KARATEC RESOURCES SDN BHD

KARATEC
CORROSION PROTECTION & CONTROL
SERVICE

MATERIALS SPECIFICATION
&
TECHNICAL DATA SHEET

HIGH PREPACKAGED MAGNESIUM

ANDOE
Product Catalogue KARATEC RESOURCES SDN BHD

HIGH POTENTIAL MAGNESIUM ANODE

General

Power in galvanic cathodic protection is generated at the anode. Cast from high-purity
magnesium. This type of anode produces an open circuit potential of 1.65 – 1.70 volts, which
is 20 – 30 % greater than conventional magnesium anodes. This high driving voltage means
greater protection can be delivered from fewer anodes. Efficiency of the anode is enhanced
even further when installed in a backfill of 75 % gypsum, 20 % Bentonite and 5 % sodium
sulfate. This special mixture lowers anode-to-earth resistance and allows electrical current to
flow more easily to the targeted structure.

Typical Applications

High potential anodes can be used to protect most buried metallic structures found in a range
of soil resistivities. Because they produce a higher driving voltage than conventional
magnesium anodes, they are ideally suited for structures buried in soils with resistivities in
excess of 2000 ohm.cm or containing numerous corrosion ‘hot spots’.

Chemical Composition

The magnesium anodes are HP magnesium alloy casting pre-packaged in a low resistivity
backfill and fitted with a cable tail.

Note: Various sizes of Magnesium Alloy Anode are available.

The magnesium compositions by weight are:

Copper 0.015 % max

Aluminium 0.0033 % max
Iron 0.0027 % max
Manganese 0.59 % min
Nickel 0.0007 % max
Magnesium Remainder
Potential - 1.65 to -1.7 Volts w.r.t. Cu./CuSO4 ref. Cell.
Utilization factor 0.85

The castings are homogeneous, with a smooth surface free from major defects such as voids,
porosity, blowholes, pitting, inclusions and any other characteristics likely to detract from its
performance in terms of current output
and life.

Anodes are provided with a 3 meters

length of single core copper cable
6mm2 HMWPE 300/500 volt grade.

The magnesium alloys are cast onto a

galvanized steel core to which the
cable were securely brazed within a
suitable recess and the connection
encapsulated with an epoxy
compound, which totally seal the core,
and cable connection.

Anodes are pre-packaged in a backfill of the following composition:

Powered Hydrated Gypsum 75 %

Granular Bentonite 20 %
Anhydrous Sodium Sulphate 5 %
2
Product Catalogue KARATEC RESOURCES SDN BHD

The anode and backfill are contained in a permeable cotton cloth bag.

EXTRUDED MAGNESIUM ANODES

General

Magnesium anodes have the highest protection capability of any galvanic material. While
these anodes are most commonly used in the cast metal form, certain structures can be
better protected through the use of extruded magnesium configurations. Extruded magnesium
anodes have high surface and length ratios in relation to cross sectional size. This allows
these anodes to deliver a greater amount of current per weight than their cast magnesium
counterparts. By supplying more current, extruded anodes can deliver effective protection to
structures buried in even highly resistive electrolytes.

Typical Applications

Extruded magnesium anodes are most suitable for structure buried or submerged in high
resistivity electrolytes. The rod shape anodes, with their small diameters, are often used in
commercial and industrial water heaters and storage tanks, or driven into the ground to
protect gas service risers. The ribbon anode is used for the protection of pipelines and
storage tanks. Extruded anodes are also employed to pre-polarize offshore structures which
are to be protected with aluminium anodes.

Chemical Composition

The extruded magnesium anodes are manufactured in flexible coils which can be easily
shaped for use on a multitude of protection projects. They are constructed with a solid steel
core which runs lengthwise through the anodes for efficient electrical discharge.

The magnesium compositions by weight are:

Copper 0.02 % max

Aluminium 0.010 % max
Iron 0.03 % max
Manganese 0.50 – 1.3 % min
Nickel 0.001 % max
Magnesium Remainder
Potential - 1.75 to -1.77 Volts w.r.t. Cu./CuSO4 ref. Cell.
Utilization factor 0.85