Corrosion protection using a sacrificial anode

Abstract

Corrosion protection of steel in concrete is provided by locating an anode assembly including both a sacrificial anode and an impressed current anode in contact with the concrete and providing an impressed current from a power supply to the anode. The impressed current anode forms a perforated sleeve surrounding a rod of the sacrificial anode material with an activated ionically-conductive filler material between. The system can be used without the power supply in sacrificial mode or when the power supply is connected, the impressed current anode can be powered to provide an impressed current system and/or to recharge the sacrificial anode from sacrificial anode corrosion products.

The invention claimed is: 
     
       1. A method for corrosion protection of a metal section in a cast body of an ionically conductive concrete or mortar material comprising:
 providing an anode assembly comprising:
 an impressed current anode; and 
 a sacrificial anode of a material which is less noble than the metal section; 
 
 maintaining the impressed current anode electrically separated from the sacrificial anode to prevent direct electrical communication therebetween; 
 prior to installation, positioning the impressed current anode and the sacrificial anode into an a common assembly, wherein the impressed current anode and the sacrificial anode are fixed at relative positions in the common assembly; 
 installing the common assembly, while the impressed current anode and said sacrificial anode are at said fixed positions, in contact with the cast body of ionically conductive concrete or mortar material so as to locate the impressed current anode in ionic contact with the cast body of ionically conductive concrete or mortar material and so as to locate the sacrificial anode in ionic contact with the cast body of ionically conductive concrete or mortar material; 
 providing a DC power supply having a first pole and a second pole; the common assembly including a first electrical connecting components component connected to the impressed current anode and a second electrical component connected to the sacrificial anode; and providing corrosion protection to the metal section by:
 providing a connection by the first electrical connecting components component of the first pole of the DC power supply to the impressed current anode; 
 providing a connection of the second pole of the DC power supply to the metal section; and 
 providing a connection by the second electrical component of the sacrificial anode to the metal section; 
 so that the impressed current anode by a current from the DC power supply provides the corrosion protection of the metal section; 
 and when the DC power supply or impressed current anode is not present functional a current between the metal section and the sacrificial anode provides the corrosion protection of the metal section. 
 
 
     
     
       2. The method according to  claim 1  wherein a voltage difference between the sacrificial anode and the impressed current anode caused by the DC power supply causes ions of the sacrificial anode material to move to the sacrificial anode so as to regenerate the sacrificial anode. 
     
     
       3. The method according to  claim 2  including providing an additive which acts to limiting gassing from the sacrificial anode. 
     
     
       4. The method according to  claim 3  wherein the additive is a surfactant. 
     
     
       5. The method according to  claim 3  wherein the additive comprises cellulose. 
     
     
       6. The method according to  claim 2  including restricting dendritic growth of sacrificial anode material on the sacrificial anode. 
     
     
       7. The method according to  claim 2  including causing moisture movement towards the sacrificial anode. 
     
     
       8. The method according to  claim 2  wherein there is an ionically conductive membrane separator between the sacrificial anode and the impressed current anode. 
     
     
       9. The method according to  claim 8  wherein the ionically conductive membrane separator is located around or adjacent to the sacrificial anode. 
     
     
       10. The method according to  claim 8  wherein the ionically conductive membrane separator acts to contain sacrificial material at the sacrificial anode, to avoid dendritic growth of sacrificial anode material on the sacrificial anode beyond the membrane and to allow moisture movement to the sacrificial anode. 
     
     
       11. The method according to  claim 1  wherein the sacrificial anode material comprises particles or powder. 
     
     
       12. The method according to  claim 1  wherein the sacrificial anode is connected to the metal section while the DC power supply is connected to the impressed current anode. 
     
     
       13. The method according to  claim 1  wherein the sacrificial anode is connected to the metal section and the DC power supply is connected to the impressed current anode when the common assembly is installed. 
     
     
       14. The method according to  claim 2  including increasing alkalinity at the surface of the sacrificial anode. 
     
     
       15. The method according to  claim 14  wherein the sacrificial anode comprises zinc and wherein the increased alkalinity acts to dissolve zinc corrosion products from corrosion of the sacrificial anode into soluble zincate ions. 
     
     
       16. The method according to  claim 1  wherein a current flowing to the sacrificial anode in response to a voltage difference between the sacrificial anode and the impressed current anode caused by the DC power supply acts to generate a current flowing to the sacrificial anode and wherein the flowing current is limited to a value such that the sacrificial anode is reactivated without recharging the sacrificial anode with transferring additional ions of to the sacrificial material. 
     
     
       17. The method according to  claim 2  including increasing a total surface area of the sacrificial anode material at the sacrificial anode. 
     
     
       18. The method according to  claim 1  including increasing a quantity of hydroxyl ions at the immediate vicinity of the sacrificial anode. 
     
     
       19. The method according to  claim 1  wherein the sacrificial anode is formed of solid anode material. 
     
     
       20. The method according to  claim 1  wherein the sacrificial anode is formed of powdered or finely divided sacrificial anode material. 
     
     
       21. The method according to  claim 1  wherein the sacrificial anode comprises zinc oxide. 
     
     
       22. The method according to  claim 1  wherein the DC power supply discharges as the current is supplied and additional electrical power is supplied when discharging has occurred.  
     
     
       23. The method according to  claim 22  wherein the additional electrical power is supplied by recharging the DC power supply.  
     
     
       24. The method according to  claim 22  wherein the additional electrical power is supplied by replacing the DC power supply.  
     
     
       25. The method according to  claim 22  wherein the sacrificial anode is connected to the metal section while the DC power supply is connected to the impressed current anode.  
     
     
       26. The method according to  claim 22  wherein the sacrificial anode is connected to the metal section and the DC power supply is connected to the impressed current anode when the common assembly is installed.