CORROSION PROTECTION OF STEEL IN CONCRETE

FIELD OF THE INVENTION

The present invention relates to electrochemical protection of steel in reinforced concrete construction using sacrificial anodes and, in particular, to the use of sacrificial anode assemblies in treating steel corrosion in corrosion damaged concrete elements which are exposed to the air.

BACKGROUND OF THE INVENTION

Above ground steel reinforced concrete structures suffer from corrosion induced damage mainly as the result of carbonation or chloride contamination of the concrete. As the steel reinforcement corrodes, it produces by-products that occupy a larger volume than the steel from which the products are derived. As a result, expansion occurs around reinforcing steel bars. This causes cracking and delamination of the concrete cover of the steel. Typical repairs involve removing this patch of corrosion damaged concrete from the concrete structure(s). It is good practice to expose corroding steel, in the area of damage, and to remove the concrete behind the corroding steel. The concrete profile is then restored with a compatible cementitious repair concrete or mortar. The concrete then consists of the “parent” concrete (i.e., the remaining original concrete) and the “new” patch repair material.

The parent concrete, adjacent to the repair area, is typically likely to suffer from some of the same chloride contamination or carbonation that caused the original corrosion damage. It is to be appreciated that steel corrosion still remains a risk in the parent concrete. Corrosion in concrete is an electrochemical process and electrochemical treatments have been used to treat this corrosion risk. Examples are described in WO 94029496, U.S. Pat. No. 6,322,691, U.S. Pat. No. 6,258,236 and U.S. Pat. No. 6,685,822.

Established electrochemical treatments include cathodic protection, chloride extraction and re-alkalisation. These are classed as either permanent or temporary treatments. Permanent treatments are based on a protective effect that is only expected to last while the treatment is applied. An example of a permanent treatment is cathodic protection. The accepted performance criterion can only be achieved while the treatment is applied (BS EN 12696:2000). Chloride extraction and re-alkalisation are examples of temporary treatments (CEN/TS 14038-1:2004). Temporary treatments rely on a protective effect that persists after the treatment has ended. In practice, this means that an applicator treats the structure and thereafter hands a treated structure back to a client or customer at the end of a treatment contract.

Electrochemical treatments may also be classed as either impressed current or galvanic (sacrificial) treatments. In impressed current electrochemical treatments, an anode is connected to the positive terminal and the steel is connected to the negative terminal of an external source of DC power. An impressed current anode will often be an inert electrode. An anode is an electrode supporting a substantial oxidation reaction and, in impressed current treatments, an electrode is turned into an anode by an applied voltage.

In galvanic electrochemical treatments, the protection current is provided by one or more sacrificial anodes that are directly connected to the steel. Sacrificial anodes are electrodes comprising metals less noble than steel (more negative than) with the main anodic reaction being the dissolution of a sacrificial metal element. The natural potential difference between the sacrificial anode and the steel drives a protection current when the sacrificial anode is connected to the steel. Sacrificial anode assemblies are self powered assemblies. The protection current flows as ions from the sacrificial anode into the parent concrete and to the steel, and returns as electrons through the steel and a conductor to the sacrificial anode. The convention of expressing the direction of current flow as the direction of movement of positive charge is used in this specification.

Sacrificial anodes for concrete structures may be divided into discrete or continuous anodes (U.S. Pat. No. 5,292,411). Discrete anodes are individually distinct elements that contact a concrete surface area that is substantially smaller than the surface area of the concrete covering the protected steel. The anode elements are normally connected to each other through a conductor that is not intended to be a sacrificial anode and are normally embedded within cavities in the concrete (ACI Repair

Application Procedure 8—Installation of Embedded Galvanic Anodes (www.concrete.org/general/RAP-8.pdf). Discrete sacrificial anode systems generally include an anode, a supporting electrolyte and a backfill. An activating agent is often included to maintain sacrificial anode activity. The backfill provides space to accommodate the products of anodic dissolution and prevent disruption of the surrounding hardened concrete. Discrete sacrificial anodes have the advantage that it is relatively easy to achieve a durable attachment between the anode and the concrete structure by embedding the anodes within cavities formed in the concrete.

Galvanic protection of steel in concrete using embedded discrete anodes differs from sacrificial cathodic protection of steel in soils and waters (BS EN 12954:2001). Anode assemblies that are embedded within concrete must be dimensionally stable as concrete is a rigid material that does not tolerate embedded expanding assemblies. Anode activating agents are specific to concrete or need to be arranged in a way that would present no corrosion risk to the neighbouring steel (WO 94029496 or GB 2431167). Anodes are located relatively close to the steel in the concrete and embedded anodes are small (a discrete anode assembly diameter is typically less than 50 mm) when compared to anodes in other environments. Galvanic protection criteria for atmospherically exposed concrete differ from those for the cathodic protection of steel in soil and water. Steel is normally passive in uncontaminated, alkaline concrete. In atmospherically exposed concrete, protection is usually achieved by restoring the passive film on reinforcing steel. This effectively polarises the anodic reactions on the steel. In soil and water, a passive film on steel is not normally stable and the objective of the protection is to polarise the cathodic reaction (usually the reduction of oxygen) to prevent steel corrosion.

One problem with the use of sacrificial anodes in galvanic treatments is that the power to arrest an active corrosion process on the steel in concrete is limited by the voltage difference between the sacrificial anode and the steel. This problem is greatest for discrete sacrificial anode systems where large currents are required from relatively small anodes to protect relatively large surfaces of the steel. A compact discrete anode will typically deliver current into an area of parent concrete adjacent to the anode that is one tenth to one fiftieth of the area of the steel that it is expected to protect.

A number of methods have recently been proposed to increase the power of sacrificial anodes in concrete using a power supply including integrating a cell with the anode assembly and applying an impressed current off a sacrificial anode assembly using an external power supply (WO 05106076, U.S. Pat. No. 7,264,708 and GB 2426008). Some early teaching also exists on increasing the power of a sacrificial anode in sacrificial cathodic protection applications applied to steel in soil and saline water where different protection criteria apply (U.S. Pat. No. 4,861,449). Soil and saline water assemblies are also not of a size suitable for use in concrete.

In WO 05106076, a sacrificial anode assembly is formed by connecting the cathode of a cell or battery to a sacrificial anode. In one arrangement, the sacrificial anode forms the casing of a cell where the cathode of the cell is adjacent to the cell casing. An alkaline cell commonly has this property. The anode of the cell is then connected to the steel. The problem with this arrangement is that the sacrificial anode is not directly connected to the steel. Furthermore the charge capacity of a cell is substantially smaller than the charge capacity of a similarly sized sacrificial anode. As a result, the useful life of the assembly is limited by the charge capacity of the cell. For example, an AA sized cell has a charge capacity of only about 10 kC (kilo coulombs). An objective of this invention is to improve the useful life of such an assembly.

The sacrificial anode in the arrangement in WO 05106076 is not connected directly to the steel, and thus the sacrificial anode cannot continue to deliver a protection current after the charge capacity of the cell has expired. It is another objective of this invention to provide an assembly in which the sacrificial anode is connected to the steel so that the sacrificial anode can continue to deliver protection current after other components of the assembly have expired.

In U.S. Pat. No. 7,264,708, an automated means is provided to connect a sacrificial anode to the steel after an external power supply, or a battery driving current from the sacrificial anode to the steel, has expired. In the example in this disclosure, diodes are used to provide the sacrificial anode to steel connection. The problem with this arrangement is that power is required to achieve such a connection and this reduces the power of the protective effect. A typical diode (a diode based on a doped silicon semiconductor) will use a voltage of 0.6V to become a conductor and there is not sufficient voltage within a typical sacrificial anode system to drive a substantial current through such diodes. Another problem with this arrangement is that the power supply is located away from the anodes and is connected to the anodes by electric cables that have to be maintained and protected from the environment and from vandalism.

GB 2426008 (U.S. patent application Ser. No. 11/908,858) discloses a new basis for corrosion initiation and arrest in concrete that relies on an acidification-pit re-alkalisation mechanism. A temporary electrochemical treatment is used to deliver a pit re-alkalisation process from sacrificial anodes before the anodes are manually connected to the steel. The pit re-alkalisation process arrests active corrosion by restoring a high pH at the corroding sites. The pit re-alkalisation process (applied as a temporary impressed current treatment) typically lasts less than 3 weeks. The corrosion free condition is then maintained with the low level galvanic generation of hydroxide at the steel. The switch between the impressed current and galvanic treatments is achieved manually and this is facilitated by the limited duration of temporary impressed current treatments. The power supply and the electric cables used for the temporary impressed current treatment are removed from the site. The problem with this approach is that the temporary impressed current treatment typically requires a skilled operator.

Another problem with discrete sacrificial anode systems is current distribution. This problem is greatest for anodes that are tied to exposed steel in cavities formed within the concrete at areas of the concrete repair. A number of solutions have been proposed to improve the current distribution from an anode tied to the steel (see, for example, GB 2451725, WO 05121760, WO 04057056). However these solutions are all based on restricting the current flow to the nearest steel by increasing the resistance for current to flow to the nearest steel.

A problem to be solved by this invention is to increase the initial power available from a sacrificial anode assembly to arrest an active corrosion process while the sacrificial anode is connected to the steel in the concrete, and to improve current distribution from a sacrificial anode connected to the steel by directing an increased current away from the nearest steel.

SUMMARY OF THE INVENTION

This invention discloses a method of controlling the current output off discrete sacrificial anodes that are less noble than steel using additional anode-cathode assemblies to modify the electric field in the environment next to the anode while the sacrificial anode is connected to with an electron conducting conductor to the steel.

In one arrangement an electric field modifier with an air cathode is used to sustain a high current output off a sacrificial anode embedded in concrete. The use of an air cathode in the modifier needs to be combined with an environment like concrete exposed to the air because in this environment, cathodic protection is achieved by changing the environment at the steel to induce steel passivity or anodic polarisation (GB 2426008) and cathodic reaction kinetics are weakly polarised. In environments like soil and water, where cathodic protection is achieved by cathodically polarising the steel, an air cathode will not work because the steel to be protected represents an air cathode with a very large surface area relative to the air cathode that might be assembled within an anode assembly and the air cathode in the anode assembly will not have the capacity to deliver the necessary protection current to polarise the air cathode on the steel that is to be protected.

In another alternative arrangement, an electric field modifier is placed in the environment adjacent to the sacrificial anode to provide an initial boost to the sacrificial anode current output to arrest the corrosion process and the sacrificial anode continues to function after the charge in the modifier has been consumed because it is connected to the steel through an electron conducting conductor and a path for ionic conduction is formed from the sacrificial anode through an electrolyte to the protected steel. A path for ionic conduction is formed at least after the charge in the modifier has been consumed and the modifier no longer functions. In this case, the life of the sacrificial anode, determined in part by its charge capacity, is much greater than the life of the modifier in the anode assembly.

In another alternative arrangement an electric field modifier is arranged to boost the current from the sacrificial anode that flows to steel further away from the anode relative to the current that flows to the steel closer to the anode. In this case the sacrificial anode is preferably tied to a section of steel bar and the modifier is arranged to boost the current flowing from the sacrificial anode away from this section of steel bar.

The electric field modifier contains at least one anode electrode electronically connected by an electron conducting connection to at least one cathode electrode. The anode and cathode preferably face away from each other. The oxidation reaction on the anode (anode reaction) and the reduction reaction on the cathode (cathode reaction) can occur without any external driving potential.

One type of electric field modifier is an element comprising a side or face that is an anode supporting an oxidation reaction that is in electronic contact with a side or face that is a cathode supporting a reduction reaction, where the anode and the cathode face away from each other (i.e., the anode and the cathode face substantially different directions). A natural potential difference is generated by the oxidation and reduction reactions on the anode and the cathode respectively that tries to drive a current through the modifier. If an electrolyte connects the anode of the modifier to its cathode, an ionic current, stimulated by electrochemical reactions, will flow from the anode to the cathode. Electrochemical reactions consume reducing and oxidising agents at the anode and cathode, respectively (i.e., reductants are oxidised and oxidants are reduced at the anode and the cathode, respectively). It is preferable that these reactions should be restricted prior to use to enhance the shelf life of the modifier. This may be achieved by keeping the modifier in a dry environment to limit the quantity of electrolyte at the anode and the cathode, and/or by preventing the electrolyte at the anode from making contact with the electrolyte at the cathode.

The modifier is located in the electric field between a sacrificial anode and the steel. The modifier increases the current flowing through a path that intersects the modifier when the cathode of the modifier faces the sacrificial anode and the anode of the modifier faces away from the sacrificial anode. As a result, the modifier also increases the total current delivered by the sacrificial anode. The modifier effectively behaves as a current pump that pumps electric current through the modifier.

The sacrificial anode is a sacrificial metal element from a compact discrete sacrificial anode assembly for use in reinforced concrete construction. Such assemblies will have a charge capacity of at least 80 kC (kilo coulombs) It is preferable that the sacrificial anode has a charge capacity of at least 100 kC and more preferable that the sacrificial anode has a charge capacity of at least 150 kC.

In another arrangement, a compact discrete sacrificial anode, for reinforced concrete construction, is arranged with the cathode of the modifier to form a cell.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention will now be described further with reference, by way of example, to the drawings in which:

FIG. 1 illustrates the effect of an electric field modifier on the current flow between a sacrificial anode and the steel.

FIG. 2 shows an arrangement illustrating the use of a sacrificial anode/modifier assembly located within a cavity formed in the concrete for the purposes of installing the assembly.

FIG. 3 shows an arrangement illustrating the use of a sacrificial anode/modifier assembly when installing the assembly in an area of concrete patch repair.

FIG. 4 shows the sandbox arrangement that was used to test the theory in Examples 1 and 2.

FIG. 5 shows the changes in galvanic current output when an electric field modifier was inserted into and removed from the sand in Example 1.

FIG. 6 shows the early galvanic current output of a control test and two tests involving two different modifiers in Example 2.

FIG. 7 shows the medium term galvanic current output of a control test and tests involving two different modifiers in Example 2.

FIG. 8 shows the experimental arrangement used in Example 3 to test the effect of a modifier on the protection current delivered to steel in a cement mortar.

FIG. 9 shows a section of the steel cathode that was used in Example 3.

FIG. 10 shows the early galvanic current output of a control test and a test involving a modifier in Example 3.

FIG. 11 shows the galvanic current output from day 6 to day 21 of a control test and a test involving a modifier in Example 3.

FIG. 12 shows the galvanic current output from day 15 to day 60 of a control test and a test involving a modifier in Example 3.

DETAILED DESCRIPTION OF THE INVENTION

The effect of an electric field modifier on current flow is illustrated in FIG. 1. In this example, a modifier 1 is placed, in an electrolyte 4, between a sacrificial anode 2 and protected steel 3. The sacrificial anode 2 is connected to the steel 3 by a connection 5. A galvanic protection current that flows from the sacrificial anode 2 through the electrolyte 4 to the steel 3 returns to the sacrificial anode 2 via the connection 5. The modifier 1 has a surface facing the sacrificial anode 2 that acts as a cathode and a surface facing the steel 3 that acts as an anode and a natural potential difference between the anode and the cathode stimulates reactions on the anode and the cathode. The anode and cathode electrodes of the modifier 1 are connected back to back by an electron conducting connection and face in opposite directions. Other electrode arrangements of the modifier 1 are also envisaged.

In FIG. 1, lines in the electrolyte 4 with arrowheads show the direction of positive ionic current flow through the electrolyte. Current is drawn from the sacrificial anode 2 through the modifier 1 to the steel 3 by the voltage between the anode and the cathode of the modifier. When the anode and cathode reactions on the modifier 1 increase, the current that would flow along a path that intersects the modifier 1, the total current flowing from the sacrificial anode 2 to the steel 3 is increased. Furthermore, current that bypasses the modifier 1 is reduced or reversed. Thus the current output of a sacrificial anode 2 may be directed through specific regions of the electrolyte while the total current is increased.

The modifier 1 acts like an electric current pump. The electrochemical reactions on its electrode surfaces drive electrons (i.e., current) on its inside from its cathode electrode to its anode electrode. This may be used to change the ionic current in the electrolyte outside the modifier 1. It is to be appreciated that the modifier 1 may be used to increase the flow of external current, change the direction of the external current or even reverse the direction of the external current.

An electric field modifier 1 is preferably in the form of a sheet shaped as a tube or a hollow container. In one embodiment, the inner surface is the cathode and the outer surface is the anode. A sacrificial anode is typically located within the modifier 1 comprising the tube or the hollow container. To increase the current output of a sacrificial anode 2, the cathode of the modifier 1 faces the sacrificial anode 2 and the anode of the modifier 1 faces away from the sacrificial anode 2. The modifier 1 may comprise a single element or several discrete elements with gaps between them or the modifier 1 may be a single element that is perforated so as to have gaps or voids. Several modifiers 1 may be used either in series or parallel with one another.

The anode of the modifier 1 is an electrode supporting an oxidation reaction, while the cathode of the modifier 1 is an electrode supporting a reduction reaction. Suitable oxidizable materials (also termed reducing agents or reductants) for the anode of the modifier 1 include, for example, zinc, aluminium, magnesium or alloys thereof. For use in concrete a zinc or zinc alloy anode is preferred. The oxidation reaction supported by a zinc anode is zinc dissolution.

The cathode of the modifier 1 includes an electron conducting surface on which reduction can take place, together with a reducible material. Suitable reducible materials (also termed oxidizing agents or oxidants) for the cathode include oxygen and manganese dioxide. The electron conducting surface and reducible material forms an electrode that is more noble than the anode of the modifier 1 (i.e., for the modifier to be effective, the potential of the cathode is more positive than the potential of the anode). Suitable electron conducting surfaces on which reduction can take place are carbon, silver and nickel. This surface preferably resists oxidation.

Other examples of possible anode and cathode materials for the modifier 1, can be found in the field of battery technology. Cathode materials are usually oxygen from the air or solids that may be porous. Solid cathode materials include metal oxides such as manganese dioxide.

The modifier 1 differs from a cell or battery in that its anode is connected to its cathode that faces away from its anode before use with a connection that allows electrons to flow between its anode and its cathode. The circuit is completed, during use, by the introduction of an electrolyte 4. By contrast the anode and the cathode of a cell or a battery are connected by an electrolyte before use and the circuit is typically completed by electron conducting components when the cell or the battery is used.

In use, an electrolyte connects the anode of the modifier 1 to the steel 3, located in concrete to be protected, and an electrolyte 4 connects the sacrificial anode 2 to the cathode of the modifier 1. An electrolyte connection between the anode and the cathode of the modifier is not required for the modifier 1 to function and is preferably omitted, prior to use, to preserve the shelf life of the modifier. The electrolyte connection 5 between the sacrificial anode and the cathode of the modifier 1, may be formed in advance of using a sacrificial anode/modifier 1 assembly and may be part of this assembly. Alternatively, the electrolyte connection, between the sacrificial anode and the cathode of the modifier, may be formed during installation of the assembly.

As the modifier 1 operates, its oxidizable and reducible materials are consumed. Thus the modifier 1 has a limited useful life that depends on the charge capacity of these materials. The life of the modifier will end when either the available oxidizable or reducible material is consumed. Anode materials like zinc tend to have a relatively high charge density and occupy a small volume compared to cathode materials like manganese dioxide. However the volume of the cathode, and therefore the modifier, 1 may be minimized if oxygen from the air is used as the main reducible material. The cathode may then comprise a thin carbon or silver coating that facilitates the reduction of oxygen from the air. Such a cathode is referred to as an air cathode and effectively has an unlimited life. The life of the modifier is then determined by its anode.

Both oxygen and water are required to support an air cathode, but oxygen is not available to support a relatively high cathodic reduction reaction rate in all environments. Oxygen from the air is readily available in concrete structures that are exposed to the air and periodically allowed to dry. In air dried concrete (which will not be completely dry), cathodic oxygen reduction rates equivalent to a current density of more than 200 mA/m²can occur. This is more than an order of magnitude greater than typical cathodic protection current densities in concrete and, under these conditions, an air cathode works well since it can promote and support high current densities. A modifier with an air cathode is suitable for use in concrete dried in the air.

In other environments like sea-water and soil, cathodic protection current densities tend to be of the same order as the limiting current equivalent to the maximum rate of oxygen reduction and in these environments an air cathode in a modifier cannot be effective because oxygen access then limits the cathode current output. A modifier with an air cathode will then block the current output of a sacrificial anode. A modifier 1 with an air cathode is, therefore, not generally suitable for use in soil and in sea-water.

FIG. 1 also shows that the direction of current in the electrolyte 4 that bypasses the modifier 1 may be reversed. Current flows through the electrolyte 4 from the anode of the modifier 1 to the cathode of the modifier 1. Reversing the current direction in the electrolyte 4, that bypasses the modifier 1, represents inefficient use of the charge in the modifier 1 in many circumstances as this charge does not form part of the current flowing to the steel. One method of minimizing the magnitude of the reversed current is to use a modifier 1 with a smaller potential difference between its anode and its cathode. A zinc-air modifier will have a potential difference between its anode and its cathode that is similar to the potential difference between a sacrificial anode 2 and passive steel and will, therefore, tend to use its charge more efficiently than a modifier 1 with an anode cathode combination that has a higher potential difference.

The useful life of an electrode depends on the charge stored in the oxidizable or reducible material and the efficiency of the use of this charge. In some cases the useful life of the sacrificial anode 2 (i.e., the period of time that the sacrificial anode 2 has a capacity to deliver a galvanic protection current to the steel 3) may be substantially greater than the useful life of a modifier 1 (i.e., the period of time a modifier has a capacity to increase the current that flows on a path that intersects the modifier). For example, the useful life of the sacrificial anode 2 may be two or three or ten times the useful life of the modifier 1. This is preferable when a high current is only required at the start of a galvanic treatment to arrest a corrosion process in concrete, as it results in the more efficient use of the charge in the sacrificial anode 2. In this case, a path for ionic conduction between the sacrificial anode 2 and the protected steel 3 is required to continue to deliver the galvanic current once the useful life of the modifier 1 expires. This may be achieved by leaving gaps or voids within the modifier 1 that are filled with a porous material containing the electrolyte 4, or by using a modifier 1 that is transformed into a porous material containing an electrolyte 4 as it is consumed, or by a combination of these features.

A zinc-air modifier 1 may be transformed into a porous solid by the corrosion of the zinc and the disruption of the electron conducting surface of the air cathode. The electron conducting surface may be disrupted by the corrosion of the zinc when it is a thin zinc surface treatment or coating attached directly to a zinc surface that supports oxygen reduction. Other modifiers, with a cathode comprising an electron conducting surface and a porous reducible material, may also be transformed into a porous solid when the electron conducting surface of the cathode is disrupted by the consumption of the anode.

The charge in the sacrificial anode 2 may also be consumed more efficiently if the current output of the sacrificial anode 2 responds to the aggressive nature of the environment. It is preferable for the protection current to respond positively to factors affecting steel corrosion risk to improve the efficient use of the charge in the sacrificial anode. Thus the sacrificial anode current output, in a dry or cold environment, is preferably lower than its current output in a hot or wet environment. The use of a modifier 1 allows the current output of the sacrificial anode 2 to be boosted without limiting the effects of wet/dry or hot/cold cycles on the current output of the sacrificial anode 2.

In some cases, it is desirable to direct the current off the sacrificial anode 2 to improve current distribution. This is relevant when the sacrificial anode 2 is tied directly to a section of steel in uncontaminated repair material at an area of corrosion damaged concrete repair. In this case, the current needs to flow to the steel in the adjacent parent concrete as opposed to the steel in the repair material. To boost this current, the modifier 1 may be positioned to the side of the sacrificial anode 2, facing away from the closest portion of steel 3. The cathode of the modifier 1 faces the sacrificial anode 2.

One arrangement illustrating the use of a sacrificial anode/modifier assembly is shown in FIG. 2. This arrangement is suited to the embedment of the assembly into a cavity 8 formed in the concrete for the purposes of installing the assembly. The cavity 8 may be a drilled or a cored hole in the concrete 9 which is typically no more than 50 mm in diameter. The cavity 8 is preferably sized to accept the assembly.

The sacrificial anode 10 is in the form of a bar located at the center of the hole or cavity 8 and will typically be no more than about 200 mm in length and be cast around a conductor. The sacrificial anode 10 is connected to the steel 11 via a conductor 12 (e.g., typically an electric cable or a wire). A preferred conductor 12 substantially comprises titanium as this would also allow the sacrificial anode 10 to be used with an impressed current (e.g., an external power supply driving a high current off the anode) which may be used to provides a facility to manage future corrosion risk by providing facility to deliver a temporary treatment to arrest future corrosion.

The modifier 13, comprising an anode 14 and a cathode 15 in the form of a tube or hollow cylinder that is open at both ends, substantially surrounds the sacrificial anode 10. The cathode may be an air cathode and oxygen from the air may diffuse into the tube through either of its openings (e.g., the top or the bottom in FIG. 2). Such openings also provide a path for ionic conduction between the sacrificial anode 10 and the steel 11 at the end of the useful life of the modifier 13.

A filler 16 provides an electrolyte that is an ionic conductor to connect the sacrificial anode 10 to the cathode 15 of the modifier 13. The filler 16 will preferably be in the form of a porous solid or putty containing the electrolyte. A backfill 17 provides an electrolyte to connect the anode 14 of the modifier 13 to the parent concrete 9. The backfill 17 and the filler 16 may conceivably be the same material or different materials and may be installed at the same time or at different times. The filler 16 may be separated from the backfill 17 by a porous layer in which the pores are lined with a hydrophobic material. This provides a breathable hydrophobic layer that allows oxygen to move to an air cathode but limits the formation of a flow path through an electrolyte between the anode 14 and the cathode 15 of the modifier 13 and therefore enhances the efficient use of the modifier. A hydrophobic porous material may be produced by treating a porous material, like hydrated cement paste, with a silane based water repellent. Breathable hydrophobic material may extend from outside the assembly to any part of the air cathode to promote oxygen access to the air cathode.

The cavity 8 in the concrete may be partially filled with the backfill 17 and the sacrificial anode 10 and the modifier 13 are installed in the cavity 8 such that the backfill 17 fills the spaces between the sacrificial anode 10, the modifier 13 and the parent concrete 9. This may be achieved by first installing the backfill 17 and then pressing the sacrificial anode 10 and the modifier 13 into the backfill 17. In this arrangement, the backfill 17 acts as both a filler and a backfill. The sacrificial anode 10 and the modifier 13 may be pre-assembled as a separate unit or assembly with the modifier 13 being attached to and spaced from the sacrificial anode. However, the sacrificial anode 10 must not be attached to the modifier 13 with an electron conducting attachment. Such an attachment is to be avoided as it consumes the sacrificial anode and the cathode of the modifier. The assembly in the cavity 8, may then be finally covered with a cementitious repair mortar or concrete 18, as illustrated in FIG. 2.

An activating agent, adapted to maintain the sacrificial anode activity, may be applied as a coating on the sacrificial anode 10, or it may be included within the filler 16 or within the body of the sacrificial anode. The anode 14 of the modifier 13 may also be coated with an activating agent, or aggressive ions in the concrete may be drawn to the anode of the modifier by ionic current induced in the adjacent concrete to maintain the activity of the anode.

Another arrangement illustrating a method of using a sacrificial anode/modifier assembly is shown in FIG. 3. This arrangement is suited for attaching the assembly to a section of steel bar exposed at an area of a concrete patch repair. The sacrificial anode 21 is attached to the steel bar 22 with an electron conducting tie 23. The sacrificial anode 21 may be spaced off the steel bar 22 by a spacer 24 to improve current distribution. The sacrificial anode 21 is substantially surrounded by a modifier 25 having a “U” shaped cross section. The modifier 25 comprises a cathode 26 facing the sacrificial anode 21 and an anode 27 facing away from the sacrificial anode 21. The modifier 25 is positioned so as to direct current away from a section of the steel bar 22. The cathode 26 of the modifier 25 is connected to the sacrificial anode 21 by the electrolyte in a filler 28. The filler 28 is generally in the form of a porous solid or a porous putty. The pores of the filler 28 may be partially filled with air to promote the function of an air cathode and may include a breathable hydrophobic material. An electrolyte should also be present in the pores of the filler 28 to facilitate ionic conduction and electrochemical reactions (oxidation at the sacrificial anode 21 and reduction at the cathode 26 of the modifier 25.). The anode 27 of the modifier 25 may be connected to the concrete 29 by a cementitious concrete repair material 30.

An activating agent, adapted to maintain activity of the sacrificial anode 21, may be applied as a coating on the sacrificial anode 21, or it may be included within the filler 28 or within the body of the sacrificial anode 21. The anode 27 of the modifier 25 may also be coated with, or contain within its body, an activating agent. The cathode 26 of the modifier 25 may be an air cathode and the ends of the “U” section modifier may be left open to facilitate the diffusion of oxygen from the air through the repair material 30 and the filler 28 to the cathode 26 of the modifier 25. These openings also provide a path for ionic conduction between the sacrificial anode 21 and the steel 22 in the concrete 29 that bypasses the modifier 25 to facilitate the continued function of the sacrificial anode 21 once the charge in the modifier 25 is exhausted.

In the arrangement shown in FIG. 3, it is preferable to form an assembly comprising the sacrificial anode 21, the modifier 25 and the filler 28 as a preformed unit or assembly. The preformed unit or assembly also preferably includes the spacer 24, the connector 23 or a connection point, and an activating agent adapted to maintain the activity of the sacrificial anode 21. Openings within the modifier 25, that are provided to facilitate the transfer or movement of oxygen from the air to the cathode 26, may be treated with a breathable hydrophobic (i.e., water repellent) treatment to improve the diffusion of oxygen from the air into the filler 28.

According to one aspect, this invention provides a method of protecting steel in hardened reinforced concrete elements exposed to the air using an ionically conductive filler and an assembly comprising a sacrificial anode and an electric field modifier that includes the steps of connecting the sacrificial anode to the steel with an electron conducting conductor and connecting the modifier to the concrete with an electrolyte wherein the sacrificial anode is a metal less noble than steel and the sacrificial anode is substantially surrounded by the modifier, and the modifier comprises an element with a side that is an anode supporting an oxidation reaction in electronic contact with a side that is a cathode supporting a reduction reaction, and the cathode of the modifier faces the sacrificial anode and is separated from the sacrificial anode by the filler, and the filler is a porous material containing an electrolyte that connects the sacrificial anode to the cathode of the modifier, and the anode of the modifier faces away from the sacrificial anode.

According to another aspect, this invention provides an assembly to protect steel in hardened reinforced concrete elements exposed to the air comprising a sacrificial anode and an electric field modifier, wherein the sacrificial anode is a metal less noble than steel and the sacrificial anode includes a connector to electronically connect it to the protected steel, and the sacrificial anode is substantially surrounded by the modifier, and the modifier comprises an element with a side that is an anode supporting an oxidation reaction in electronic contact with a side that is a cathode supporting a reduction reaction, and the cathode of the modifier faces the sacrificial anode and is separated from the sacrificial anode, and the anode of the modifier faces away from the sacrificial anode.

The cathode of the modifier may comprise an air cathode with a reduction reaction that substantially comprises the reduction of oxygen from the air. A breathable hydrophobic material may be included with the sacrificial anode/modifier assembly.

The useful life of the sacrificial anode may be substantially greater than the useful life of the modifier and a path, for ionic conduction between the sacrificial anode and the concrete, may be provided at least after the useful life of the modifier has ended.

The sacrificial anode may be connected to a section of steel in an area of concrete patch repair and the modifier may be positioned relative to the sacrificial anode to enhance the flow of current in a direction away from a section of steel. The assembly may include a face that is tied to a section of steel within an area of concrete patch repair and the modifier may be positioned relative to the sacrificial anode to enhance the current flowing in a direction away from the side of the assembly to be tied or otherwise connected to the steel.

A cavity, which is sized to accept the assembly, may be formed in the hardened concrete and thereafter the assembly may be installed within the cavity. The assembly may be installed in a backfill in the cavity wherein the backfill contains the electrolyte that connects the anode of the modifier to the concrete.

The assembly may include an activating agent specially adapted for use in concrete in order to activate the sacrificial anode. The anode of the modifier and the sacrificial anode may comprise zinc, aluminium or magnesium or alloys thereof.

EXAMPLE 1

An electric field modifier was constructed using a zinc casing of a standard zinc chloride D size cell (also referred to as a zinc-carbon battery with the International Electrotechnical Commission classification of R20). A sheet of zinc was cut from the casing and flattened and sanded to clean any deposit(s) from the zinc. It measured approximately 55 by 100 mm. One side of the zinc sheet was coated with two coats of an electrically conductive silver paint of the type used to make electrical connections on circuit boards. The sheet was then baked at 240° C. for 15 minutes to remove the coating solvent. Carbon, in the form of a graphite rod, was then rubbed onto the silvered surface to produce a loose thin grey coating. Any coating on the reverse side of the zinc sheet was removed using a 220 grit sandpaper to leave a clean, bright zinc surface. The silver and carbon surface is designed to act as an air electrode (i.e., the cathode) to facilitate the reduction of the oxidizing agent, oxygen, while the zinc surface is designed to provide the reducing agent (zinc) to be oxidized (i.e., the anode). When an electrolyte is added, the reduction of oxygen and the oxidation of zinc will provide an electric field to enhance current flow from a sacrificial anode to steel.

The test arrangement is shown in FIG. 4. A high resistivity sandbox was used in the place of a concrete or mortar in specimens to facilitate accelerated testing of the theory. The sandbox 33 was formed using fine damp sand to simulate a high resistivity porous environment, similar to concrete, for testing purposes. The sand was dampened with water, but it was not saturated, so as to provide some electrolyte and some air in a resistive porous environment. Approximately 1 kg of damp fine sand was mixed with a tablespoon of table salt to produce an environment that contained an activating agent for the zinc anodes. It was placed in a plastic container measuring 100 by 150 by 50 mm to form the sandbox 33. A clean zinc sheet, also taken from a D-cell, was inserted into the sand at one end of the sandbox 33 to act as a sacrificial anode 34. A similarly sized sheet of steel 35 was inserted into the sand at the other end of the sandbox 33.

The zinc 34 was connected to the steel 35 by cables 36 and an ammeter 37. After 10 minutes, the initial galvanic current reduced to 0.55 mA. The rate of change at this point was sufficiently slow that it could be regarded as being substantially stable for a short term test.

The modifier 38 was then inserted into the sand, between the zinc sacrificial anode 34 and the steel 35, with its silver surface facing the zinc anode 34 and the zinc surface facing the steel 35. As the modifier 38 was inserted, the current began to rise. The current continued to rise, following insertion of the modifier 38, and peaked at 0.82 mA between 5 and 20 minutes. After 20 minutes, the current started to show signs of falling.

The galvanic couple was left connected overnight. After 10 hours, it was measured again at 0.68 mA. The air temperature was approximately 15° C.

The sandbox 33, with the modifier 38, was then placed in a warmer environment. After 39 hours, the sandbox 33 had warmed up to about 20 to 25° C. The current was again measured and this time it was 1.26 mA. The modifier 38 was removed and the current then stabilised at 0.48 mA after 30 minutes. The modifier 38 was again inserted into the sand, but this time it was rotated so the silvered surface faced the steel 35. The current fell to −0.08 mA. The electric field of the modifier 38 completely overcame the electric field of the zinc steel couple and reversed the direction of the current flow.

The above procedure was then repeated after water had been added to the sand to replace water lost through evaporation. This time the current between the zinc sacrificial anode 34 and the steel 35 was recorded using a datalogger. The current-time behaviour is shown in FIG. 5.

The starting galvanic current was measured without the modifier 38 being present. The galvanic current stabilised at just over 2 mA. The modifier 38 was then inserted (at time zero in FIG. 5) between the sacrificial anode 34 and the steel 35 with the cathode of the modifier 38 facing the sacrificial anode 34. The galvanic current increased to 3.3 mA over the next 45 minutes. After 45 minutes the modifier 38 was removed and the galvanic current fell back to 2 mA for 20 minutes. After 65 minutes the modifier 38 was again inserted between the sacrificial anode 34 and the steel 35, but this time the anode of the modifier 38 faced the sacrificial anode 34. The galvanic current fell to 0.7 mA for 30 minutes. After 95 minutes the modifier 38 was again removed and the galvanic current rose to 2 mA.

The above test has shown that a modifier 38 may be used to substantially increase or decrease the current output of the sacrificial anode.

EXAMPLE 2

Two electric field modifiers of approximately 55 by 50 mm in size were constructed using the same zinc sheet as described in Example 1. One side of each zinc sheet was first coated with two coats of silver paint and then baked as described in Example 1. Thus one side of each sheet was zinc and the other side was a conductive silver coating. The silver coated surface was then coated with a carbon rich paint. Two make the carbon paint, a carbon bar from the center of a zinc-carbon battery was sanded down to produce a fine carbon powder. The power was mixed with a drop of clear outdoor varnish and approximately 10 times as much varnish solvent thinner. A carbon to binder ratio in the dry paint film of greater than 10:1 was targeted. The painted zinc sheet was then baked further to remove the solvent. The conductivity of the painted surface was checked using a resistance meter with two probes which were lightly pressed onto the carbon coated surface. The resistivity was less than 1 ohm. One of these sheets will be referred to as the zinc-air modifier in this example.

A manganese dioxide-carbon mixture was then applied to the carbon coated surface of the other zinc-carbon sheet. The manganese dioxide-carbon mixture was sourced from the cathode side of a standard zinc chloride D size cell. It was applied as a layer to the carbon coated surface of one zinc-carbon sheet and then covered with wall paper paste and then covered with a thin absorbent paper tissue and then pressed firmly together under a weight of approximately 60 kg. The manganese dioxide-carbon mixture and absorbent tissue was then trimmed to the edge of the zinc sheet to provide a zinc sheet with a 2 mm thick manganese dioxide-carbon layer on one side and uncoated zinc on the other side. This modifier is referred to as a zinc-manganese dioxide (MnO₂) modifier.

A batch of a damp fine sand-salt mixture, containing both electrolyte and air was made as described in Example 1. The mixture was used to fill three small sandboxes 33 measuring 90 by 65 by 35 mm. A bare zinc sheet measuring approximately 55 by 50 mm was partially inserted into one end of each sandbox 33 and a similarly sized steel sheet was partially inserted into the other end of each sandbox 33. The zinc was connected to the steel through a 100 ohm resistor in each sandbox to form a galvanic cell. A galvanic current flowed through the resistor and produced a voltage that was measured to monitor the galvanic current. The general layout was similar to that shown in FIG. 4, with the ammeter being replaced by a 100 ohm resistor.

The galvanic currents in the sandboxes 33 were first measured without any modifiers being used. The sandbox 33 that produced the highest galvanic current was chosen to be the control. The zinc-air modifier was inserted between the zinc sacrificial anode and the steel of the second sandbox The carbon surface of the modifier faced the zinc sacrificial anode. The zinc-manganese dioxide modifier was inserted between the zinc sacrificial anode and the steel of the third sandbox. The manganese dioxide surface of the modifier faced the zinc sacrificial anode. The galvanic current was logged (recorded on a data logger) during this process.

The galvanic currents from the three sandboxes 33 are shown in FIGS. 6 and 7. The electric field modifiers were inserted into the sand between the zinc anode and the steel at time zero in these Figures. Immediately after the modifiers were inserted, the galvanic cell with the zinc-manganese dioxide modifier produced the highest galvanic current (FIG. 6). However this high initial current decayed over 10 hours and then the galvanic cell with the zinc-air modifier produced the highest galvanic current. The currents from all three cells decayed at a slow rate, probably as the result of the sand between the zinc and the steel drying out. After 7 days, the sandboxes were inserted into a large plastic bag to slow the rate of further drying of the sand and the galvanic currents stabilised, to primarily show daily fluctuations that would be associated with daily variations in temperature (FIG. 7). Over time, the galvanic current produced by the cell with the zinc-manganese dioxide modifier recovered to a value closer to that of the zinc-air modifier.

These results again indicate that an electric field modifier is capable of substantially boosting the short term current output of a sacrificial anode. In addition, a modifier with a more powerful manganese dioxide cathode, at the start, may become a modifier with an air cathode after the manganese dioxide is spent (consumed by reduction) as a cathode material.

EXAMPLE 3

The test arrangement for Example 3 is shown in FIG. 8. Two cement mortar blocks 41 (measuring 270 mm long by 175 mm wide by 110 mm high) were cast using damp sand, Portland cement and water in the weight ratio 4:1:0.8. The mortar was of a relatively poor quality and some bleed water formed on top of the casting. A steel cathode 42 with a surface area of 0.12 m²was positioned in the outer edge of each mortar block during the casting process. The steel cathode was formed from two 300 mm by 100 mm steel shims that were cut and folded to form a set of 20 mm wide by 90 mm long steel strips connected by a 10 mm by 300 mm strip to allow both sides of the steel to receive current during the testing process. A segment of the cut and folded steel cathode 42 is shown in FIG. 9. An electric cable 43 was connected to the steel cathode 42 and extended beyond the cement mortar 41 to enable electrical connections to be made to the steel cathode 42. A hole 44, measuring 40 mm in diameter by 70 mm deep, was formed in the center of the cement mortar block 41 to house a sacrificial anode assembly. The cement mortar blocks were covered and left for 7 days to cure.

An electric field modifier 45 was made from a zinc cylinder from a standard zinc chloride D size cell described in Example 1 after removing the base, top and inside of the cell. The zinc cylinder measured 32 mm in diameter by 55 mm long. It was lightly sanded and washed with soap to remove any deposit(s). The inside of the zinc cylinder was then coated with two coats of silver conductive paint and one coat of carbon conductive paint and baked, as described in Example 2, to form the cathode 46 of the modifier 45. The outer surface of the cylinder formed the anode 47 of the modifier 45. A salt paste, consisting of a starch based wall paper paste and table salt (primarily sodium chloride) in equal volumes was mixed up and applied to the outer zinc surface of the modifier. The modifier was then baked again in an oven at 240° C. for 15 minutes to dry the salt paste and form a crusty layer of salt on the outer zinc surface. The purpose of the salt-starch coating was to provide an activating agent for the zinc anode. This modifier 45 is referred to as a zinc-air modifier as the anode reaction is the dissolution of zinc and the cathodic reaction is the reduction of oxygen from the air.

Two zinc sacrificial anodes were formed by casting a 15 mm diameter, 35 mm long bar of zinc around a titanium wire. The charge capacity of the anodes was about 150 kC. The surface of the zinc bar was coated with the salt paste, described above, and baked to form a crusty layer of salt on the zinc surface.

After the cement mortar specimens had cured for 7 days, the 40 mm diameter hole in the center of each specimen was partially filled with lime putty 50 and the zinc sacrificial anode 49 was inserted into the lime putty 50 such that the sacrificial anode 49 and the putty 50 filled approximately 85% of the space within the hole. The sacrificial anode 49 was connected to the steel cathode 42 by an electric cable 51 and a 100 ohm resistor 52 and the galvanic current was measured and recorded, as described in Example 2. The two specimens were left for 1.5 hrs to stabilize and the specimen that produced the highest galvanic current was selected as the control specimen while the second specimen was used to test the zinc-air modifier.

After 1.5 hours, water was added to the lime putty 50, in both specimens to soften the putty 50. The zinc-air modifier 45 was then pressed into the lime putty 50 around the sacrificial anode 49 in one specimen to substantially surround the sacrificial anode 49. The galvanic currents were recorded and are given in FIGS. 10, 11 and 12. In these figures, time zero is the time when the modifier 45 was installed. The control specimen has no modifier.

Initially no positive effect of the modifier 45 was seen (FIG. 10). Indeed the effect appeared to be negative. The control specimen, with the wet putty, appeared to deliver substantially more current than the specimen with the wet putty and the modifier 45. However, as the putty 50 started to dry and harden, a significant positive effect of the modifier 45 became evident.

To explain this observation, it is noted that a galvanic current of 3 mA is a relatively high current for such a small sacrificial anode assembly in a cement mortar. It equates to a cathode current density on the modifier of 550 mA/m². It is postulated that it is difficult for the cathode 46 of the modifier 45 to support such a high current density in a very moist putty 50 as oxygen from the air must come into contact with the carbon on the cathode 46 of the modifier 45 to sustain the cathodic reduction reaction. In this case, the cathode of the modifier would block the high current density. As the putty 50 eventually dries, oxygen has easier access to the cathode 46 of the modifier 45 while the anode reactions (the dissolution of zinc) become more restricted. Thus the modifier 45 tends to sustain the current as the putty 50 dries and hardens. This observation indicates that both electrolyte and air are needed for the modifier with an air cathode to work.

After 2.6 days, the sacrificial anode assembly, in each cement mortar specimen, was covered with cement mortar which filled the remainder of the hole or cavity. The two specimens were placed outside and exposed to the weather of the UK Midlands. The weather was initially sunny and dry with direct sunlight falling on the specimens in the late afternoon and the specimens were drying fairly rapidly. This weather was sustained until day 11. The daily maximum air temperature rose from 17° C. on day 3 to 26° C. on days 8 and 9. On day 12, the first of a series of cold fronts passed over the region and the daily maximum temperature dropped to a low of 13° C. There were also more clouds and less sunshine. On day 15, it began to rain with some significant rain showers wetting the specimens. Intermittent showers continued through to day 19. On day 17, the position of the control and zinc-air modifier mortar blocks was switched to minimize the effect of any changes in microclimate. The daily maximum air temperature rose to 17° C. by day 20.

The galvanic currents from the two specimens, between days 6 and 21, are provided in FIG. 11. The data suggests the modifier 45 has a substantial positive effect on the galvanic current output of the anode assembly. The modifier 45 resulted in an average galvanic current over any 24 hour period on day 6 onwards that was between 1.6 and 5.6 times higher than the control specimen. The effect of the daily variations in air temperature and rain on day 15 are also evident in the data and indicates that a beneficial responsive behaviour of the protection current output to changes in the aggressive nature of the cement mortar was retained and amplified by the presence of the modifier 45. The most pronounced daily variations occurred between days 7 and 12 when the specimens were directly heated by the sun's radiation. These pronounced variations disappeared when the weather clouded over. The effect of wetting the specimen with rain water is a slower process that occurred after day 15.

The galvanic currents from the two specimens between days 15 and 65 are shown in FIG. 12. The data suggests that the effect of the modifier 45 lasted until day 45. After the modifier 45 expired, the sacrificial anode 49 continued to deliver current at a similar magnitude to the control specimen. Thus, it is possible to produce an anode assembly with a modifier where the modifier delivers an initial boost in the sacrificial anode current output without any substantial adverse effect on the longer term galvanic current output of the sacrificial anode.

	Number	Date	Country
Parent	12814120	Jun 2010	US
Child	13625387		US

CORROSION PROTECTION OF STEEL IN CONCRETE

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