Cathodic protection of concrete

Abstract

An existing concrete structure is restored by embedding sacrificial anodes into the concrete layer at spaced positions over the layer and connecting the anodes to the reinforcing members to provide a cathodic protection against corrosion. Each anode is inserted into a drilled hole in the layer of sufficient depth to expose the reinforcement. A steel pin passes through a bore in the cylindrical anode and is attached to the reinforcement by arc welding or by impact so as to hold the anode rigidly within the hole. The hole is filled by a settable filler material. In order to maintain effective current conduction from the anode to the reinforcement through the filler over an extended period to maintain the required protection, there is added a material to hold the pH in a preferred range of the order of 12 to 14 and a deliquescent material to absorb moisture into the filler.

1. A method for cathodic protection of a concrete structure comprising:
 providing a concrete structure having a layer of concrete and a steel member in contact with the layer of concrete;  
 providing a sacrificial anode member;  
 burying the anode member within the layer so as to be in contact with the concrete layer;  
 the sacrificial anode member as provided and prior to being buried in the concrete layer comprising an anode body of an anode material which is covered on at least one surface thereof by a coating material which is carried by the anode body;  
 the anode member being arranged such that, when the anode member is buried, the coating material is in contact with the concrete layer;  
 the coating material being arranged to allow communication of current through the coating material and the concrete layer between the anode body and the steel member so as to provide cathodic protection for the steel member by an electrical potential between the anode body and the steel member which causes a current to flow through the concrete layer tending to inhibit corrosion of the steel member;  
 the coating material comprising a solid material with a binder attaching the coating material to the anode body;  
 providing in the coating material an additive different from the coating material itself which additive is a deliquescent material which is bound into the coating materials;  
 causing the presence of the deliquescent material bound into the coating material to absorb sufficient moisture into the coating material to maintain conductivity around the anode body;  
 and causing the presence of deliquescent material to keep the interface between the anode body and the coating material electrochemically active to ensure that sufficient current is maintained between the anode body and the steel member during the life of the anode body to maintain said cathodic protection.  
 
     
     
       2. The method according to  claim 1  wherein the coating material fully surrounds the anode member. 
     
     
       3. The method according to  claim 1  wherein the deliquescent material is in solid form in the coating material. 
     
     
       4. The method according to  claim 1  wherein the coating material has a pH in the range 12 to 14. 
     
     
       5. The method according to  claim 1  including the step of rigidly attaching the anode member to the steel member. 
     
     
       6. The method according to  claim 5  wherein the anode member is attached to the steel member by an impact thereon causing flow of a flowable metal portion to attach the flowable metal portion to the anode member and to the steel member. 
     
     
       7. The method according to  claim 1  wherein the anode member is attached to the steel member by a solid pin rigidly attached to the anode member and rigidly attached to the steel member. 
     
     
       8. The method according to  claim 7  wherein the solid pin passes through the anode member such that the anode member surrounds the solid pin. 
     
     
       9. The method according to  claim 7  wherein the solid pin has one end driven into the steel member by an impact tool. 
     
     
       10. The method according to  claim 7  wherein the solid pin has one end electrically welded to the steel member. 
     
     
       11. A method for cathodic protection of a concrete structure comprising:
 providing an existing concrete structure having a steel reinforcing member and a layer of concrete covering the reinforcing member so as to define a surface of the concrete layer spaced from the reinforcing member;  
 providing a sacrificial anode body formed of an anode material;  
 drilling a hole in the layer of the existing concrete structure so as to expose a reinforcing member therein;  
 inserting the anode body into the hole, the anode body being shaped for insertion into the drilled hole;  
 attaching the anode body to the reinforcing member;  
 filling the hole with a filler material;  
 the anode body being arranged such that, when the anode body is buried, the filler material is in contact with the concrete layer;  
 the filler material being arranged to allow communication of current through the filler material and the concrete layer between the anode body and the reinforcing member so as to provide cathodic protection for the steel reinforcing member by an electrical potential between the anode body and the steel reinforcing member, which generates a current tending to inhibit corrosion of the steel reinforcing member while causing the sacrificial anode to be consumed;  
 providing in the filler material an additive which is a deliquescent material which is bound into the filler material;  
 causing the presence of the deliquescent material bound into the filler material to absorb sufficient moisture into the filler material to maintain conductivity around the anode body;  
 and causing the presence of the deliquescent material to keep the interface between the anode body and the filler material electrochemically active to ensure that sufficient current is maintained between the anode body and the steel reinforcing member during the life of the anode body to maintain said cathodic protection.  
 
     
     
       12. The method according to  claim 11  wherein the anode body is attached to the reinforcing member by a solid pin rigidly attached to the anode body and rigidly attached to the reinforcing member. 
     
     
       13. The method according to  claim 12  wherein the pin passes through the anode body such that the anode body surrounds the pin and such that the pin extends longitudinally within the drilled hole. 
     
     
       14. The method according to  claim 12  wherein the solid pin has one end driven into the reinforcing member by an impact tool. 
     
     
       15. The method according to  claim 12  wherein the solid pin has one end electrically welded to the reinforcing member. 
     
     
       16. The method according to  claim 11  wherein the anode body is attached to the reinforcing member by an impact thereon causing flow of a flowable metal portion to attach the flowable metal portion to the anode body and to the reinforcing member. 
     
     
       17. A method for cathodic protection of a concrete structure comprising:
 providing a concrete structure having a steel reinforcing member and a layer of concrete covering the reinforcing member so as to define a surface of the concrete layer spaced from the reinforcing member;  
 providing a sacrificial anode member;  
 forming a hole in an existing layer of concrete so as to expose a reinforcing member therein;  
 inserting the sacrificial anode member into the hole and rigidly attaching the sacrificial anode member to the reinforcing member so as to extend therefrom into the hole;  
 filling the hole with a filler material;  
 and arranging the buried sacrificial anode member and the steel reinforcing member so as to provide cathodic protection for the steel reinforcing member by an electrical potential between the sacrificial anode member and the steel reinforcing member which generates a current tending to inhibit corrosion of the steel reinforcing member while causing the sacrificial anode member to be consumed.  
 
     
     
       18. The method according to  claim 17  wherein the sacrificial anode member is attached to the reinforcing member by a solid pin rigidly attached to the sacrificial anode member and rigidly attached to the reinforcing member. 
     
     
       19. The method according to  claim 18  wherein the pin passes through the sacrificial anode member such that the sacrificial anode member surrounds the solid pin and such that the solid pin extends substantially at a right angle to the reinforcing member. 
     
     
       20. The method according to  claim 18  wherein the solid pin has one end driven into the reinforcing member by an impact tool. 
     
     
       21. The method according to  claim 18  wherein the solid pin has one end electrically welded to the reinforcing member. 
     
     
       22. The method according to  claim 17  wherein the sacrificial anode member is attached to the reinforcing member by an impact thereon causing flow of a flowable metal portion to attach the flowable metal portion to the sacrificial anode member and to the reinforcing member. 
     
     
       23. A method for cathodic protection of a concrete structure comprising:
 providing an existing concrete structure having a steel reinforcing member and a layer of concrete covering the reinforcing member so as to define a surface of the concrete layer spaced from the reinforcing member;  
 providing a sacrificial anode body formed of an anode material;  
 excavating a hole in the layer of the existing concrete structure so as to expose a reinforcing member therein;  
 inserting the anode body into the hole, the anode body being shaped for insertion into the excavated hole;  
 attaching the anode body to the reinforcing member;  
 providing around the anode body a filler material;  
 the anode body being arranged such that, when the anode body is buried in the concrete layer, the filler material is in contact with the concrete layer;  
 the filler material being arranged to allow communication of current through the filler material and the concrete layer between the anode body and the reinforcing member so as to provide cathodic protection for the steel reinforcing member by an electrical potential between the anode body and the steel reinforcing member which generates a current tending to inhibit corrosion of the steel reinforcing member while causing the sacrificial anode to be consumed;  
 providing in the filler material an additive which is different from the filler material itself which additive is a deliquescent material which is bound into the filler material;  
 causing the presence of the deliquescent material bound into the filler material to absorb sufficient moisture into the filler material to maintain conductivity around the anode body;  
 and causing the presence of the deliquescent material to keep the interface between the anode body and the filler material electrochemically active to ensure that sufficient current is maintained between the anode body and the steel reinforcing member during the life of the anode body to maintain said cathodic protection.  
 
     
     
       24. The method according to  claim 1  wherein the deliquescent material provided in the coating material comprises lithium nitrate. 
     
     
       25. The method according to  claim 1  wherein the deliquescent material provided in the coating material comprises calcium nitrite. 
     
     
       26. The method according to  claim 1  wherein the coating material comprises a porous material. 
     
     
       27. The method according to  claim 1  wherein the sacrificial anode member comprises a compressible material. 
     
     
       28. The method according to  claim 23  wherein the deliquescent material provided in the filler material comprises lithium nitrate. 
     
     
       29. The method according to  claim 23  wherein the deliquescent material provided in the filler material comprises calcium nitrite. 
     
     
       30. The method according to  claim 23  wherein the filler material comprises a porous material. 
     
     
       31. The method according to  claim 1  wherein the deliquescent material provided in the coating material comprises calcium nitrate. 
     
     
       32. The method according to  claim 1  wherein the deliquescent material provided in the coating material comprises calcium chloride. 
     
     
       33. The method according to  claim 1  wherein the deliquescent material provided in the coating material comprises magnesium chloride. 
     
     
       34. The method according to  claim 1  wherein the deliquescent material provided in the coating material comprises calcium sulphate. 
     
     
       35. The method according to  claim 23  wherein the deliquescent material provided in the coating material comprises calcium nitrate. 
     
     
       36. The method according to  claim 23  wherein the deliquescent material provided in the coating material comprises calcium chloride. 
     
     
       37. The method according to  claim 23  wherein the deliquescent material provided in the coating material comprises magnesium chloride. 
     
     
       38. The method according to  claim 23  wherein the deliquescent material provided in the filler material comprises calcium sulphate. 
     
     
       39. The method according to  claim 1  wherein the coating material comprises a porous material, and the coating material, including the deliquescent material, has an alkalinity which alone is insufficient to maintain said cathodic protection. 
     
     
       40. The method according to  claim 1  wherein the pH of the deliquescent material is less than  12 . 
     
     
       41. The method according to  claim 1  wherein the deliquescent material comprises a material other than an alkali metal oxide or an alkali metal hydroxide. 
     
     
       42. The method according to  claim 1  wherein the deliquescent material comprises a material other than a material selected from the group consisting of lithium hydroxide, potassium hydroxide, sodium hydroxide, sodium oxide and potassium oxide and the coating material comprises a cementitious mortar. 
     
     
       43. The method according to  claim 42  wherein the deliquescent material is admixed into the mortar. 
     
     
       44. The method according to  claim 1  wherein the current between the anode body and steel member is maintained at a level greater than would occur without the presence of the deliquescent material. 
     
     
       45. The method according to  claim 1  wherein the coating material comprises a material other than a gel or paste. 
     
     
       46. The method according to  claim 1  wherein the coating material is of a solid form so as not to deform when the anode member is buried in the concrete layer. 
     
     
       47. The method according to  claim 1  wherein the anode body is connected to the steel member using an electrical connector which is attached to the anode material. 
     
     
       48. The method according to  claim 1  wherein the electrical connector comprises steel. 
     
     
       49. The method as claimed in  claim 1  wherein the deliquescent material comprises a material other than an alkali metal oxide or an alkali metal hydroxide, said coating material comprises porous material comprising a cementitious material, the current between the anode and steel member as maintained at a level greater than would occur without the presence of the deliquescent material, and said electrical connector being attached to anode material and being comprised of steel. 
     
     
       50. The method according to  claim 1  wherein said anode member comprises at least two anode materials. 
     
     
       51. The method as claimed in  claim 1  wherein said coating material comprises a cementitious material, said deliquescent material has a pH less than  12  and said coating material is of solid form so as not to deform when the anode member is buried in the layer. 
     
     
       52. The method according to  claim 1  wherein said deliquescent material is other than an alkali metal oxide or an alkali metal hydroxide and said coating material is other than a gel or paste. 
     
     
       53. The method according to  claim 1  wherein the anode member is installed in direct contact with the reinforcing member. 
     
     
       54. The method according to  claim 53  wherein the anode member conforms to the reinforcing member. 
     
     
       55. The method according to  claim 1  wherein the deliquescent material is in liquid form within the coating material. 
     
     
       56. The method according to  claim 1  wherein the sacrificial anode member comprises a fibrous material. 
     
     
       57. The method according to  claim 17  wherein the anode member is maintained in spaced relationship with respect to the reinforcing member. 
     
     
       58. The method according to  claim 17  wherein an outer surface of the reinforcing member is engaged by the rigid attachment.