TRANSMITTAL

No. 00042
100 Flankers Road Phone: 404-734-3340
Ft. Gillem, GA 30297 Fax: 770-956-1322
PROJECT: Ft. Gillem-Enclave Force Protection DATE: 5/27/2010
PROJECT NO.: 20918
REF: Submittals
TO: Slone Associates, Inc.
835 Gil Harbin Industrial Blvd.
FAX: (229) 244-7778
Valdosta, GA 31601
PHONE: (229) 244-6709
ATTN: Kevin Kilpatrick
WE ARE SENDING: SUBMITTED FOR: ACTION TAKEN:
ü Shop Drawings ü Approval Approved as Submitted
Letter Your Use Approved as Noted
Prints ü As Requested Returned After Loan
Change Order Review and Comment Resubmit
Plans Submit
Samples SENT VIA: Returned
Specifications ü Attached Returned for Corrections
ü Other: Made from Submittal Separate Cover Via: Mail Due Date:

ITEM NO. COPIES DATE ITEM NUMBER REV. NO. DESCRIPTION STATUS

0 5/27/2010 SUT 26-42-14 SD-02 001 Dwg: Title: Cathodic Protection Desc: NEW
Original Submission
REMARKS:

CC: Signed:
Andrew Hannon

Expedition ®
 SUBMITTAL OF CATALOG DATA

FOR

CORROSION PROTECTION MATERIALS

Ft Gillem Enclave Force Protection Gate

W9128F-09-C-0085
Cathodic Protection Requirements
Forest Park, GA

Submitted to:

Batson-Cook
Atlanta, GA

Submitted by:
Company Information

For over 25 years, Corrpro has been a leading provider

of cathodic protection systems and engineering
services. As a subsidiary of Insituform Technologies,
Inc., Corrpro offers corrosion solutions for every
industrial market including pipeline, refinery, above and
underground storage tanks, water, wastewater,
concrete, infrastructure, offshore, and marine.
Corrpro strives to provide high-quality cathodic
protection materials and cost-effective services;
including engineering, pipeline integrity, construction,
and coating inspection.
Dedicated to ensuring preservation of energy resources,
protection of the environment, and the integrity of the
world's infrastructure, Corrpro has more than 30
operating facilities and warehouses worldwide.
Ft Gillem Enclave Force Protection Gate
W9128F-09-C-0085
Cathodic Protection Requirements
Forest Park, GA

Similar Experience:

Site Name Service Date

Ft Bragg (Phase I) Engineering & Material 2006-2010

Ft Bragg (Phase II) Engineering & Material 2008-2010
Eglin AFB (AF Hanger) Design & Engineering 2008-2009
Eglin AFB (Dining Facility) Design & Engineering 2008-2009
Eglin AFB (ATC) Design & Engineering 2008-2009
Eglin AFB (Navy Hanger) Design & Engineering 2009
Eglin AFB (Infrastructure) Design & Engineering 2009
MacDill AFB Engineering & Material 2009-2010
Hickam AFB F22 Design & Engineering 2009-2010
Ft Gillem Enclave Force Protection Gate
W9128F-09-C-0085
Cathodic Protection Requirements
Forest Park, GA

Catalog Data of Materials:

Item No. Description Quantity

1) #12 RHW-USE Cable 200ft

2) #8 HMWPE Cable (Bonding) 100ft
3) 17-lbs Magnesium Anodes 6pcs
4) 9-lbs Magnesium Anodes 4pcs
5) Thermite Weld Equipment 2set
6) Thermite Weld Elastomeric Filled Caps 58pcs
7) Test Stations 5set
8) Current Measurement Shunt (0.01 Ohm) 5pcs
9) Reference Electrodes 3pcs
10) Test Station Terminal Lugs 25pcs
CATALOG DATA OF MATERIALS

SUBMITTAL
 SPEC 2255

January 1, 2003

ROME VW-1 USE-2 or RHW-2 or RHH

Rome FR-EPR Insulation, 600 Volts
APPLICATION: General purpose wiring for lighting and power-residential,
commercial, industrial buildings in accordance with the National Electrical
Code and for other general purpose wiring applications. Suitable for use in
circuits not exceeding 600 volts at conductor temperatures not exceeding
90oC in wet or dry locations. May be installed in raceway, cable tray, direct
burial and aerial installations. Rome FR-EPR Copper
Insulation Conductor

↓ ↓
STANDARDS:
1. Listed by UL as Type USE-2 (90oC wet or dry) per Standard 854 for
Service Entrance Cables.
2. Listed by UL as Types RHW-2 (90oC wet or dry) or RHH (90oC dry) per
Standard 44.
3. All sizes carry the VW-1 flame test designation.
4. Cables are UL listed as Sunlight Resistant (1/0 AWG and larger, black

↑
only).
5. Sizes 1/0 AWG and larger pass UL and IEEE-383 ribbon burner flame test
Separator
and are UL listed For CT Use.
6. Conforms to ICEA S-95-658/NEMA WC70, utilizing Column A thicknesses.

CONSTRUCTION: Annealed copper conductor, Rome FR-EPR thermosetting

flame-retardant ethylene-propylene-rubber insulation, surface printed.

Copper Conductor
Size Ampacity
AWG Insulation Nom. Approx. 90oC * **
or No. of Thickness Diam. Net Wt. USE-2 75oC
kcmil Strands Mils Inches Lb./1000 Ft. RHW-2 USE
RHH RHW

Solid

14 Solid 45 .16 24 25 t 20 t
12 Solid 45 .18 32 30 t 25 t
10 Solid 45 .20 46 40 t 35 t

Stranded
t t
12 7 45 .19 33 30 25
t
10 7 45 .21 47 40 35 t
8 7 60 .27 75 55 50

6 7 60 .30 110 75 65
4 7 60 .35 160 95 85
3 7 60 .38 198 110 100
2 7 60 .41 245 130 115
1 19 80 .49 320 150 130

1/0 19 80 .53 390 170 150

2/0 19 80 .57 485 195 175
3/0 19 80 .63 600 225 200
4/0 19 80 .68 745 260 230

250 37 95 .76 890 290 255

300 37 95 .81 1050 320 285
350 37 95 .86 1215 350 310
400 37 95 .91 1375 380 335

500 37 95 .99 1700 430 380

600 61 110 1.10 2065 475 420
750 61 110 1.20 2550 535 475
1000 61 110 1.35 3330 615 545

* AMPACITY in accordance with NEC for not more than three conductors. As RHW-2: in raceway, 90oC conductor temperature and 30oC ambient in
wet or dry locations. As RHH: in raceway, 90oC conductor temperature and 30oC ambient in dry locations. As USE-2: direct burial, 90oC conductor
temperature and 30oC ambient in wet locations.

** AMPACITY in accordance with NEC for not more than three conductors. As RHW: in raceway, 75oC conductor temperature and 30oC ambient in
wet or dry locations. As USE: direct burial, 75oC conductor temperature and 30oC ambient in wet locations.
t
The over current protection shall not exceed 15 amperes for 14 AWG, 20 amperes for 12 AWG and 30 amperes for 10 AWG copper.

NOTES: 1. Standard color is black. Other colors available on request.

Information on this sheet subject to change without notice.

 SPEC 2255

1-1-03

Specification

ROME VW-1 USE-2 or RHW-2 or RHH

Rome FR-EPR Insulation, 600 Volts

1. SCOPE
1.1 This specification describes single conductor Rome FR-EPR, Type USE-2 or RHW-2 or RHH, flame-retardant ethylene-
propylene-rubber insulated cables for use in circuits not exceeding 600 volts. Cables are listed by UL as Type USE-2
and are recognized for underground use in wet locations at a maximum continuous conductor temperature of 90oC in
accordance with Article 338 of the National Electrical Code. The cables are also listed by UL as Type RHH or RHW-2
for general purpose wiring applications at maximum continuous conductor temperature of 90oC in dry locations (RHH)
or 90oC in wet or dry locations (RHW-2) and may be installed in air, conduit or other recognized raceways in accor-
dance with Article 310 of the National Electrical Code. All cables comply with UL’s VW-1 (Vertical-Wire) Flame Test.
Sizes 1/0 AWG and larger may be used in cable tray in accordance with Article 392 of the NEC.

2. APPLICABLE STANDARDS
2.1 The following standards form a part of this specification to the extent specified herein:
2.1.1 Underwriters Laboratories Standard 854 for Service Entrance Cables.
2.1.2 Underwriters Laboratories Standard 44 for Rubber-Insulated Wires and Cables.
2.1.3 ICEA Pub. No. S-95-658, NEMA Pub. No. WC70 for Nonshielded Power Cables Rated 2000 Volts or Less.

3. CONDUCTORS
3.1 Conductors shall be solid and Class B stranded, annealed uncoated copper per UL Standard 854 and 44.

4. SEPARATOR
4.1 A suitable separator over the conductor may be used at the option of the manufacturer.

5. INSULATION
5.1 Each conductor shall be insulated with Rome FR-EPR, a flame-retardant ethylene-propylene-rubber complying with
the physical and electrical requirements of UL Standard 854 for Type USE-2 and UL Standard 44 for Types RHW-2 or
RHH and Table 3-7, Class E-2 of ICEA S-95-658. In addition, the Rome FR-EPR insulation shall comply with the For
CT Use (sizes 1/0 AWG and larger) and VW-1 flame test ratings of UL Standard 44.
5.2 The average thickness of insulation, for a given conductor size, shall be as specified in UL Standard 44 for Types
RHH and RHW-2 and Table 3-4, Column A of ICEA. The minimum thickness at any point shall be not less than 90% of
the specified average thickness. The insulation shall be applied tightly to the conductor and shall be free-stripping.

6. IDENTIFICATION
6.1 The wire shall be identified by surface marking indicating manufacturer’s identification, conductor size and metal,
voltage rating, UL symbol, VW-1, type designations and Sunlight Resistant For CT Use (1/0 AWG and larger).

7. TESTS
7.1 Wire shall be tested in accordance with the requirements of UL Standard 854 for Type USE-2, UL Standard 44 for Types
RHW-2 or RHH and ICEA S-95-658.

8. LABELS
8.1 The wire shall bear the Underwriters Laboratories labels for Type USE-2.
CABLE

HMWPE
Direct Burial Cable

Multi-Purpose Cathodic Protection

Cable
Selecting the right cable for connecting anodes,
power supplies, and structures is an important
pert of any cathodic protection design. Corrpro
makes this selection process easy by offering a
cable manufactured specifically for the cathodic
protection industry. It is composed of copper
wire, which is covered by high-molecular-
weight polyethylene (HMWPE). The copper
wire is stranded and annealed to permit extra
flexibility. Because the polyethylene on the
cable is approximately twice as thick as on
conventional HMWPE wire, it serves as both
electrical insulator and mechanical cover for the
Typical Applications
conductor. This provides Corrpro's cathodic
HMWPE cable is offered in a variety of sizes. It
protection cable with outstanding dielectric
can be used as a header cable on cathodic
strength and moisture resistance. During
protection systems, or to make anode-lead or
installation, the cable can withstand considerable
negative-return connections. The thick
mechanical abuse without risk of damage to the
polyethylene cover permits direct burial of the
copper electrical conductor. The polyethylene
cable in native soils or submersion in freshwater.
cover is also chemically resistant, and protects
The cable exhibits superior flexibility, and can
against most organic and inorganic substances.
be bent without risk of notch propagation. It is
not recommended for use in environments
Corrpro's HMWPE cable is manufactured
containing chlorine, hydrochloric acid, or
according to strict quality control standards.
petroleum hydrocarbons.
The polyethylene coating is made to meet
American Society for Testing Materials
Standard D-1248 for plastic molding and
extruded materials. In addition, routine tests are
performed to ensure that the cable possesses
certain mechanical and electrical properties.

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
 CABLE

HMWPE
Direct Burial Cable
Ordering Procedure
Corrpro's HMWPE cable is readily stocked in a
range of wire sizes, and in available for
immediate shipping. To order the right cable for
your particular application, indicate that you
need Corrpro HMWPE cable, and specify the
lineal feet and wire size desired. An example is
provided to help illustrate this process.

Ordering Procedure Example

HMWPE Order Information
ITEM EXAMPLE WIRE SIZE NUMBER INSULATION NOMINAL O.D.
Quantity OF THICKNESS
AWG (mm ) 2
STRANDS in. (mm) in. (mm)
(Lineal Feet) 2,000 ft. 14 (2.5) 7 0.11 (2.794) 0.299 (7.59)
Wire Size #4 AWG 12 (4) 7 0.11 (2.794) 0.31 (7.87)
10 (6) 7 0.11 (2.794) 0.34 (8.64)
Wire Type HMWPE 8 (10) 7 0.11 (2.794) 0.36 (9.14)
6 (16) 7 0.11 (2.794) 0.41 (10.41)
4 (25) 7 0.11 (2.794) 0.46 (11.68)
2 (35) 7 0.11 (2.794) 0.52 (13.21)
1 (45) 19 0.125 (3.175) 0.59 (14.99)
1/0 (50) 19 0.125 (3.175) 0.63 (16.00)
2/0 (70) 19 0.125 (3.175) 0.67 (17.02)
4/0 (120) 19 0.125 (3.175) 0.78 (19.81)

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
SACRIFICIAL ANODES

High Potential
Cast Magnesium Anodes

Delivering Superior Protection

Power in galvanic cathodic protection is
generated at the anode. With Corrpro's
certified line of high-potential anodes, you get
the most powerful protection available today.
Cast from high-purity magnesium, these
anodes produce an open circuit potential of
1.75-1.77 volts, with is 20-3- percent 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 Typical Applications
flow more easily to the targeted structure. High potential anodes can be used to protect
most buried metallic structures found in a range
Corrpro certified high-potential anodes are of soil resistivities. Because they produce a
manufactured according to strict quality control higher driving voltage than conventional
standards. Each production run of high-potential magnesum anodes, they are ideally suited for
anodes is subjected to capacity, potential, and structures buried in soils with reesistivities in
consumption analysis. This ensures the anodes excess of 2,000 ohm-cm, or containing
you purchase will perform as specified. numerous corrosion "hot spots".

CHEMICAL COMPOSITION
Element Content %
Al 0.010
Mn 0.50 to 1.30
Cu 0.02 Max
Ni 0.001 Max
Fe 0.03 Max
Other 0.05 each or 0.3 Max Total
Magnesium Remainder

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
 SACRIFICIAL ANODES

High Potential
Cast Magnesium Anodes
Ordering Procedure
Certified high-potential anodes are
manufactured in a variety of dimensions
and weights. To order the required anode
for your structure, indicate that you need
high-potential magnesium anodes, and
specify the quantity desired, the anode
type, and whether they should be packaged
or bare. The anodes are shipped standard
with 10 ft.-#12 solid TW lead wire unless
otherwise specified. An example is
provided to help illustrate this process.

Ordering Procedure Example

ITEM EXAMPLE
Quantity 200
High-Potential Standard Dimensions and Shipping Weights
Anode Material
Magnesium NOMINAL DIMENSIONS NOMINAL WT.
in. (mm) lbs. (kg)
Anode Type 17S3 ANODE
TYPE "A" "B" "C" "D" "E" BARE PKGD.
Packaging
Packaged 3S3 3 (76) 3 (76) 4.5 (114) 6.5 (165) 6 (152) 3 (1.4) 9 (4.1)
(Bare or Pkgd.)
5S3 3 (76) 3 (76) 7.5 (191) 13.5 (343) 6 (152) 5 (2.3) 14 (6.4)
Wire:
Length 10 ft. 9S2 2 (51) 2 (51) 27 (686) 31 (787) 5 (127) 9 (4.1) 36 (16.3)

(10 ft. = Standard) 9S3 3 (76) 3 (76) 13.5 (343) 17 (432) 6 (152) 9 (4.1) 24 (10.9)
Size 17S2 2 (51) 2 (51) 51 (1295) 55 (1397) 5 (127) 17 (7.7) 61 (27.7)
(#12 solid = #12 17S3 3 (76) 3 (76) 25.5 (648) 30 (762) 6 (152) 17 (7.7) 42 (19.1)
Standard)
20S2 2 (51) 2 (51) 60 (1524) 62.5 (1588) 5 (127) 20 (9.1) 70 (31.8)
Insulation
TW
(TW = Standard) 32S3 3 (76) 3 (76) 45 (1143) 6 (1549) 6 (152) 32 (14.5) 90 (40.8)

32S5 5 (127) 5 (127) 21 (533) 30 (762) 8 (203) 32 (14.5) 70 (31.8)

40S3 3 (76) 3 (76) 60 (1524) 64(1626) 6 (152) 40 (18.1) 105 (47.6)

48S5 5 (127) 5 (127) 31 (787) 34 (864) 8 (203) 48 (21.8) 96 (43.6)

60S4 4 (102) 4 (102) 60 (1524) 64 (1626) 6.75 (171) 60 (27.2) 130 (59.0)

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
TEST STATIONS AND JUNCTION BOXES

Flush-To-Grade
Cathodic Protection Test Stations

Suitable For Numerous Landscapes

Cathodic protection systems are utilized on
structures located in water, on land, in rural,
urban, industrial, and residential regions. To
monitor the performance of these systems in
areas where aesthetics are important or traffic
flow is present, Corrpro offers flush-to-grade
test stations. The stations are manufactured with
tube sections made from various types of plastic
materials. These special tube sections are
lightweight, durable, corrosion resistant, and
provide a watertight area for housing test lead
terminals. Terminal boards are connected either
to the test head cap or recessed into the plastic
tube for easy access. The test boards can
accommodate from one to nine terminals, which
are made from nickel-plated brass to assure
many years of accurate readings.

The quality of the lid utilized in flush-to-grade

test stations is very important. The lids are the
only means of identifying and locating the test
stations, and provide protection against water
penetration and vandalism. Corrpro flush-to-
grade test stations are equipped with special
locking lids, which are clearly marked for easy
identification. The caps are made from either
cast iron or high-impact-strength plastic, and are
available with built-in magnets for locating by
electromagnetic detectors.
Typical Applications
Corrpro flush-to-grade test stations are designed
for use in areas where maintaining a landscape's
aesthetic quality is important. The stations are
also ideal for use in human or vehicle traffic
areas, such as roads, parking lots, or sidewalks.
Using the test stations, readings can be obtained
to determine structure-to-soil potentials and the
level of stray currents.

Authorized Distributor for the

Following Manufacturers
Cott Manufacturing Company
C. P. Test Services
Handley Industries

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
 TEST STATIONS AND JUNCTION BOXES

Flush-To-Grade
Cathodic Protection Test Stations
Ordering Procedure
The flush-to-grade test stations supplied by
Corrpro are manufactured by several different
companies. To order the required station for
your application, indicate the brand and model
desired, and specify the quantity and terminal
configuration needed. An example is provided
to help illustrate this process.

Ordering Procedure Example

ITEM EXAMPLE
Quantity 200
Test Station
Manufacturer Cott
Test Station Model Flush Fink
Test Station Ordering Information
STANDARD MAXIMUM
Number of Terminals 5 TERMINAL TERMINAL
MANUFACTURER MODEL LEADS LEADS
Cott Flush Fink 5 11
Street Fink 5 9
Handley M2 2 2
T2 1, 2, 5 5
T4 1, 2, 5 5
C. P. Test NM 4, 5, 7 7
Services Mini 2 5
Glenn 4 5

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
Cott Shunt Page 1 of 2

CottShunt®
Cathodic
Protection
Circuit
Components

A calibrated
CottShunt® makes
it possible to
measure cathodic
protection currents
and potentials with
the highest degree
of accuracy,
reliability, and ease.
Designed specifically
for the cathodic
protection industry
and manufactured from the finest materials available
by Cott Manufacturing Company in Los Angeles,
California, the CottShunt® is available through Cott's
worldwide network of authorized distributors.

Features

Circuit Board
Makrolon® polycarbonate is one of
the world's toughest plastics. Color
coded for easy value recognition.

Current Strips and Potential

Posts
Nickel plated brass.

Resistance Wire
Manganin (ASTM B267, CI.VI)

Configuration
Standard 1/4" holes on 1" centers
fits all Fink® brand cathodic
protection test stations.

Quality Assurance
All CottShunts® are 100% tested
and calibrated to within ±1% of
advertised resistance value.

http://www.cottmfg.com/shunt.htm 11/16/04
Cott Shunt Page 2 of 2

http://www.cottmfg.com/shunt.htm 11/16/04
REFERENCE CELLS

Permacell® 802
Permanent Reference Cell

For Reliable Potential Measurements

On Buried Structures
Permanent reference electrodes provide accurate
and reliable potential measurements on buried
metallic structures. Their placement in close
proximity to protected structures permits
readings which are more exact and less affected
by fluctuating soil conditions than those
obtained by portable cells. Corrpro’s Permacell
802 is a permanent copper/copper sulfate
reference electrode with a proven track record
for stability. Long-life performance is achieved
through a rugged design, which includes impact-
resistant PVC tubing. The tubing houses a
99.99% pure copper element and a
supersaturated solution of copper sulfate. The
copper sulfate mixture ensures that the copper
element remains electrically stable, so that the
cell’s potential value will not fluctuate. From
this special composition, the cell achieves a
minimum design life of fifteen years, and
maintains an accuracy level of ±5 millivolts.

Corrpro’s Permacell 802 is designed for trouble- Typical Applications

free installation. The cell is pre-packaged in a
cloth bag containing a low-resistance backfill
material, and is completely assembled and ready
for immediate installation. Plastic positioning
pins on the cell assure that a sufficient amount of
the backfill will exist around the cell’s electrical
contact point. Because of this, a low-resistance
groundbed can be created simply by watering
the area surrounding the cell. Lead wire
connections to the cell are made using #14
AWG wire containing HMWPE insulation. The
cell is provided with fifteen feet of this wire to
address numerous types of applications.
The Permacell 802 permanent reference cell is
designed to measure electrical potentials on
buried metallic structures, such as underground
pipelines and storage tanks. It is ideal for
structures located under pavement or other
impediments which prevent the use of a portable
cell. The cell can be operated in temperatures of
up to 135°F, but should not be used in areas
containing high chloride concentrations. The
cell should be installed below the frost line in
relatively moist soil.

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
 REFERENCE CELLS

Permacell® 802
Permanent Reference Cell
Ordering Procedure
Corrpro’s Permacell 802 is made according to
customer specifications. To order this cell for
your particular application, indicate that you
need a Permacell 802 copper/copper sulfate
reference electrode, and specify the quantity
desired and the lead wire length, size, and
insulation if different from the standard
provided. An example is included to help
illustrate this process.

Ordering Procedure Example

ITEM EXAMPLE
Quantity 10
Permanent Reference Product Specifications
Product
Cell NOMINAL
Permacell Model 802 DIMENSIONS WEIGHT ELECTRICAL DESIGN
in. (mm) lbs. (kg) STABILITY LIFE
Lead Wire: Ø LENGTH
Length Bare
2 8 4
±5 millivolts
(15 ft. = Standard) 15 ft. (50.8) (203.2) (1.82)
with 8.0 20 years
8 15 19
Size Pkgd.
(203.2) (406.4) (8.62)
microamp load
(#14 AWG = Standard) #14 AWG
Insulation
(HMWPE = Standard) HMWPE

1090 Enterprise Drive / Medina, OH 44256

Tel: 1-330-723-5082 / Fax: 1-330-723-0694
http://www.corrpro.com
GALVANIC CATHODIC PROTECTION SYSTEM
OPERATIONS & MAINTENANCE MANUAL
Ft Gillem Enclave Force Protection Gate
W9128F-09-C-0085
Cathodic Protection Requirements
Forest Park, GA

PREPARED BY:
CORRPRO COMPANIES, INCORPORATED
581 SIGMAN ROAD, SUITE 300
CONYERS, GEORGIA 30013
770-761-5400
 Will also be used as the training guide
OPERATION AND MAINTENANCE INSTRUCTIONS
GALVANIC CATHODIC PROTECTION SYSTEM

I. THE BASIC CORROSION MECHANISM:

Corrosion has been described as oxidation, a chemical attack, and as an

electrical phenomenon, electrolysis. None of these descriptions, by
themselves, are correct, yet each one is partially true. It can be stated that the
corrosion process is basically electrochemical in nature and that the presence
of oxygen in some form is necessary.

There are certain conditions which must be met before a galvanic corrosion cell
can function. They are:

1. There must be an anode and a cathode.

2. There must be an electrical potential difference between the anode and

cathode.

3. There must be a metallic path electrically connecting the anode and

cathode.

4. The anode and cathode must be immersed in an electrically conductive

electrolyte that is ionized - meaning that some of the water molecules are
broken down into positively charged hydrogen ions and negatively
charged hydroxyl ions.

Once these conditions are met, an electric current will flow and metals will be
consumed at the anode.

The major components of a galvanic anode type cathodic protection system are
as follows:

1. Metal structure, such as steel pipe, underground storage tanks, or the

external bottoms of on-grade storage tanks.

2. Anode to be placed in the electrolyte. Magnesium is usually employed

as anode material, although zinc and aluminum are sometimes used.
The anode may be in the form of a cast ingot or a long rod or ribbon.

3. Metallic connection such as a mechanical ground clamp type or thermite

type connection to the structure. This may be accomplished through a
test station or by connecting a wire directly to the structure.
4. Insulators installed at flanges or unions to electrically isolate the structure
considered for galvanic cathodic protection from "foreign" structures.

5. Test stations, either flush-to-grade or post mounted. Occasionally,

galvanic type anode systems are installed without test stations.

2
II. BASIC THEORY OF CATHODIC PROTECTION:

As described in the previous section, corrosion is caused by a current flow from

an anode to a cathode through an electrolyte. To complete the circuit, the
current flows back along the metallic path from the cathode to the anode. This
can occur on a single structure with areas of the surface being the anode and
cathode (see Figure 1 below).

Figure 1

Thus, corrosion takes place at the anode, where the current leaves the pipe and
enters the electrolyte, while none takes place at the cathode - because the
cathode is receiving current from the electrolyte. So, it is obvious that if all the
exposed surface of the pipe could be made to collect current, it would not
corrode because the entire surface would then be cathodic. This is exactly
what cathodic protection does. The galvanic anode method of cathodic
protection utilizes galvanic anodes that have a high natural potential difference
with respect to the structure to be protected. The anodes are made of a
material which is anodic to the structure. Generally, magnesium or zinc is used
as anode material and the anodes are electrically connected to the structure,
either directly or through a test station. With the anodes connected to the
structure and a sufficient amount of DC electric current flowing to the structure,
the entire structure will become cathodic to its surroundings and the anodic
areas will be eliminated.

III. LIMITATIONS OF CATHODIC PROTECTION:

1. Continuous Electrolyte:

The electrolyte with which the structure is in contact must be continuous.

Metal above ground will not be protected from atmospheric corrosion by
cathodic protection.

2. Continuous Operation:

Cathodic protection is effective only while the system is in operation.

Therefore, the cathodic protection system should be allowed to operate
continuously.

3. Effect of New Construction:

Addition of new underground metallic structures or alterations made to

existing structures can materially affect the operation of a cathodic
protection system. If such changes are extensive, a field investigation
3
 should be performed to determine the effect of the new construction on
the existing structures, which are being cathodically protected.

IV. WHEN TO MEASURE STRUCTURE-TO-ELECTROLYTE POTENTIAL:

1. Tests should be made a short time after the installation of the cathodic
protection system. The methods or testing to use are described in the
"Test Procedures" section of these Operation and Maintenance
Instructions.

2. After the installation, tests should be performed at least once each year.

3. If operation of the system is interrupted or changed for any of the

following reasons, additional testing should be performed as quickly as is
possible:

a. Damage to anodes or test stations where one or more anodes are

connected to the structure through the test station.

b. Addition(s) to the piping system as a result of new construction.

V. DESCRIPTION OF THE SYSTEM:

The purpose of the cathodic protection system is to prevent corrosion of the

external metallic surfaces. When constructed, the pipelines and/or pipe fittings
are provided an external coating. The cathodic protection system supplements
the corrosion protection provided by the coating in preventing corrosion at
coating holidays. This is accomplished by the passage of DC current from
anodes through the soil to the piping. The system is energized by connecting
the anodes to the structure(s) to be protected, either directly or through a test
station.

The cathodic protection system utilizes high purity sacrificial magnesium or zinc
anodes, test stations for monitoring the cathodic protection system, and
dielectric material to isolate the structure to be protected from all other foreign
underground metallic structures.

VI. OPERATION OF THE SYSTEM:

A cathodic protection system that makes use of galvanic type anodes is

capable of many years of continuous operation with very little maintenance. In
order for the system to function effectively, it is important it be kept in
continuous operation and that all dielectric material remain intact.

Although a cathodic protection system using galvanic anodes is capable of

many years of trouble-free operation, it is recommended that this system be
rechecked thoroughly each year by a corrosion engineer or technician. This will
insure that the system is operating properly and an adequate level of protection
4
 is being maintained. It is possible that changes in conditions such as coating
quality, the environment, or in the piping network(s) may have occurred and
additional protective current may be required.

VII. MAINTENANCE:

1. Inspection:

Inspection of the test stations and dielectric material, flanges or unions

should be done at least each month and incorporated into a routine
inspection procedure for these facilities. Such appurtenances found
damaged or missing should be repaired or replaced immediately. At the
time of these inspections, particular attention should be given to the
insulating flanges to see if they have been worked on and not repaired
properly. Flush-to-grade type test stations should be kept clear of
objects or debris placed over them.

2. Cleaning and Clearing:

Dirt and debris should be kept from accumulating within the crevices of
all metallic test stations and insulating flanges. Where screws, bolts, or
threads are involved, with relation to test stations, such items should be
lubricated periodically.

Grass, weeds, scrub vegetation, debris, etc., should be cleared from test
station areas to enable clear visibility of test stations as well as to
facilitate easy access for monitoring purposes.

3. Painting:

The test stations installed do not require painting. However, if painting is

necessary due to color-coding, company identification, etc., a paint
compatible with the test station material should be used, and particular
care should be taken to enable easy removal of the covers.

When painting the piping in the vicinity of the insulating material, metal-
base paints should not be used since the paint itself can provide a path
for current to flow and render the insulating material ineffective.

5
VIII. TEST PROCEDURES:

1. Structure-to-Soil Potential Measurements:

Structure-to-soil potential measurements should be obtained at least

once each year. Equipment should be set-up to obtain potential data as
shown in figure 2. The most common criterion is that the potential
reading should be more negative than -0.850 volts to satisfy NACE
International (formerly the National Association of Corrosion Engineers)
criterion for cathodic protection. Where short sections of piping exist,
potential measurements should be obtained at representative locations
on what exists.

Standard equipment required:

a. High-impedance digital multimeter.

b. Copper-copper sulfate reference electrode.

c. Test leads.

d. Portable wire reel with 1500 feet of #22 AWG insulated wire.

e. Miscellaneous hand tools.

Refer to diagram below for test procedures.

Figure 2

6
2. Anode Current Output Measurements:

Anode current output should be made at each of the test stations as

shown in Figure 3. If there are no test stations provided with the
cathodic protection system, these measurements cannot be obtained.

Equipment required:

a. DC ammeter or Voltmeter with a minimum of 3-1/2 digit resolution.

b. Test leads.

c. Miscellaneous hand tools.

Refer to diagram below for test procedures.

Figure 3.

Remove brass strap, if applicable, and connect ammeter between the anode
and structure leads. Record current measurement. If a shunt is installed
between the anode lead and the structure lead, utilize the DC millivolt scale
of the multimeter to measure the voltage drop across the shunt and convert
to current ("I") using Ohm's Law. To calculate the current flow, the voltage
measured (in volts) is divided by the resistance of the calibrated shunt (in
ohms).

7
 SECTION I

INTRODUCTION
 INTRODUCTION

Corrpro Companies has been retained by Batson-Cook to provide cathodic protection

related services underground utilities for the buildings associated with the Enclave

Force Water Line Ft Gilem, GA. The requirements for cathodic protection are

addressed in Section 26 42 14.00 10 of the Specifications for this project. In

accordance with this document cathodic protection is to be afforded all underground

metallic components of the potable water and fire water pipelines associated with this

project. The type of system is based on the pipeline material selected by the

mechanical contractor.

For this project, the mechanical contractor has opted to utilize a combination of PVC

pipe and ductile iron mechanical fittings for the fire and potable water lines. Therefore,

the buried metallic fittings and sections of ductile iron are to be cathodically protected.

Contained within Section III of this submittal are detail drawings for the cathodic

protection system. In accordance with these drawings each Fire Hydrant fitting is to be

afforded two (2) 17-pound magnesium anodes and each Pipeline fitting is to be afforded

two (2) 9-pound magnesium anodes.

The coating requirements for the fittings are addressed in Chapter 1.2.7 of Section 26 42

14.00 10. In review, the coating is to be a coal tar base mastic. These coatings are well

suited for use on ductile iron pipe with cathodic protection.

Holiday testing of the applied coating should be conducted on the ductile iron fittings

and any damages to the coatings should be repaired prior to back fill.

For a galvanic cathodic protection system to be effective, electrical isolation is a

requirement at building risers and at connections to foreign structures (tie-ins). If

electrical isolation is not used, it is possible that the piping or fitting at that location may

become electrically continuous with other structures (i.e. building ground, existing

metallic pipelines or existing metallic fittings) not being cathodically protected. This

shorted condition would likely prevent the ability to cathodically protect the piping at

these locations. Contractor should review any locations where electrical isolation is a

potential concern during installation.

Calculations illustrating current requirement for each metallic pipe or component are

given in Section II.

 SECTION II

CALCULATIONS
 DESIGN CALCULATIONS
Ductile Iron Fittings
Enclave Force Protection Gate-Fort Gillem, GA

COMPUTATIONS:

1 Surface Area to be Protected:

The approximate exposed surface area (5% bare) for 8-inch ductile iron fittings with a coal tar
epoxy coating is as follows:

FH assembly = 0.30 sq. ft. (0.02 sq. m)

45-degree bend = 0.04 sq. ft. (0.002 sq. m)
90-degree bend = 0.06 sq. ft. (0.004 sq. m)
tee = 0.07 sq. ft. (0.005 sq. m)
valve = 0.10 sq. ft. (0.008 sq. m)
Building entrance,
typical length = 10 ft, 0.30 sq. ft. (0.03 sq. m)
=
For design purposes the elbows, tees, and valves will be assumed to be of the same surface
area. Also, the nominal diameter of the fittings ranges from 4-inch to 8-inch; because the 8-
inch fittings are the largest and therefore have largest current requirement, the calculations
presented here are sufficient for all fittings.
2 Current Required:

The amount of current required to achieve protection is based upon the operating parameters
of the structure being protected, the soil conditions and the surface area exposed to the soil.
This pipe will operate at ambient temperature and is buired in soils described earlier in this
report. In this case, a desgin current density of 10.76 mA/sq. m (1 milliamp per square foot) of
exposed area will provide adequate protection for the ductile fittings.
IT = AB (total) x Cd

where:
Cd = Current density = 1.0 mA/sq.ft.

Elbows/tees/valves

IT = 0.10 x 1.
IT = 0.10 mA or 0.00010 A

Building Entrance
IT = 0.30 x 1.
IT = 0.30 mA or 0.00030 A

Page 1 of 3
 Hydrant Assembly
IT = 0.30 x 1.
IT = 0.30 mA or 0.00030 A

3 Cathodic Protection Type Selection

Based upon current requirements and fitting arrangement, a galvanic type cathodic protection
system would provide the most economical and practical performance. The anodes shall be
connected through monitoring test stations. In addition, the line must be electrically isolated at
each connection to an exisiting line and within casings. This recommendation is based upon
the line being well coated.

4 Anode Type
High potential alloy magnesium, prepackaged, with #12 Awg/TW lead wire is recommended.
Type: P 17s3

Packaged dimensions:
diameter: 6 inches
length: 30 inches
Anode bare weight: 17 pounds
Anode consumption rate: 17 pounds/amp-year
Anode natural potential: -1.75 volts (relative to Cu/CuSO4 cell)

5 Anode Current Output

Using a soil resistivity of 30,000 ohm-cm, the current output of a single anode can be
calculated using Dwight's equation and Ohm's law as follows:
Dwight's equation for a single anode resistance to earth is:

ρ 0.0627 4x L
R=
L
(ln ( r
) - 1)

where:
R = Anode to earth resistance
ρ= Soil resistivity = 30,000 ohm-cm
r= Anode radius = 3.0 inches
L= Anode length = 30.0 inches

ρ 0.0627 4 x 30.
R=
30.0
(ln ( 3.0
) - 1)

R= 168.59 ohms

According to Ohm's Law:

I= (EP - Ea) / R

Page 2 of 3
 where:
R = Anode to earth resistance
Ea = Anode Potential = -1.75 mV
EP = Desired Pipe Potential = -0.85 mV

I= 0.00534 amps or 5.34 mA per anode

The minimum number of anodes therefore is:

N= IT / I

where N = number of anodes required

Elbows/tees/valve
N = 0.08 / 3.56 = 1 anode

Building Entrance
N = 0.26 / 3.56 = 1 anode

Hydrant Assembly
N = 0.20 / 3.56 = 1 anode

To ensure adequate current distribution, and to overcome possible unforeseen coating flaws or
coating damage, two (2) anodes per fitting shall be used.

5 Theoretical Anode Life:

0.116 x W x E xU
Y= --------------- -----------------------------------------------
I
where:
Y = anode life in years
W= Anode weight = 17.0 pounds
E= Efficiency = 50%
U= Utilization factor = 70%
I= Anode current = 0.00010 amps

Y= over 50 years

Page 3 of 3
 SECTION III

INSTALLATION DRAWING