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EMACOCP INTACT

John Halsall

Regional Business Segment ManagerRepair & Grouts

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What is Emaco CP Intact?

Discrete Zinc Anodes Placed in the Repair Area to corrode Preferentially

to the Reinforcement

Provide Galvanic Corrosion Protection

Family of Products

- EMACO CP INTACT 65

- EMACO CP INTACT 105

- EMACO CP INTACT 150

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Why is Corrosion of Reinforcing

Steel a Problem?

When steel corrodes the iron turns into iron oxide or rust. The

rust takes up to four times the volume as the steel. This puts

pressure on the concrete and causes cracking and spalling.

4 Fe + 2 H2

O + 3 O2

4FeOOH

Corrosion also

dissolves the

steel which results

in a loss of

structural strength.

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Incipient Anode / Ring Anode Effect

Patch repairs are Chloride Free

Surrounding Area High Concentration

Induce Corrosion Between Two Regions

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Revision - Corrosion Cell

Anode4 Fe 4 Fe4 Fe 4 Fe4 Fe 4 Fe4 Fe 4 Fe2+2+2+2+ + 8 e+ 8 e+ 8 e+ 8 e----

4 Fe4 Fe4 Fe4 Fe2+2+2+2+ + O+ O+ O+ O2222+ 8OH+ 8OH+ 8OH+ 8OH---- 4 FeOOH + 2 H4 FeOOH + 2 H4 FeOOH + 2 H4 FeOOH + 2 H

2222OOOO

2 O2 O2 O2 O2222+ 4 H+ 4 H+ 4 H+ 4 H

2222O + 8 eO + 8 eO + 8 eO + 8 e---- 8 OH8 OH8 OH8 OH----

e----

Electrolyte

Connectio

n

Cathode

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What is Cathodic Protection?

A way control the corrosion of a metal surface (Reinforcement) by making it

the CATHODE of an Electrochemical Cell.

This can be achieved is by connecting the Reinforcement to another more

easily corroded metal (eg Zinc in Emaco CP Intact)

The Zinc then acts as theANODE which is where the corrosion will take

place, and corrodes in preference to the steel.

THIS IS CALLED GALVANIC CATHODIC PROTECTION

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Galvanic Series

PotassiumMagnesium

Beryllium

Aluminium

Zinc

Chromium

Iron

Nickel

Tin

Copper

Least energy

required

Most energy

required

Noble Metals

Silver

Platinum

Gold

More likely

to corrode

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Cathodic Protection in Construction

Cathodic Protection Was First Used As Early As 1824 In Recent Years Cathodic Protection Has Been Adopted In The

Construction Industry

Last 10 Years Promoted As Part Of A Holistic Approach To ConcreteRepair

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Sacrificial Cathodic Protection Systems

What are they?

In the Emaco Intact CP anode, Zinc corrodes in place than Iron (steel) and so

protects the reinforcing bar

The Zinc is slowly consumed over time often lasting decades.

Anode systems such as EMACO INTACT CP anodes or Galvashield are often

called Sacrificial Anodes

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Sacrificial Cathodic Protection Systems

How Do They Work ?

A pre-manufactured Anode is attached to thereinforcing steel

The steel must have continuity

Spacing depend upon a number of factors

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Sacrificial Cathodic Protection Systems

How Do They Work ?

Anode Protects the Adjacent Reinforcing Steel fromCorroding Area of cathodic

protection.

Sometimes called

the throw of the

anode.

BASF

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Why do we need different sizes?

The Emaco CP Intact anodes (and others in the market) are made in

different sizes because the different quantities of zinc only increase the

design life of the anode.

A larger weight anode does not throw more current, nor do you require

less of them nor can you increase the spacing (related to the amount of

steel to be protected and the throw of the anode).

Choice of size is dependent on the conditions to which it will be exposed.

e.g. in an aggressive environment a larger anode may be chosen to

maximise the life of the patch whereas a smaller anode maybe chosen forless aggressive environments. The intention is to provide decades of

protection.

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EMACOCP INTACT - Technology Advancements

SUPERIOR ZINC ALLOY

ASTM B418 Type II zinc

- Low iron content means

less intergranular corrosion

- Dont Corrode in the box!

- Slower Corrosion in service

- Longer life

No Cadmium

- Environmentally friendly

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EMACO

CP INTACT - Technology Advancements

SUPERIOR DESIGN

Increased Zinc surface area

Pre-Twisted Wires

Rounded corners in mortar

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EMACO

CP INTACT - Technology advancements

SUPERIOR ENCASEMENT MORTAR

Uses more effective mechanism to ensuresacrificial corrosion - Chelation

-Faster removal of oxidation products

- Non-caustic, safe to handle

- Prevents passivation of anode by preventingdeposition of corrosion products

-Reliable reactivation at wet/dry cycles

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Chelation

Chelants, according toASTM-A-380, are chemicals that form soluble, complex molecules with

certain metal ions, inactivating the ions so that they cannot normally react with other elementsor ions to produce precipitates or scale.

For example chelants are used in medicine to capture heavy metals when someone has been

poisioned

Also in detergents where stains are trapped in the chelants so the stains are washed away withthe water

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Chelation

Emaco CP Intact Anode mortar contain Chelants which grab the zinc oxide formed in the

corrosion reaction and form a complex soluble compound

This compound of chelant and zinc oxide dispurses away from the anode in the surrounding

mortar

Other systems rely on high pH to form a soluble zinc oxide

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EMACOCP INTACT Installation Details

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Summary

Emaco CP intact form part of the BASF repair package

They should be considered as key to A long term repair solution

- Preventative measure to prevent incipient anodes

- Superior design

- Advanced encapsulation mortar

- Cost effective

-

Proven technology

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END

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EMACOCP INTACT vs. Competition

EMACO CP INTACT

Zinc ASTM B 418 Type II

2-4 times greater Zinc surface area

Chelation Driven safer to handle andunaffected by pH changes in concrete

(meaning longer life)

Surface saturate when installing therepair mortar (same as for normalconcrete repairs)

Pre-twisted wires to create properstand-off

Longer life-Will not passivate duringwet and dry cycles.

COMPETITION

Zinc type I more likely subject tointergranular corrosion

Lower surface area from solid Zincanodes

pH Driven system highly caustic

Must presoak 10-30 minutes to ensurethat caustic materials are available

Rely on contractor for proper stand-off

Shorter life possibly subject topassivation and not restarting ifexposed to wetting and drying cycles

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Value Proposition

Consultant/Specifier:

Proven technology

Choice of sizes

Optimum stand off for optimumcurrent throw

Different colours makes easy visualinspection during installation

Improved technology over standardanodes

Owner:

Increases life span of structures No maintenance-no ongoing costs

Increased protection over simplepatch repairs

Contractor:

Quick and easy to install Safe handling-no possibility of

burns

Pre soaking not required

Colour coded for easy Quality

Assurance

No special tools or equipmentrequired for installation

Compliments BAF Repair Range

Long shelf life (3yrs)- nodeterioration during storage