Corrosion Protection Solutions for New and Deteriorating Structures

Zinc Layer Roll Anode (ZLRA)

What is Zinc Layer Roll Anode Used For?

Zinc Layer Roll Anode is a self-contained, corrosion protection and durability enhancement system, designed to be installed into drilled holes, using a purpose formulated, ion-conductive, auto moistening Zinc Activation Paste of atmospherically exposed reinforced concrete structures, to provide long-term protection from corrosion. 

 

Zinc Layer Roll Anode provides multi-staged corrosion protection, which effectively stops and prevents concrete deterioration resulting from reinforcement corrosion.

 

When connected to the embedded reinforcement and embedded within the concrete, the zinc anode corrodes and provides galvanic cathodic protection to the embedded reinforcement.

 

This product provides active corrosion control by cathodic protection, meeting the requirements of BS EN 1504 Part 9 Principle 10 (cathodic protection by applying an electrochemical potential) and provides benefits in line with Principal 7 (preserving or restoring passivity) of the embedded reinforcement.

 

Where installed with monitoring facilities, this product can be monitored and evaluated against the cathodic protection criteria listed within BS EN ISO 12696.

Zinc Layer Roll Anode - Bridge Abutment

Zinc Layer Roll Anode Product Description

Zinc Layer Roll Anode utilizes Zinc Layer Anode technology, and consists of a high purity zinc foil, complete with an ion-conductive, auto moistening, humectant/activator/adhesive layer. Each anode is fitted with a centralized galvanized steel wire tail which is spot welded to the zinc foil and then fabricated to form a cylindrical discrete anode.

 

The anodes are supplied in the following standard sizes: 

  • 125mm long x 22mm diameter 60g Zinc

  • 250mm long x 22mm diameter 120g Zinc

 

Specific zinc weights and sizes can be fabricated to suit specific applications, design life, and performance requirements.

 

The anodes are installed directly into drilled holes within the parent concrete, surrounded by the purpose formulated Zinc Activation Paste and the cable tails are then connected either directly or via a monitoring facility to the embedded reinforcement.

 

The Zinc Activation Paste is delivered separately in 600ml sausages, which can be applied with a standard manual or battery powered sealant gun.

Where Can Zinc Layer Roll Anode Be Used?

Zinc Layer Roll Anode is designed for protecting atmospherically exposed reinforced concrete structures, suffering from chloride or carbonation-induced reinforcement corrosion and resulting concrete deterioration. 

 

Capable of stopping and preventing concentration cell corrosion (incipient anodes), Zinc Layer Roll Anode, can limit or prevent the need for removal and replacement of sound undamaged chloride contaminated or carbonated concrete.

 

Suitable for use locally, to provide patch repair enhancement and prevent incipient anode formation, for concrete patch repairs in chloride contaminated concrete, or when incorporating old chloride contaminated structures into a new build.

 

Suitable for use globally across repaired or undamaged, contaminated structures, to provide corrosion protection, durability enhancement, and deterioration prevention, when installed before the onset of corrosion-related deterioration or following structural remediation.

 

Zinc Layer Roll Anodes can be used in conjunction with the surface applied Zinc Layer Anode, to provide enhanced protection in restricted access areas, such as bearing shelves, joints, or other difficult to reach areas requiring protection. 

 

Suitable for use on high-risk elements like pre-stressed and post-tensioned structures, as it will not exceed the potential limits for susceptible high strength steel listed within BS EN ISO 12696, and requires no further potential limitation or control during operation.

 

Zinc Layer Roll Anodes can be used as a replaceable protection system, when embedding the anodes into the structure using a high-performance non-setting Zinc Activation Paste, spent anodes can be removed and replaced using the existing holes, without additional drilling.

 

Depending on the anode quantity, size, spacing, and prevailing exposure conditions, Zinc Layer Roll Anodes can:

  • Prevent early patch repair failure of chloride contaminated concrete for periods of greater than 10 years.

  • Prevent corrosion initiation and subsequent concrete deterioration in contaminated but undamaged structures for periods of 10 to 20 years.

Technical Benefits of Zinc Layer Roll Anode

Zinc Layer Roll Anode can be installed as a stand-alone system, connected directly to the reinforcement, or provided with embedded monitoring facilities to meet the monitoring requirements listed within BS EN ISO 12696 - Cathodic Protection of Steel in Concrete.

 

The large surface area of the anode provides a low anode to cathode circuit resistance, ensuring the highest cathodic protection current flow under the natural zinc to steel, driving voltage.

 

The humectant/activator layer enables high dissolution and mobility of the zinc corrosion product, preventing loss of performance, typically found with embedded galvanic anode systems.

 

The use of the Zinc Activation Paste further enhances the anode performance and enables anode removal and replacement without additional drilling.

 

Once installed, Zinc Layer Roll Anode provides multi-staged protection, which effectively stops and prevents concrete deterioration, resulting from reinforcement corrosion.

The protection afforded by Zinc Layer Roll Anodes includes:

  • Stopping corrosion of the reinforcement by delivering cathodic protection.

  • Promotes passive film healing at corrosion sites on the embedded reinforcement by producing hydroxide.

  • Heals and maintains passive film stability on the reinforcement.

  • Consumes water and oxygen within the concrete through electrochemical reactions.

 

The system is easy to install, repair, replace, requires no additional AC or DC power for operation, does not interfere with the concrete repair activities, and is relatively maintenance-free.

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