitate
ease of installation
and no short circuits

Positive ring main cable to

anodes

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Developments in Cathodic Protection of
Steel in Concrete
Tanger New Port:
SRPTM. Corrosion
Control Client
Technical Advisor
2004-2007
Slip-formed Caissons
CP for 50 year life

Atmospheric,
Splash &
Tidal Zones
CP by cast in
Immersed structure CP MMO/Ti ribbons
by immersed MMO/Ti
tube anodes in seawater CORROSION CONTROL
Developments in Cathodic Protection of
Steel in Concrete
Floating Jetty Northern Europe: CP Design and
Supervision by Corrosion Control 2006-2008
Conventionally cast 50 Year Life
MMO/Ti
Ribbon on
plastic
spacer
rail

Ti
Conductor
strip on
plastic
spacer
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Developments in Cathodic Protection of
Steel in Concrete
Coastal Bridge Structure Performance
Specification by Corrosion Control, Contractor
Detail Design. Repair for 25+ Year Life. 2007-8
MMO/Ti mesh &
gunite to deck
soffit and
transverse
beams

MMO/Ti discrete
anodes to front
& rear beams

MMO/Ti mesh &

micro concrete
in GRP forms to
columns

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 Developments in Cathodic Protection of
Steel in Concrete
Coastal Bridge Structure Detail Design &
Specification by Corrosion Control, Contractor
CRL. Repair for 50+ Year Life. 2008-9
RC Outer Deck Extensions MMO/Ti Mesh above and below

Outer RC Beams
MMO/Ti Discrete Anodes
RC Corbels
MMO/Ti Discrete Inner Concrete Clad RSJ
Anodes Beams MMO/Ti Mesh and
Discrete Anodes
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS

Cathodic Protection is well established for

both New Construction and Repair & Protection
There are well established Standards and an
extensive Track Record
For New Construction first option should be
competent design of a durable concrete and
construction defect free concrete placement,
compaction & curing, with correct cover
Cathodic Protection can be the optimum
solution for added durability/reliability or for
repair/protection when corrosion initiates
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS

CP of Steel in Concrete is Cost Effective:

In repairs CP can reduce total project costs to
1/8 of alternates:
- No removal of undamaged but
contaminated concrete
- Often avoids temporary support
- Reduced project programme: traffic
management and access costs
New construction CP costs c. 25% of those for
retrofit
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS

The Proper Design of CP to Steel in Concrete is:

More complex than for steel in soils or waters
- Close Anode/Cathode
- High IR errors
- Non uniform and non continuous
Cathode
- Extensive Anode network often stuck
on concrete
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS
The Proper Execution of CP to Steel in Concrete
is:
More complex than for steel in soils or waters
due to
- All the previous reasons
- Necessity to integrate with civil
construction or repair works
- Necessity to interface with those who
know little, and may care little, for CP
- Often difficult access
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS

As a result of the foregoing:

Specifications are sometimes inadequate:
- Written by the non Specialist or worse
Designs are sometimes inadequate:
- Negligible attention to balancing local
current demand and provision etc etc
Installations are sometimes inadequate:
- Interfaces between different Engineering
or Trade skills
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS

With the appropriate expertise in the selection

and specification of the CP systems, in their
design, their installation, testing,
commissioning and operation there is clear
evidence that:
CP systems are reliable
With appropriate anodes the theoretical life
can exceed 100 years
With replacement of electronics and external
cabling practical life can exceed 25 years
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 Developments in Cathodic Protection of
Steel in Concrete
CONCLUSIONS
If the CP industry, Designers, Manufacturers
and Specialist Contractors maintain a high
quality of delivery to the Client base, Owners,
Civil Consultants and Contractors there is every
reason to believe that this application of
corrosion control will grow significantly, in both
new build and repair.
This will benefit economies and provide
sustainability & environmental benefits.
IF we fail in quality, the sector will fail.
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Developments in Cathodic Protection of
Steel in Concrete

Thank You

Any Questions

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