Sacrificial anode assembly

Abstract

A method of using and a steel reinforced concrete protector in an anode cavity which comprises a cored hole, a drilled hole or a cut chase formed in concrete. The protector comprises a sacrificial anode assembly and a separate backfill. The sacrificial anode assembly comprises a sacrificial metal element that is a metal less noble than steel and an activator to maintain an activity of the sacrificial metal element. The at least one spacer prevents the sacrificial metal element and the activator from contacting the surface of the anode cavity. The spacer and the sacrificial metal element have a coupling mechanism which facilitates connection of the sacrificial metal element to the spacer. The backfill is a pliable and viscous material which contains an electrolyte, and the backfill facilitates embedding the anode assembly in the anode cavity. The invention also relates to a prepackaged sacrificial anode assembly and a method of increasing a shelf life of the sacrificial anode.

1 - 25 . (canceled) 
     
     
         26 . A method of protecting steel in concrete using a sacrificial metal element, an activator, a backfill and at least one spacer, the method comprising the steps of:
 forming an anode cavity in the concrete, and the anode cavity being sized so as to be substantially filled by the sacrificial metal element, the activator and the backfill;   placing the sacrificial metal element, the activator and the backfill in the anode cavity;   using at least one spacer to space the sacrificial metal element and the activator away from an inwardly facing surface of the anode cavity; and   passing a current from the sacrificial metal element to the steel;   wherein the sacrificial metal element comprises a metal less noble than steel, and the backfill is sufficiently pliable and viscous so that the backfill does not harden until after an installation process of the sacrificial metal element, the activator and the backfill is completed.   
     
     
         27 . The method according to  claim 26 , further comprising the step of using the at least one spacer for captively retaining the sacrificial metal element and the activator within the anode cavity in a spaced relationship from an inwardly facing surface of the anode cavity, and the at least one spacer being retained by compression of at least one retaining member extending radially outwardly from the at least spacer, the at least one retaining member engaging with the inwardly facing surface of the anode cavity once the assembly is inserted within the anode cavity. 
     
     
         28 . The method according to  claim 26 , further comprising the step of assembling the sacrificial metal element with the activator prior to locating the sacrificial metal element and the activator in the anode cavity. 
     
     
         29 . The method according to  claim 28 , further comprising the step of, following assembly of the sacrificial metal element and the activator, sealing the sacrificial metal element and the activator within a package which is substantially free of at least one of oxygen, water vapor and carbon dioxide, in order to increase a shelf life of the sacrificial anode assembly. 
     
     
         30 . The method according to  claim 26 , further comprising the step of coupling the sacrificial metal element to the at least one spacer via a coupling mechanism. 
     
     
         31 . The method according to  claim 26 , further comprising the step of housing the sacrificial metal element within an internal bore formed in the at least one spacer. 
     
     
         32 . The method according to  claim 26 , further comprising the step of connecting the sacrificial metal element to the steel, via a conductor, and passing a current from the sacrificial metal element to the steel. 
     
     
         33 . The method according to  claim 26 , further comprising the step of using a catalytic activator as the activator, and selecting the sacrificial metal element from the group consisting of at least one of zinc and a zinc alloy. 
     
     
         34 . A method of increasing a shelf life of a sacrificial anode assembly, the method comprising the steps of:
 assembling of the sacrificial metal element less noble than steel with an activator to maintain an activity of the sacrificial metal element and form the sacrificial anode assembly; and   sealing the sacrificial anode assembly within a package which is substantially free of at least one of oxygen, water vapor and carbon dioxide in order to increase a shelf life of the sacrificial anode assembly.   
     
     
         35 . The method according to  claim 34 , further comprising the step of, prior to sealing the sacrificial anode assembly within a package, removing substantially all oxygen from an interior compartment of the package accommodating the sacrificial anode assembly. 
     
     
         36 . The method according to  claim 34 , further comprising the step of, prior to sealing the sacrificial anode assembly within a package, removing substantially all water vapor from an interior compartment of the package accommodating the sacrificial anode assembly.