METHOD STATEMENT

Corrosion Control using Sika®

FerroGard®-300s Duo Hybrid Galvanic
Anodes for slim structures
DECEMBER 2018 / VER.: 5 / SIKA SERVICES AG / MICHEL DONADIO

REFURBISHMENT
TABLE OF CONTENTS
Scope 3
System Description 3
2.1 References 3
2.2 Limitations 3
Products (not limited) 4
3.1 Material Storage 4
Health and Safety 4
4.1 Risk Assessment 4
4.2 Personal Protection 4
4.3 First Aid 4
Environment 5
5.1 Cleaning Tools / Equipment 5
5.2 Waste Disposal 5
Preliminaries 5
Installation 6
Additional Information 8
8.1 Process Monitoring 8
8.1.1 Visual inspection 8
8.1.2 Routine inspection and maintenance 8
8.1.3 Steel Corrosion Rate Measurement 9
Limitation 9
Site QC Record 9
Typical Drawings 10
Typical Spacing 10
12.1 Comments 10
12.2 Tables of Spacing 10
Legal Note 11
11

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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 SCOPE
This method statement describes the step by step procedure for applying Sika® FerroGard®-300s Duo hybrid
galvanic anode when concrete structures have not enough thickness to support the application of the standard
hybrid anodes. They can also be installed in area of congested reinforcement where it is difficult to drill holes
without hitting the reinforcement.

SYSTEM DESCRIPTION
The Sika® FerroGard®-300s Duo hybrid anode is a dual technology anode based on the use of a sacrificial metal in
both an impressed current and sacrificial anode role. Initially an impressed current is driven from the Sika®
FerroGard®-300s Duo anodes to the steel using a temporary power supply. In the process corroding sites on the
steel are moved to the surface of the installed anode. This occurs because the treatment generates inhibitive
hydroxide ions at the steel and aggressive chloride ions are drawn from the concrete to the installed anodes. At
the end of the brief impressed current treatment the Sika® FerroGard®-300s Duo anodes are connected to the
steel to act as a sacrificial anode in a long term preventative role.
Sika® FerroGard®-350 to 355 Duo are typically inserted in sound but contaminated concrete.

2.1 REFERENCES
This method statement has been written in accordance with the guidance contained in European Standards EN
12696:2016 and CEN/TS 14038-2:2011.

2.2 LIMITATIONS
▪ Products shall only be applied in accordance with their intended use.
▪ Local differences in product may result in performance variations. The most recent and relevant local Product
Data Sheets (PDS) and Material Safety Data Sheets (MSDS) shall apply.
▪ For specific construction / build information refer to the Architect’s, Engineer’s or Specialist’s details,
drawings, specifications and risk assessments.
▪ Design of the Sika® FerroGard®-300s Duo system should be undertaken by a competent designer.
▪ All work shall be carried out as directed by a supervising officer or a qualified engineer.
▪ This method statement is only a guide and shall be adapted to suit local product and standards, legislation or
other local requirements.

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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 PRODUCTS (NOT LIMITED)

Sika Product Names Product dimensions Section to be chased out

Sika® FerroGard®-350 Duo L: 100 mm; Ø: 32 mm L: 120; D: 47; W: 52 mm

Sika® FerroGard®-355 Duo L: 135 mm; Ø: 32 mm L: 1055; D: 47; W: 52 mm

Sika® FerroGard®-360 Duo L: 190 mm; Ø: 32 mm L: 210; D: 47; W: 52 mm

Sika® FerroGard®-365 Duo L: 245 mm; Ø: 32 mm L: 265; D: 47; W: 52 mm

3.1 MATERIAL STORAGE

Materials shall be stored properly in undamaged original sealed packaging, in dry cool
conditions. Refer to specific information available on the product data sheet regarding
minimum and maximum storage temperatures. Do not allow contact with oxidizing
materials. Protect from moisture.
The plastic container should only be opened when product is required, and re-sealed when
no tin use. The silica gel parcels should not be removed from the packaging container..

HEALTH AND SAFETY

4.1 RISK ASSESSMENT

The risk to health and safety from falling objects or defects in the structure shall be
properly assessed.
Where structures are considered to be unsafe appropriate action shall be carried out to
make the working area safe.

4.2 PERSONAL PROTECTION

Work safely!
Protective clothing must be worn. Wear gloves and eye protection at all
times. Always wash hands with suitable soap after handling products and
before food consumption.
FOR DETAILED INFORMATION REFER TO THE RELEVANT MATERIAL SAFETY
DATA SHEET

4.3 FIRST AID

Sika® FerroGard®-300s Duo are safe for use. However care shall be exerced when using accessory
products such as repair material.

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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FOR DETAILED INFORMATION REFER TO THE RELEVANT MATERIAL SAFETY DATA SHEET

ENVIRONMENT

5.1 CLEANING TOOLS / EQUIPMENT

Clean all tools and application equipment immediately after use, with water.
Hardened material can only be mechanically removed.

5.2 WASTE DISPOSAL

Do not empty surplus material into drains; dispose responsibly through licensed waste disposal
contractor in accordance with legislation and local / regional authority requirements. Avoid run off
onto soil or into waterways, drains or sewers.

FOR DETAILED INFORMATION REFER TO THE MATERIAL SAFETY DATA SHEET

PRELIMINARIES
The structure should be assessed prior to application of the Sika® FerroGard®-300s Duo hybrid anode range
technology as follows;
i. Review of records: All available drawings and recorded information should be reviewed for information
relating to location, quantity, nature and continuity of reinforcement and to concrete quality.
ii. Reinforcement continuity: This shall be proven on site by measuring the electrical resistance between
reinforcing bars in mutually remote locations across the structure and between reinforcing bars exposed
during concrete repairs or other works following the method and acceptance criteria as specified in ISO
12696:2016. Any discontinuous components should either be treated as a separate zone or bonded to the
main steel reinforcement. These measurements shall include the following:
a. The continuity between elements of the structure.
b. The continuity of metallic items, other than reinforcement. Any external metallic items shall, as a
minimum, be electrically bonded during the initial impressed current phase of treatment.
iii. Reinforcement location/concrete cover: Steel reinforcement size and location
should be established to confirm details in the drawings.
iv. Concrete cover: The cover of the area to be protected should be determined
to ensure a minimum cover of at least 30mm for the purposes of installation of
the Sika® FerroGard®-300s Duo anode system.
v. Stray currents: The structure should be assessed for the presence of ac or dc
stray currents. If stray currents are evident, remedial action must be undertaken under the auspices of a
competent electrical/corrosion engineer.

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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 INSTALLATION
1. Confirm steel continuity in areas to be treated. DC resistance between bars should be ≤ 1 mVolt as per EN
12696:2016 clause 7.1. If steel is discontinuous, it should be dealt with as detailed in (ii) above. Keep proper record
– refer to clause 10.
2. Undertake a reinforcing steel survey as follows:
a) Mark steel locations on concrete surface in conjunction with drawings
b) Mark locations for Sika® FerroGard®-300s Duo units on concrete surface in conjunction with drawings.
c) Mark locations for saw cuts in conjunction with drawings.
d) Mark locations for reference electrodes (if used).
e) Mark locations for Sika® FerroGard®-300s Duo anodes surrounding the reference probes in the test areas,
if utilized.
f) Mark position of the monitoring/connection boxes if used.
g) Mark position for the temporary power supplies.
3. Break out rectangular section at the locations identified in the drawings –
Dimension of the hole shall be according to the table in clause 3 above.
Note that in zones where there is traffic (e.g. on a car park deck situation), the
rectangular section shall be cut with the direction of the traffic flow with the
shorter edge exposed to the direction of traffic.
4. Cut chases as identified above, 4 mm wide x 15 mm deep, between holes for
location of titanium feeder wires. Ensure that no reinforcing steel is exposed as this has the potential to cause
electrical shorts.
Cut chases for the additional titanium wire connections as identified above.
Cut chases for the copper cables as identified above.
All holes and saw cuts shall be fully cleaned out prior to application of the Sika®
FerroGard®-300 DuoCrete mortar and Sika® concrete repair mortar.
5. Make electrical connections to the reinforcing steel by first exposing the steel,
drilling a 4 mm hole and riveting a titanium wire connection with a 3.2 mm
diameter stainless steel rivet (grip range 3.2 - 4.8 mm). At least two steel
connections per zone of anodes shall be made.
6. Position temporary power supplies.
7. Identify the locations for reference electrodes (if required) and install in 105 mm
deep x 30 mm diameter drilled holes into the concrete deck. Run the cabling back in
20 mm deep x 7 mm wide saw cuts to the appropriate enclosure. Fill the saw cuts
with a low shrink repair mortar.
8. Strip the coating from the titanium wire using wire strippers, only in the location
where the anodes are to be fixed. Electrically pre-connect the individual Sika® FerroGard®-300s Duo units to the
titanium feeder wire using the plastic screw connectors, with the Sika® FerroGard®-300s Duo units positioned in
the holes. Twist the excess wire from the Sika® FerroGard®-300s Duo units around
the titanium feeder wire to ensure electrical continuity. The screw connectors should
be hand tight – electrical resistance between the primary titanium anode wire and
the individual Sika® FerroGard®-300s Duo units should be checked to ensure
electrical continuity (<0.5 ohm). Keep proper record – refer to clause 10.
9. With the Sika® FerroGard®-300s Duo units now fixed onto the titanium feeder
wire, they should be removed from the holes prior to application of the Sika® low resistivity, low shrinkage mortar
such as a SikaGrout® for horizontal application or Sika MonoTop®-412 N for vertical.
10. Prewet the holes prior to the placement of the mortar. However, the holes shall
be free of excess water prior to application.
11. Mix the Sika mortar according to the information containing in the technical

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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data sheet.
12. Immerse the Sika® FerroGard®-300s Duo units in water for not more than 10 minutes. (Note: The water will be
absorbed rapidly into the bedding harden mortar of the anodes – DO NOT soak for longer than 10 minutes as this
may be detrimental to Sika® FerroGard®-300s Duo performance).
13. Remove the anodes and allow the surface water to escape.
14. Dampen the concrete void to be filled with the mortar, and dampen the surface of the anode at the same time.
Apply the mortar to the bottom of the broken out section to a depth of 25 mm. Press the individual Sika®
FerroGard®-300s Duo unit into the mortar – the mortar should flow to fully encapsulate the anode. Ensure that
any trapped air is removed and that the plastic screw connector is below the concrete surface. The hybrid anode
shall be placed immediately after the mortar is applied in the broken out section.
15. Allow some time for the bedding mortar to stiffen enough prior to fill the remaining void (at least 20 mm
depth) with the same Sika mortar. This is to ensure the anodes are not disturbed during this operation. Finish so
the mortar is flush with the concrete surface. Ensure proper curing of the mortar.
16. The installation is checked for electrical shorts by measuring the electrical potential between the reinforcing
steel and the Sika® FerroGard®-300s Duo units using a high impedance voltmeter during installation. The potential
difference should be greater than 300 mV and stable. – refer to clause 10 for example of suitable QC site record
form.
17. The remaining void at the top of the anode hole shall be filled with a low shrink repair mortar within 2 hours of
installation. The installation should continue to be checked for electrical shorts as detailed in section 12. Any
electrical shorts should be rectified immediately. The chases within which the titanium wire is situated, and
excavations where steel connections have been made, can also be filled with the low shrink Sika® concrete repair
mortar at this stage.
18. The installed Sika® FerroGard®-300s Duo units in each zone are connected to a 12V temporary power supply.
The titanium feeder wire from the Sika® FerroGard®-300s Duo units is connected to the positive terminal; the wire
from the steel is connected to the negative terminal. This should be completed within 2 hours of installation of the
units.
Also ensure that any bare titanium wires outside of the concrete, which can possibly short, are insulated using
insulation tape.
19. Undertake a polarity check and record the data. The steel potential must shift more negative relative to the
reference electrode. If the potential moves to a more positive potential relative to the reference electrode then
the current should be disconnected immediately and professional advice sought. A method statement must be
provided by the contractor.
Polarity check data will be recorded for all zones of Sika® FerroGard®-300s Duo application. Record number of
tests undertaken and detail any areas which fail the test prior to rectification.

Note: A method of obtaining a polarity check is to place a surface reference electrode adjacent to a Sika®
FerroGard®-300s Duo unit and observe the change in potential registered as the impressed current is
applied. Ensure that the reference electrode is in the COM terminal for polarity checks.
Note: The Sika® mortar should only be applied and cured at a temperature greater than 5ºC and rising.

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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20. Activate the power supply typically for 1 week. If rechargeable batteries are used, exchange battery power
units on a daily basis or as necessary to maintain charge capacity in excess of 50% (ensure that replacement
batteries are kept fully charged).
If car battery is used, control the voltage in order to ensure that the battery does not get discharge completely as
this might indicate a short circuit. Battery voltage may drop significantly as this will depend on the zone
environment and the resistance of the concrete. The voltage and current output for each zone shall be recorded
on a daily basis (refer to clause 10 for suitable QC record form). A method statement must be provided by the
contractor.
Each treated zone is logged as follows***;
Zone Date Date power Daily measurement
connected supply
1 2 3 4 5 6 7
to power disconnected
supply V mA V mA V mA V mA V mA V mA V mA

***A copy of this information is to be forwarded to the client.

Note: To determine the voltage of the battery or power supply, use a voltmeter to direct read from the terminals
of the battery. A typical method of measuring the current delivered from the power supply is to measure the
voltage drop across a 0.1 Ohm resistor placed in series with the circuit.
Once the targeted current flows has been applied according to the life expectation calculation sheet but at least
after 1 week, disconnect the wires from the positive and negative terminals of the 12V power supply and connect
them together within the connection box. Note that in dry environment, the targeted current flow may take longer
than the typical 1 week period.
21. The Sika® FerroGard®-300s Duo units are now operating in galvanic mode.
22. The feeder wires are buried in the chases using repair mortar or pourable compound as specified which is
allowed to cure according to the manufacturer’s instructions.
23. Clean the treatment area.
24. The installation phase is now complete

ADDITIONAL INFORMATION
Any unusual site details should be discussed with the engineer/Sika prior to installation of the system.

8.1 PROCESS MONITORING

8.1.1 VISUAL INSPECTION
Before the Sika® FerroGard®-300s Duo hybrid anode system is connected to the power supply for the impressed
current, the installation and all its component parts shall be subjected to a complete visual inspection to check
they are installed correctly, labeled and protected from environmental, human and animal damage.
8.1.2 ROUTINE INSPECTION AND MAINTENANCE
Routine inspection shall be carried out at least once a day during the impressed current phase. The following
checks shall be carried out and the data recorded:

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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Phase 1 – Impressed current
1) Confirmation that the battery/power supplies are functioning correctly and have sufficient charge capacity for
the impressed current treatment.
2) Measurement of current delivery to each treatment zone.
3) Visual checks of cable insulation and anode connections, to confirm their proper function.
Phase 2 – Galvanic protection current
Confirmation of galvanic activity after the 1st phase impressed current treatment may be undertaken by
measuring current between the Sika® FerroGard®-300s Duo anodes and the reinforcing steel after a period of 2
hours after disconnection of the power supply. A protective current will be observed from the Sika® FerroGard®-
300s Duo anodes.
Acceptance Criteria:
The immediate and continued effectiveness of the Sika® FerroGard®-300s Duo system shall be assessed using steel
corrosion rate measurement.
8.1.3 STEEL CORROSION RATE MEASUREMENT
This method uses the applied current density of a segment of the anode system and the steel potential shift
achieved from application of the galvanic current to calculate the open circuit steel corrosion rate. The rest of the
Sika® FerroGard®-300s Duo system should remain connected in sacrificial anode mode to act as a guard ring to the
Sika® FerroGard®-300s Duo anode group to be tested. Small or large perturbation techniques can be utilised in
measuring steel corrosion rates, the former identified with the polarisation resistance method and the latter using
larger potential perturbations as detailed elsewhere (G.K. Glass, A.C. Roberts and N. Davison, ‘Criteria for novel
electrochemical treatments of steel in concrete’, Proceedings of the 7th International Conference on Concrete in
Hot and Aggressive Environments, Volume 2, p.477-492, 13-15 October 2003).
Corrosion rates less than 1-2 mA/m2 (less than 1-2 μm of steel section loss per year) are in general deemed to be
negligible rates obtained on passive steel. (See Corrosion, vol 55, 1999, pg 286).

LIMITATION
In order that suitable current flow and lifetime be achieved from the Sika® FerroGard®-300s Duo anodes, certain
practical considerations should be taken into account.
The patch repair material cover for the Sika® FerroGard®-300s Duo unit must be a minimum depth of 20 mm.
When installed in a patch repair, the resistivity of the repair material should be in the range 50-200% of the parent
concrete.
Any discontinuous steel should be either electrically bonded to or electrically isolated from the system negative.
Any cracks or delamination in the concrete which affect ionic current flow will affect performance of the Sika®
FerroGard®-300s Duo units and should thus be pre-treated.
During installation, electrical shorts between the Sika® FerroGard®-300s Duo anodes and other metal components
must be avoided.
The time to achieve passivity will be dependent on site conditions. Depolarisation of treated steel will be slower in
moist conditions.

SITE QC RECORD
Contractor shall fill and retain a suitable QC record for the installation of anodes and the monitoring system.
Example of suitable QC record is embedded in the document.

Site QC
Record_Hybrid Anodes_V3.docx

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
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 TYPICAL DRAWINGS

TYPICAL SPACING
12.1 COMMENTS
The spacing provided in the table 1 below is given for guidance only. Spacing will depend on site conditions, steel
density, reinforcement bar sizes & geometries, chloride content, humidity, temperature, etc. Specialist design
engineer shall confirm the spacing based on the site conditions.
Assumes concrete broken out and steel exposed to EN 1504 guidelines.
Corrosion protection systems must be designed by suitably qualified personnel.

12.2 TABLES OF SPACING

Table 1

MAXIMUM ANODE SPACING

Sika® FerroGard®-350 Sika® FerroGard®-355 Sika® FerroGard®-360 Sika® FerroGard®-365

Steel Density Duo Duo Duo Duo
Ratio
Inches mm Inches mm Inches mm Inches mm
<0.3 20 500 20 500 22 550 24 600
0.31-0.60 18 450 20 500 20 500 20 500
0.61-0.90 15 380 18 450 19 475 20 500
0.91-1.20 13 330 16 400 17 425 18 450
1.21-1.50 12 300 14 350 16 400 16 400
1.51-1.80 --- --- 12 300 15 380 16 400
>1.81 --- --- 11 280 13 325 14 350

Note: Typical data – in more aggressive or benign conditions these may be adjusted – consult a suitably qualified
engineer. Steel geometry and lifetime requirements will affect the layout and design.

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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 LEGAL NOTE
The information, and, in particular, the recommendations relating to the application and end-use of Sika products,
are given in good faith based on Sika's current knowledge and experience of the products when properly stored,
handled and applied under normal conditions in accordance with Sika’s recommendations. in practice, the
differences in materials, substrates and actual site conditions are such that no warranty in respect of
merchantability or of fitness for a particular purpose, nor any liability arising out of any legal relationship
whatsoever, can be inferred either from this information, or from any written recommendations, or from any
other advice offered. The user of the product must test the products suitability for the intended application and
purpose. Sika reserves the right to change the properties of its products. The proprietary rights of third parties
must be observed. All orders are accepted subject to our current terms of sale and delivery. Users must always
refer to the most recent issue of the local Product Data Sheet for the product concerned, copies of which will be
supplied on request.

© 2013 Sika Services AG / Nr 850 73 05

Sika Services AG Version given by

Tüffenwies 18 M. Donadio
8048 Zürich Phone: +33 6 700 300 59
Switzerland
www.sika.com Mail: donadio.michel@fr.sika.com

Method Statement For External Diffusion

Corrosion Control using Sika® FerroGard®-300s Duo REFURBISHMENT
Hybrid Galvanic Anodes for Slim Structures
December 18, Ver.: 5
MDo/32-2018

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