SECTION 13113 Impressed Current CP of Reinforced .......... Structures Rev 0

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SECTION 13113:
GUIDELINE SPECIFICATION FOR

IMPRESSED CURRENT CATHODIC PROTECTION OF
REINFORCED CONCRETE STRUCTURES
0 15/02/06 I Issued for Use ~\-

REV DATE DESCRIPTION PREPARED BY RC APPROVED
KINGDOM
OFSAUDIARABIA
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forJubail&Yanbu
RoyalCommission ~~ ~ ~144f.l1
SECTION 13113
IMPRESSED CURRENT CATHODIC PROTECTION OF REINFORCED CONCRETE STRUCTURES
TABLE OF CONTENTS
Item No Title Page No
PART 1 GENERAL............................................................................................................ 1
1.01 DESCRIPTION OF WORK .................................................................................. 1
1.02 SECTION INCLUDES .......................................................................................... 1
1.03 RELATED SECTIONS ......................................................................................... 1
1.04 REFERENCES..................................................................................................... 2
1.05 DEFINITIONS....................................................................................................... 4
1.06 SUBMITTALS....................................................................................................... 8
1.07 QUALITY CONTROL ......................................................................................... 10
1.08 HEALTH AND SAFETY CONSIDERATIONS.................................................... 11
1.09 DESIGN CRITERIA............................................................................................ 12
1.10 JOB CONDITIONS............................................................................................. 17
1.11 INTERFACES..................................................................................................... 18
1.12 DELIVERY, HANDLING AND STORAGE ......................................................... 19
PART 2 PRODUCTS ....................................................................................................... 21
2.01 GENERAL .......................................................................................................... 21
2.02 POWER SUPPLY SYSTEM............................................................................... 21
2.03 AC POWER SUPPLY ........................................................................................ 26
2.04 ANODE SYSTEM............................................................................................... 26
2.05 NEGATIVE CONNECTIONS ............................................................................. 28
2.06 REFERENCE ELECTRODES............................................................................ 28
2.07 DC AND INSTRUMENT CABLING .................................................................... 29
2.08 JUNCTION BOXES............................................................................................ 30
Rev 0 i Contract No:

SECTION 13113
TABLE OF CONTENTS (Contd.)
Item No Title Page No
PART 3 EXECUTION ...................................................................................................... 32
3.01 PREPARATION ................................................................................................. 32
3.02 INSTALLATION.................................................................................................. 34
3.03 TESTING AND COMMISSIONING .................................................................... 38
3.04 INTERFERENCE TESTING............................................................................... 41
3.05 PROVISION OF OPERATION AND MAINTENANCE MANUAL....................... 41
3.06 PROVISION OF TRAINING IN SYSTEM OPERATION .................................... 42
Rev 0 ii Contract No:

SECTION 13113
PART 1 GENERAL
1.01 DESCRIPTION OF WORK
A. The Contractor shall design, install, test, commission and document impressed
current cathodic protection (CP) for existing and new reinforced concrete structures.
The purpose of the CP system is to protect the reinforcing steel in concrete
structures against corrosion by passing a low voltage current from an anode system
to the reinforcing steel.
B. The Contractor shall furnish all labor, materials, tools and equipment required to
complete the Work.
1.02 SECTION INCLUDES
A. This Section establishes the general criteria for the design, installation, testing,
energizing, and commissioning of impressed current CP for reinforced concrete
structures as required for this and other related Sections of these Specifications.
B. This Section does not include cathodic protection using galvanic anodes.
1.03 RELATED SECTIONS
A. Section 01320 Construction Progress Documentation
B. Section 01330 Submittal Procedures
C. Section 01410 Regulatory Requirements
D. Section 01450 Quality Control
E. Section 01650 Product Delivery Requirements
F. Section 01660 Product Storage and Handling Requirements
G. Section 01780 Closeout Submittal
H. Section 01830 Operation and Maintenance
I. Section 03205 Reinforcement for Concrete
J. Section 03310 Structural Concrete
K. Section 03930 Concrete Rehabilitation
L. Section 13111 Impressed Current Cathodic Protection of Submerged and Buried

Underground Metallic Structures
M. Section 13112 Sacrificial Anode Cathodic Protection of Submerged and Buried

Underground Structures
Rev 0 1 of 43 Contract No:

SECTION 13113
N. Section 13450 Central Control
O. Section 16060 Grounding and Bonding
P. Section 16075 Electrical Identification
Q. Section 16150 Wiring Connections
R. Section 16410 Enclosed Switches and Circuit Breakers
1.04 REFERENCES
A. The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these references and
text specification, the specification text shall govern.
B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict between codes and/or references, the Contractor shall
conform to the BS EN Standards.
C. ACI American Concrete Institute
1. ACI 222R Corrosion of Metals in Concrete
2. ACI 318RM Building Code Requirements for Structural Concrete

and Commentary
D. ASTM American Society for Testing Materials
1. ASTM B265 Standard Specification for Titanium and Titanium

Alloy Strip, Sheet, and Plate
2. ASTM C150 Standard Specification for Portland Cement
3. ASTM C876 Standard Test Method for Half-Cell Potentials of

Uncoated Reinforcing Steel in Concrete
4. ASTM G3 Standard Practice for Conventions Applicable to

Electrochemical Measurements in Corrosion Testing
E. BSI British Standards Institution
1. BS 89 Direct Acting Indicating Analog Electrical

Measurement Instruments
2. BS 148 Specification for Unused and Reclaimed Mineral

Insulating Oils for Transformers and Switchgear
3. BS 171 Specification for Power Transformers
4. BS 4678 P4 Cable Trunking – Part 4. Specification for Cable

Trunking Made of Insulating Material

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5. BS 6004 Electric Cables
6. BS 7361 P1 Code of Practice for Land and Marine Applications
7. BS 7671 Requirements for Electrical Installations. IEE Wiring

Regulations
8. BS 9720 Custom Built Transformers
9. BS EN 1504-1 Products and Systems for the Protection and Repair

of Concrete Structures. Definitions, Requirements,
Quality Control and Evaluation of Conformity.
Definitions
10. BS DD ENV 1504-9 Products and Systems for the Protection and Repair
Quality Control and Evaluation of Conformity.
General Principles for the Use of Products and
Systems
11. BS EN 1504-10 Products and Systems for the Protection and Repair
Quality Control and Evaluation of Conformity. Site
Application of Products and Systems and Quality
Control of Works
12. BS EN 1542 Products and Systems for the Protection and Repair
of Concrete Structures. Test Methods. Measurement
of Bond Strength by Pull-Off
13. BS EN 12696 Cathodic Protection of Steel in Concrete
14. BS EN 50162 Protection Against Corrosion by Stray Current from

Direct Current Systems
15. BS EN 60146 Semiconductor Converters. General Requirements

and Line Commutated Converters
16. BS EN 60529 Specification of Protection Provided by Enclosures

(IP Code)
17. BS EN 60947-2 Low Voltage Switchgear and Controlgear Circuit

Breakers
F. DNV Det Norske Veritas Industri Norge AS
1. DNV RP B401 Cathodic Protection Design
G. IEEE/ANSI Institute Electrical Electronic Engineers/American National

Standards Institute
1. IEEE/ANSI 449 Ferroresonant Voltage Regulators
H. NACE National Association of Corrosion Engineers

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1. NACE RP0177 Mitigation of Alternating Current and Lighting Effects

on Metallic Structures and Corrosion Control
Systems
2. NACE RP0187 Design Considerations for Corrosion Control of

Reinforcing Steel in Concrete Structures
3. NACE RP0290 Impressed Current Cathodic Protection of

Reinforcing Steel in Atmospherically Exposed
Concrete Structures
4. NACE RP0390 Maintenance and Rehabilitation Considerations for

Corrosion Control of Existing Steel Reinforced
Concrete Structures
5. NACE TM0294 Testing of Embeddable Impressed Current Anodes

for Use in Cathodic Protection of Atmospherically
Exposed Steel-Reinforced Concrete
I. NEMA National Electrical Manufactures Association
1. NEMA AB 1 Molded-Case Circuit Breakers, Molded Case

Switches, and Circuit-Breaker Enclosure
J. NFPA National Fire Protection Association
1. NFPA 70 National Electrical Code
K. In addition to the above standards, the anode manufacturer's guidelines and

recommended installation and overall procedures shall be recognized as part of this
Specification. No deviation from the manufacturer’s recommendation, and/or quality
standards shall be permitted without prior approval by the Royal Commission.
1.05 DEFINITIONS
A. anode: The electrode of an electrochemical cell at which oxidation occurs.
B. anode backfill: Material with low resistivity, which may be moisture-retaining,

immediately surrounding a buried anode for the purpose of decreasing the effective
resistance of the anode to the electrolyte.
C. anode ground bed: System of buried or immersed galvanic or impressed current

anodes.
D. anode zone: The anode system may be divided into zones to supply current to a
fully continuous reinforcement matrix, and a current provision to each zone can be
separately controlled and measured.
E. backfill: See anode backfill.
F. bond: Metal conductor, usually copper, connecting two metallic points on the same
or on different structures usually with the intention of making the points equipotential.

SECTION 13113
G. buried structure: Any metal construction built or laid beneath ground level or built
on ground level and covered with earth.
H. carbonation: The process by which carbon dioxide in the atmosphere reacts with
water in concrete pores to form carbonic acid and then reacts with alkalis in the
pores, neutralizing them.
I. cathode: The electrode of an electrochemical cell at which reduction occurs.
J. cathodic protection: A process of protecting a metallic structure from corrosion by

installing an impressed current system that makes the protected structure cathodic
and thus resistant to corrosion.
K. cathodic protection system: Entire installation including active and passive

elements that provides cathodic protection.
L. coating: Electrically insulated covering bonded to a metal surface for protection

against corrosion by preventing contact between the electrolyte and the metal
surface.
M. conductive coating: A paint, mastic or metallic spray which is heavily loaded with
an electrically conducting component.
N. conductive mortar/concrete: Mortar or concrete with additives formulated to

conduct electrical current.
O. continuity bond: Bond designed and installed specifically to ensure electrical

continuity of a structure.
P. copper/saturated copper sulphate reference electrode: Reference electrode

consisting of copper in a saturated solution of copper sulphate.
Q. current density: Electric current per unit area of an electrode surface.
R. electrical continuity: Physical state of a structure such that a current circulating

within it does not produce a significant voltage drop.
S. electrical interference: See interference.
T. electrical isolation: Electrical isolation exists when there is no electrical path

between structures or components.
U. electrolyte: Liquid, or the liquid component in a medium such as soil, in which

electric current flows by the movement of ions.
V. electrolyte resistivity: The specific resistance of the electrolyte assuming that the
electrolyte is homogenous. Note: Usually expressed in ohm.meter (Ω·m).
W. energizing: The process of initially applying power to a cathodic protection system.
X. foreign structure: Any metallic structure that is not intended as a part of a system
under cathodic protection.
Y. galvanic anode: A metal that provides sacrificial protection to another metal that is

SECTION 13113
more noble when electrically coupled in the electrolyte. This type of anode is the
source in one type of cathodic protection.
Z. impressed current: Electric current supplied by a rectifier connected to a power

source that is external to the electrode system.
AA. immersed structure: Any metallic structure or part of a structure laid in a liquid
environment such as fresh water (rivers, lakes), brackish water (estuaries), or sea
water.
BB. impressed current anode: Anode in an impressed current source.
CC. impressed current station: Station which comprises the equipment and materials
required to provide cathodic protection by impressed current. Such materials and
equipment will include impressed current anodes, cables and a DC source.
DD. interference: Any change in the structure to electrolyte potential, which is caused by
foreign electrical sources.
EE. interference test: Test to determine the severity of corrosion interaction between
two buried or immersed structures.
FF. IR drop: Voltage difference, due to any current, developed in an electrolyte such as
the soil, between the reference electrode and the metal of the structure, in
accordance with Ohm's Law (V = I x R).
GG. IR free potential: Structure potential measured without the voltage error caused by
the IR drop due to the protection current or any other current.
HH. manganese/manganese dioxide reference electrode: Reference electrode

consisting of manganese, manganese dioxide and an electrolyte of sodium
hydroxide.
II. measuring point: The point at which the actual measurement takes place. Note: In
case of structure to electrolyte potentials, this refers to the location of the reference
electrode.
JJ. negative connection: Electrical connection to the reinforcement to be protected by

the cathodic protection system.
KK. instant off potential: Structure to electrolyte potential measured immediately after
synchronous interruption of all sources of applied cathodic protection current.
LL. on potential: Structure to electrolyte potential measured with the cathodic protection
current flowing.
MM. permanent reference electrode: Permanently buried, immersed or embedded

reference electrode designed for a long life and installed close to the structure or
within the structure.
NN. polarization: Change in the potential of an electrode (e.g. structure) as the result of
current flow to or from that electrode.
OO. primary anode: Current is fed from the rectifier to the primary anodes, which serves

SECTION 13113
as current distributors in the cathodic protection system on to the anode

mesh/ribbons/conductive mortar etc.
PP. protected structure: Structure to which cathodic protection is effectively applied.
QQ. protection current: Current made to flow into a metallic structure from its electrolytic
environment in order to effect cathodic protection of the structure.
RR. protection potential: Structure to electrolyte potential for which the metal corrosion
rate is acceptable.
SS. reference electrode: An electrode of which the potential is accurately reproducible

and which serves as a basis of comparison in the measurement of other electrode
potentials.
TT. service life: The time until safety, serviceability and acceptable appearance of the
structure or its main components falls below a defined minimum level or requires
unduly high costs for maintenance and repair.
UU. shield: Conductive or non-conductive object, which modifies the protection current
distribution on a structure to be protected.
VV. silver/silver chloride reference electrode: Reference electrode consisting of silver,

coated with silver chloride, in an electrolyte containing a fixed concentration of
chloride ions.
WW. stray current corrosion: Corrosion caused by electric current from a source
external to the intended electrical circuit, for example, extraneous current in the
earth.
XX. structure: Metallic construction, whether coated or not, which is in contact with an
electrolyte (e.g. soil, water). Note: The structure may represent a construction of
great length, such as a pipeline, pipe networks, underground electric cables, or well
casings as well as constructions on a smaller scale such as piles, sheet pilings, tanks
or other underground constructions.
YY. structure to reference electrode potential (also called electrode potential):

Difference in potential between a structure and a specified reference electrode in
contact with the electrolyte at a point sufficiently close to, but without actually
touching the structure.
ZZ. test connection: Negative connection to the reinforcement to be protected by the

cathodic protection system. The negative connection is used solely for testing.
AAA. test station: Installation that provides measuring and test facilities for the buried
structure. Note: Such installations will include cabling and structure connections.
BBB. transformer rectifier (T/R): Device that transforms AC voltage to DC voltage. DC

voltage derived in this way is used as a power source for impressed current cathodic
protection systems.
CCC. zinc electrode: Measuring electrode made from sufficiently pure zinc.
DDD. zone: A defined part of a cathodic protection system.

SECTION 13113
1.06 SUBMITTALS
A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:
1. Manufacturer's Data
a) Submit copies of manufacturer's specifications and installation

instructions for all proprietary materials and products such as power
supply system, anode system, reference electrodes, cables, junction
boxes, etc. Include all manufacturers' certifications and laboratory test
reports, as required.
2. Shop Drawings
a) Submit Shop Drawings showing complete detail and schedule for

fabrication and installation of the CP system. The Shop Drawings shall
consist of, but not be limited to, the power supply system, anode
system, test stations, header cables, reference electrodes, signals I/O
list and disconnect switches.
b) The Shop Drawings shall indicate component sizes, locations, and cable
and anode routings. Identify any special handling requirements for each
of the components.
3. Calculations
a) Provide complete detailed design calculations for each component

demonstrating compliance with this Specification, BS EN standards or
NACE recommendations. Detailed calculations shall be provided which
demonstrate acceptance for each component.
b) The calculations shall demonstrate that the impressed current anode

system can meet the current density requirements as specified in
par. 1.09 B and are capable of providing the required design life as
specified in par. 1.09 D.
c) Detailed calculations to support the design shall be:

1) Calculation of cathode current requirement based on calculations
of surface area of reinforcement including starter bars, tie wires or
clamps. In addition, metallic items in electrolytic contact with the
concrete surface (metallic plates, bolts etc.) shall also be included
in the calculation.
2) The risk of stray current corrosion shall be addressed for any
metallic items and any neighboring steel structure in electrolytic
contact with the concrete surface. Any metallic items or structures
with risk of stray current corrosion shall be electrically connected
to the reinforcement. The surface areas of these metallic
components shall be included in the calculations for the cathode
current requirement.
3) Calculation of anodes, including Primary (Current Distribution)

SECTION 13113
Anodes
(a) Type, number and configuration.
4) Calculation of anode zone layout.
5) Circuit resistance of each zone.
4. Method Statements
a) Provide method statements for items included in par. 3.01 A, for e.g.
visual inspection, delamination survey, concrete cover, verification of
reinforcement size and position, ‘as found' potential survey and
verification of environmental parameters such as electrical resistivity of
concrete.
b) Provide method statement for electrical continuity, including test

method, content and establishing of electrical continuity as specified in
par. 3.01 D.
c) Provide method statements for structural assessment of the concrete

structures included in the preparation, as specified in par. 3.01 C, e.g.
establishing of reinforcement continuity, removal of any delaminated,
non-conductive repairs, membranes or similar and concrete
reinstatement.
d) Provide method statement for trial installation of each anode system to

be installed as specified in par. 3.02 C.
e) Provide method statement for installation of each component, e.g.

power supply system, anode system, test stations, negative
connections, cables, data acquisition system, data communication
systems and the central monitoring and central control system. The
method statement shall be prepared taking the manufacturer's
guidelines into consideration.
f) Provide method statement for commissioning, e.g. pre-commissioning

survey, energizing, performance testing and interference testing. The
method statement shall be prepared in strict accordance with the
manufacturer's guidelines and as specified in pars. 3.03 and 3.04.
5. Submit the following items for review and approval before commissioning:
a) Operation and Maintenance Manual

1) Submit copies of the Operation and Maintenance Manual per
SECTION 01830. The manual shall include, as minimum, the
following:
(a) Description of structure and CP system(s).
(b) Periodic inspection requirements and monitoring method
statement.
(c) System output parameter.
(d) Transformer rectifier operating instructions and
maintenance requirements.

SECTION 13113
(e) Rectifier circuits drawings.

(f) Spare part list.
(g) System reporting records.
(h) Required test procedures.
(i) Data collection and management system together with
requirements to performance criteria.
b) As-Built Drawings
1) Submit copies of As-built Drawings per SECTION 01780,
following installation of the CP system. The Drawings shall
provide complete details including, but not limited to, the power
supply system, anode system, test stations, negative connections,
cables, data acquisition system, data communication systems,
signals I/O-lists and the central monitoring and central control
system. The As-built Drawings shall further indicate component
sizes, locations, anode zones and cable runs.
1.07 QUALITY CONTROL
A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing to achieve the specified
quality to the approval of the Royal Commission, in accordance with
SECTION 01450.
B. The design, installation and commissioning of the CP system shall meet the Royal
Commission’s Quality Control standards. In addition, the CP system component
manufacturer’s own recommended installation and material standards and
procedures shall be recognized as part of this Specification. No deviations shall be
permitted without prior written agreement by the Royal Commission. The Contractor
and Subcontractor shall review and remain cognizant of all other specifications
related to this scope of work.
C. The design, installation, energizing, and commissioning of the CP system shall be

fully documented and recorded. The quality documentation shall constitute part of the
permanent record of the Project. All documents shall be provided to the Royal
Commission for review and approval.
D. Each element of the work shall be undertaken in accordance with a fully documented
quality plan.
E. Each and every stage of the work including installation, energizing, commissioning
and long term operation shall be subject to appropriate visual inspection, mechanical
and/or electrical testing and all testing shall be documented.
F. A suitable quality management system, which may be adapted by the Contractor to

achieve this purpose, is EN ISO 9001. The Contractor is required to prepare and
submit a detailed quality management program for the review and approval of Royal
Commission.
G. Field Representative, Inspection and Supervision

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1. The Contractor shall be responsible for the coordination of all works relating to
this Contract. It shall be the responsibility of the Contractor to ensure that all
work and equipment to be furnished under the Contract results in a complete
and satisfactory installation.
2. All work shall be carried out under the supervision of an experienced Cathodic
Protection Engineer. The Cathodic Protection Specialist/Engineer shall have a
Degree in Electrical or Electrochemical Engineering or Science Degree in
Physics or Chemistry from a recognized Institution, a minimum of 10 years
practical experience in cathodic protection design, installation and
commissioning. A professionally qualified NACE Certified Cathodic Protection
Specialist or a professional member of the Institute of Corrosion, with a
Bachelor Degree in Physical Science or Engineering is preferable.
3. All Contractor’s engineers and supervisory staff involved with the installation of
the cathodic protection (CP) system shall have at least 3 years experience in
this type of work and the Contractor shall provide Resumes for the Royal
Commission’s approval prior to commencement of work.
4. All installation work shall be supervised by the Cathodic Protection Engineer

who is nominated by the Contractor and approved by the Royal Commission.
The Cathodic Protection Engineer shall be on site at all times when cathodic
protection work is in progress and shall be responsible for the workmanship
and safety of all the cathodic protection works throughout the Contract period.
5. Supervision shall be carried out to a high standard throughout the works. All
equipment shall be inspected upon delivery and again prior to installation.
Inspection hold points shall be introduced for items or works which will be
buried so that assurance and responsibility is recorded for all items or works
prior to backfilling.
6. Any defect shall be reported to the Royal Commission and shall be recorded in
a retrievable data system. Corrective actions taken, which must be approved
by the Royal Commission, shall also be recorded.
7. The Contractor shall submit a quality plan, detailing his proposed procedure for
Quality Control, for review and approval by the Royal Commission.
8. All testing and commissioning work shall be carried out the by above Cathodic
Protection Specialist Staff. The staff who are deemed to have insufficient
experience shall be prohibited from carrying out critical work tasks as
described in the relevant parts of the specification. In such cases, replacement
manpower and any delays incurred shall be borne by the Contractor.
H. Codes, Standards and Specifications
1. The Contractor/Subcontractor shall comply with the provisions of the codes

and standards listed in par. 1.04 and Specifications listed in par. 1.03, except
as otherwise noted or specified.
1.08 HEALTH AND SAFETY CONSIDERATIONS
A. All works undertaken in relation to this Specification are to be completed in full

SECTION 13113
accordance with the respective health and safety requirements established by the
following:
1. Kingdom of Saudi Arabia
a) Legislation, Regulation, Standards and Codes.
2. Royal Commission Regulations
a) Standards, Contractual Conditions, and Health and Safety Systems.
3. Contractor
a) Health and Safety Standards and Systems as accepted by the Royal

Commission.
B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.
C. Measures shall be taken to avoid any safety hazards caused by the cathodic
protection system. The considerations shall include, but not be limited to, electric
shock, hydrogen and chlorine gas generation.
1.09 DESIGN CRITERIA
A. System Description
1. The CP system shall consist of the following sub-systems:
a) Power Supply System

1) Consisting of the transformer/rectifier (T/R) and the associated
control logic circuitry for automatic control and operation. The
power supply system shall also possess a built-in current
interrupter to obtain depolarization measurements.
b) Anode System
1) Consisting of anode(s) including any overlay, associated power
distribution bars, cables, and all fastening devices to support the
anode material.
(a) For new structures, an anode system shall consist of an
activated titanium anode system.
(b) For existing structures, an anode system shall consist of
activated titanium anodes (mesh, ribbon, rods, wire, tubes
etc.) mounted directly on the concrete surface with a
cementitious overlay or placed in holes or slots encased in
cementitious grout/graphite backfill.
(c) The anode system may consist of other anode types
specific for the particular structure being protected.
(d) The type of anode system shall be chosen taking into
consideration, among others, factors such as the

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performance requirements, service life, environmental

condition, load carrying capacity, aesthetics and operation
and maintenance.
c) Cathode System
1) Consisting of the negative cabling from the rectifier connected to
the reinforcement, including the structure continuity ties or clamps
and any other metallic items or objects to be protected.
d) Monitoring and Control System

1) Consisting of reference electrodes, test connections to the
reinforcement, local data acquisition system, remote
communication/relay system for data transmission for remote
system monitoring and control built into the T/R system, and a
central unit capable of performing the specified remote control
and monitoring, for remote monitoring and control system refer to
SECTION 13450.
B. Criteria for Protection; Current Density Requirements
1. The CP system for existing structures shall be designed to produce a minimum

continuous current density of 20 mA/m2 of steel surface area in all CP zones.
2. The CP system for new structures shall be designed to produce a minimum

continuous current density of 5 mA/m² of steel surface area in all CP.
3. The maximum allowable current density at the anode-concrete interface shall

be 110 mA/m², unless a higher current density is acceptable to the
manufacturer.
4. The effectiveness of the current flow shall be in accordance with BS EN 12696

or NACE RP0290 and monitored regularly by depolarization testing:
a) For above ground level and above water tidal level, the following
protective criteria shall be achieved:
1) An ‘INSTANT OFF’ potential more negative than - 720 mV with
reference to Ag/AgCl/0.5M KCl.
2) A potential decay after maximum 24 hours of at least 100 mV
from 'INSTANT OFF' or a potential decay after more than
24 hours of at least 150 mV.
b) For below ground level and below water tidal level, the following
protective criteria shall be achieved:
1) A minimum negative shift in 'INSTANT OFF' potential to - 720 mV
with respect to Ag/AgCl/0.5 M KCl.
c) No 'INSTANT OFF' potential shall be more negative than - 1100

or - 900 mV with respect to Ag/AgCl/0.5 M KCl for plain steel and pre-
stressing steel, respectively.
d) The ‘INSTANT OFF’ potential shall be measured 0.1 to 1 second after

SECTION 13113
switching the DC circuit open.
e) In some instances, it may necessary to combine potential decay data

and the values of instantaneous off potentials in order to determine the
effectiveness of a cathodic protection system using best engineering
judgment.
C. CP Zones
1. The CP system shall be sectioned into zones with the anode circuit being the
principal basis of zoning. A zone is defined as a discrete section of concrete
structure energized as an independent unit. A zone may be divided into
smaller elements called sub-zones comprising different sections of concrete.
The sections of concrete combined into a single zone shall have similar
environmental exposure and conditions as well as similar conditions of
separation of anode to reinforcement steel and similar concrete quality.
2. For existing structures, the total design current requirement of a single zone
shall not exceed 4 A. In case the driving voltage to obtain the 4 A exceeds the
manufacturer’s recommended maximum driving voltage, the anode zones shall
be sub-divided to meet the manufacturer’s requirements.
3. For new structures, the total design current requirement of a single zone shall
not exceed 2.5 A.
4. A minimum of 2 positive and 2 negative connections per zone shall be

provided, provided all concrete sections are combined into a single zone.
There shall be 2 positive and 2 negative connections for each sub-zone.
5. The anode distribution within each zone shall be determined by current

requirement calculations of the steel area to be protected and subject to the
current spread considerations. The manufacturer's requirement to maximum
anode spacing shall be taken into consideration.
6. No zone shall be designed so that the voltage drop within the system exceeds
250 mV from the power supply terminals of the T/R unit to the furthest point in
the circuit, i.e., positive supply terminal to furthest anode and negative terminal
to furthest section of reinforcement.
7. Cable sizes and lengths shall be selected such that the resistance of each
anode feeder and system negative in a given zone or sub-zone shall be within
80 to 120% of the value of any other anode feeder and system negative in that
zone or sub-zone.
D. Anode Circuit Criteria
1. The anode system shall provide protection against reinforcement corrosion for
the required service life:
a) A minimum of 25 years service life is required for the existing structures.
b) A minimum of 50 years service life is required for the new structures.
c) The service life of the CP system shall be in accordance with the Royal

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Commissions requirements. If an anode system with a shorter service

life than the requirement is accepted by the Royal Commission,
preparation for easy replacement shall be incorporated in the design
and method statement for replacement shall be submitted as part of the
operation and maintenance manual.
2. The design and installation of all elements shall be made such that no major
maintenance shall be required within the service life unless replacement of the
anode system is part of the design.
3. The design of the anode system for the existing structures shall be such that it
contains a 25% redundancy in anode current output as well as 25%
redundancy in rectifier output current for each zone.
4. The design of the anode system for the new structures shall be such that it
contains a 50% redundancy in anode current output as well as 50%
redundancy in rectifier output current for each zone.
5. The design of the anode system shall be such that not more than 5% of an
anode within a given zone is made inoperative under either one random break
down in power feed or two random breaks in the anode system.
6. No anode material may cross an expansion joint. Concrete elements within a

section bounded by such joints shall be protected independently of all other
sections; i.e., they shall be independent zones or sub-zones.
7. The anode distribution shall be in accordance with the design calculations of

the current requirements taking into account the manufacturer's requirement to
the anode geometry including the minimum spacing between anodes or
primary anodes and spacing between anodes and current connectors.
8. Distribution of anode ribbons shall be as follows:
a) Maximum spacing between anodes shall be 300 mm or corresponding

to the manufacturer’s requirements.
b) No surface area of any reinforcement to be protected shall lie more than

300 mm from any anode surface. Particular attention shall be paid to
corners and edges of structures. At corners, the reinforcement, which is
most diagonally offset, shall specifically be considered.
c) For concrete sections less than 400 mm in thickness with two

reinforcement layers, anodes can be positioned as double layers on
reinforcement at 300 mm maximum spacing alternately between the
reinforcement layers, i.e. a maximum spacing of 600 mm on a single
layer of reinforcement.
d) For concrete sections with thickness between 300 and 400 mm, a single
line of anode at 300 mm maximum spacing, supported on central links
may be adopted. This option is an alternative to the option of positioning
double anode layers; each secured to the reinforcement.
e) For concrete sections greater than 400 mm in thickness, one anode

layer for each reinforcement cage shall be used. The anodes shall be

SECTION 13113
secured to the reinforcement at a maximum spacing of 300 mm between

anodes.
f) Where double anode layers are required, the anodes shall be mounted
directly on the reinforcing cage using appropriate non-metallic fasteners
for reasons of anode-to-reinforcement separation. The fasteners shall
be positioned at every crossing point of anode and reinforcement. The
anode ribbon shall be positioned between, and not on, the parallel
reinforcement bars wherever possible.
g) The minimum concrete cover over any anode ribbon shall be 20 +

10 mm.
h) Where a single anode layer is used to protect 2 layers of reinforcement,

the anode shall be positioned midway within the reinforcement cage
supported on reinforcement steel support links positioned for that
purpose but still fixed with appropriate non-metallic fasteners.
i) Reduced anode spacing may be required on any of the above

positioning options, subject to calculations or reinforcement steel density
and current density criteria, for both anode and cathode.
E. Cathode Circuit Criteria
1. All reinforcement steel of the entire structure shall be electrically continuous

within each concrete element and established prior to concrete repair.
Electrical continuity is defined as a closed electrical path between metal
components such that electrical current does not bypass the metallic
components and (rather) flow through the electrolyte, be it water, concrete or
ground.
2. All metallic items in addition to the reinforcement, which lie in or are mounted
on the concrete surface, shall be accounted for in calculating cathode current
requirements and shall be made continuous with the reinforcement.
3. Localized increases in reinforcement density shall be addressed in the anode

distribution.
4. It may be appropriate not to cathodically protect certain metal items mounted

on, in, or adjacent to the protected structure. Electrical isolation and avoiding
stray current corrosion of such items shall be addressed during the CP system
design and installation.
F. Monitoring and Control Criteria
1. Each zone shall be provided with a minimum of 2 reference electrodes,

positioned such that they represent the most exacting geometric configuration
for each zone, both, in areas of high and low steel density.
2. Each reference electrode shall be accompanied by its own test connection to

the reinforcement cage positioned adjacent to the reference electrode and in
such a manner that it lies away from the reading face of the electrode.
3. Where a zone consists of 2 or more sub-zones, then minimum 1 reference

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electrode shall be provided in every sub-zone up to 75 m2 in size and

2 reference electrodes shall be provided in every sub-zone greater than
75 m2. The requirement stated in par. 1.09 F.1 above with 4 electrodes for the
overall zone (counting all sub-zones) shall prevail, however, where there are a
limited number of sub-zones, limited in size, it could result in 2 electrodes,
especially in zones up to 75 m2 in size.
4. The individual local units of the CP system shall be automatically controlled by

an integral control unit.
5. The CP system shall further be remotely monitored and controlled. A central

PC workstation with Data Management software shall be part of a remote
monitoring and control system. The monitoring shall allow for evaluation of
whether the protective criterion is met or not. As a minimum, ON, INSTANT
OFF and depolarization over 24 hours shall be made automatically on a
monthly basis or on operator request from the central unit. The monitoring data
shall be stored for 3 years operation. In addition, it shall be possible to
centrally read current and voltage output and to adjust these set-values.
1.10 JOB CONDITIONS
A. Examine conditions of the Project site and the reinforced concrete structure for which
the CP system shall be installed. Do not proceed with installation until all
unsatisfactory conditions have been corrected.
1. Provide structural assessment method statement for review and approval by

the Royal Commission.
2. Document structural assessment results, which will include test location and
results. All results shall be recorded on a plan sheet designating each location
to be tested.
3. Any defect area (e.g. delaminated, cover less than 15 mm, high resistance)
within the concrete cover with respect to installing a cathodic protection system
shall be repaired. The repair bond strength shall be verified by pull-off testing.
The electrical resistance of the repair material shall be tested, and an
acceptance criterion corresponding to the original concrete resistance shall be
established.
a) The original concrete resistance shall be tested on three drilled cores of

100 mm diameter. The outer 20 mm (concrete surface) and the bottom
part of the core shall be sawn immediately after coring allowing for
measuring between parallel faces. The circumference and end faces of
each core shall be blotted dry and the concrete resistance measured
between the end faces using an AC-method.
b) The repair concrete resistance shall be measured on 3 prisms cast with

2 inserted strips of anode material of known surface area, and using an
AC resistance method to measure resistance between the 2 anode
strips.
c) For larger projects (> 50 m2), additional testing shall be conducted

based on test program accepted by the Royal Commission.

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4. The repairs, inclusive the bond strength testing and electrical resistance
testing of the repair material shall be documented. The extent of the repairs
shall be documented on the plan sheet. An original plan sheet shall be
provided to the Royal Commission for review and approval following repairs.
B. Verify electrical continuity of the reinforcement steelwork (see par. 1.09 E) as well as
other externally mounted steel items which may experience stray current corrosion.
Verify that the appropriate methodology of producing continuity is in place
(par. 3.01 C).
1. Verification of reinforcement geometry on site. All results shall be recorded on

a plan sheet designated to each location to be tested.
2. Provide electrical continuity Method Statement for review and approval by the
Royal Commission.
3. Electrical continuity shall be verified for all reinforcement layers, including links,
saddles, etc. and other embedded metallic fixtures according to par. 3.01 D.
If discontinuity exists, document such conditions and verify that corrections are
made.
4. Document continuity test results, which will include test location and resistance
reading. All resistance readings shall be recorded on a plan sheet designating
each location to be tested.
5. Any discontinuous steel reinforcement must be made continuous with the

cathode circuit. In this connection, partly embedded items and metallic plates
or other items having electrolytic contact with the reinforcing steel shall have
separate negative connections being connected to the T/R unit. These
connections can run from the item in question with, for e.g., a titanium cable to
the reinforcement or as external connections outside the structure.
6. It shall be verified that bonding cables are present for those metallic
components not yet placed, but to be installed after the concrete pour.
7. Following continuity bonding, the reinforcement steel resistance shall be

documented on the plan sheet. Metallic connections from partly embedded
items and other metallic items being in electrolytic connection with the
reinforcement shall also be shown on the plan sheet. An original plan sheet
shall be provided to the Royal Commission for review and approval following
continuity tests.
1.11 INTERFACES
A. The Contractor shall identify and define all interfaces between his works and other
parties' work, including other plant and systems under the responsibility of the Royal
Commission, other Contractors' plant and systems and third parties' plant and
systems. The Contractor shall keep updated records of all interface agreements
made with other parties.
B. Examples of such interfaces are:
1. Power supply to transformer rectifiers (T/R). For each T/R, the exact point of

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connection for the power supply shall be identified, whether in an existing

switchboard or distribution board or in a junction box or equal provided by the
Royal Commission for this purpose. Items such as labeling of circuit-breakers,
interruption of existing supply to the switchboard for connection of the CP-
power supply, electrical load from the T/R, short-circuit data at the connection
point, cable routing in buildings and/or underground, discrimination/selectivity
to upstream protection gear, etc. must be defined and agreed with the Royal
Commission.
2. Integration with the Royal Commission remote monitoring system. For each
T/R the physical interface, the communication protocol and the data format
and content shall be defined and agreed with the Royal Commission.
3. Other buried structures or components which may be affected by interference

from the CP system shall be identified. Construction details and time planning
of physical connection of bonds for electrical continuity, including any
excavation, backfilling and making good within the site belonging to the Owner
of the affected structure, shall be agreed with the Owner.
4. Negative connections and test connections to the protected structure.

Construction details and time planning of the physical connections of input
cables from the T/R and test wires to the structure, including any excavation
and backfilling, repair of coating etc. shall be agreed with the Owner of the
structure, whether it may be the Royal Commission or a Contractor prior to
handing-over the structure.
1.12 DELIVERY, HANDLING AND STORAGE
A. The Contractor shall deliver, handle and store equipment and material in accordance
with SECTIONS 01650 and 01660, as well as the following requirements:
1. Deliver all CP components to the Project site in sufficient quantities and at

such time as to assure the continuity of installation.
2. Each component shall be securely wrapped, packaged, labeled and marked

for safe handling.
3. Store components in a secure and dry storage facility to prevent damage,

distortion or deterioration.
4. Handle components in such a way as to ensure against damage and that

identification markings remain clearly visible.
5. Copies of the manufacturer’s storage and handling procedures for the CP

components (power supply system, anodes, reference electrodes, etc.) shall
be submitted to the Royal Commission for review prior to shipment to the site.
6. Spare Parts
a) One set of manufacturer's recommended spare parts shall be supplied

for each transformer rectifier. These shall include all fuses, light sources
and operator replaceable items. Spare parts shall be housed in an
enclosed compartment within the transformer rectifier cabinet. The

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compartment shall have an external label indicating spares.
7. The Contractor shall be held responsible for damage to the materials or

equipment during storage and transportation.

SECTION 13113
PART 2 PRODUCTS
2.01 GENERAL
A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.
2.02 POWER SUPPLY SYSTEM
A. All the equipment and components for the Cathodic Protection systems shall be rated
for the nominal voltage, current, and frequency as specified in the Contract
Drawings/Documents, and the Saudi Electricity Company (SEC) or Marafiq
guidelines, and shall include the requirements indicated below.
B. General
1. The transformer rectifiers (T/R) shall provide fully controllable DC output to the
anodes and shall meet or better the requirements of this Specification. The
units shall be installed adjacent to the structures to be protected.
2. The transformer rectifiers shall be oil-cooled or air-cooled, type as specified in

the approved Contract Drawings/Documents, with fully controllable outputs.
The required individual transformer rectifiers shall be adequate to meet the CP
system requirements.
3. Transformer rectifiers shall be rated to operate continuously at maximum rated

output under the site conditions prevailing. They shall be designed to provide a
minimum operational life of 25 years without major maintenance.
4. The transformer rectifier’s mode shall be switchable between constant voltage

with current limit and constant current with voltage limit, or constant potential
with voltage and current limit.
5. Synchronized output current interruption facilities shall be incorporated into the

units to enable ohmic corrected (‘IR free’) electrochemical potentials to be
measured by means of total system ‘instantaneous off.’
6. The transformer rectifiers shall have the provisions ready to connect hardware
systems with a remote monitoring and data management systems as specified
in the Contract Drawings/Documents. Refer to SECTION 13450 for remote
monitoring and central control system.
C. Enclosures
1. Transformer rectifiers shall be mounted in stainless steel Grade 316 or coated

enclosures and shall be sun-shaded when mounted outdoors and shall be
suitable for the prevailing climatic conditions. The enclosures shall be mounted
in approved locations after consultation with the Royal Commission.
Enclosures including cable ducts shall be protected to meet IP 65 as specified
in BS EN 60529, or as approved by the Royal Commission.

SECTION 13113
2. Doors shall be gasketed, stiff and lockable with a brass lock or padlock. All
transformer rectifier enclosure locks shall be capable of being opened with the
same key. Unhindered access to the DC positive and negative cable
terminations is required.
3. Each transformer rectifier shall have an external identification plate to clearly

identify it with an unambiguous number and also the anode zones to which it
supplies DC current.
4. Whenever possible, the transformer rectifiers shall be housed indoors in

existing facilities located adjacent to the structures protected.
D. Controls and Connections
1. Each individual transformer rectifier shall supply the designed output current to
the anodes as detailed in the design and shall include:
a) Automatic control of connected CP system by each power supply unit

according to set parameters. All operational parameters setting shall be
retained and the unit shall re-initialize after power failure.
b) Each power supply unit shall have its own logical address and each
channel in the rectifier shall have a unique address so that it is possible
to individually control and monitor every single zone and reference
electrode.
c) Analog meters, showing output current and voltage.
d) Two pairs of 4 mm² terminals or sockets to enable measurement of

output voltage and output current by an external digital voltmeter.
Current measurement shall be by voltage drop across a 0.01 ohm shunt
resistor (0.5%). Voltage measurement shall be by precision resistor
(0.5%) fitted in a voltage divider configuration to attenuate voltages of 50
to 2 V. The attenuated voltage measurement facility is to provide
compatibility of transformer rectifiers with a future data acquisition
system, remote monitoring and control system, refer to SECTION 13450
for central control system. The multiplying factor and attenuation factor
shall be clearly marked in each case.
e) All fuse holders shall be labeled with the circuit designation and rating of
individual fuses and shall be marked by indelible labels in accordance
with SECTION 16075 on the panel adjacent to the appropriate fuse
holder.
f) DC positive output to the anodes shall be taken from a common output,

via a suitably rated copper bus bar or similar, to the anode cables.
g) DC negative output to the protected structures shall be taken from a

common terminal via a suitable copper bus bar.
h) Terminals shall be clearly marked “+ ve ANODE XXX” and “- ve

STRUCTURE XXX” (where XXX is the relevant anode or structure
identification) as shown on the Contract Drawings.

SECTION 13113
i) A suitably rated circuit breaker for operation at the ambient temperature

shall be provided on the main input to provide short circuit and thermal
overload protection.
j) Lamps, LED’s or other means of indicating AC power ON and DC output

ON.
k) The transformer rectifier shall provide a standard single phase socket

outlet to be connected to the adjacent test station (for use by a future
data acquisition system to be provided by others).
l) Integrated cyclic timer for interruption (‘ON’/‘OFF’) testing. Timer shall

include a synchronization system which will enable synchronized
‘INSTANT OFF’ within each facilities being protected. The interruption
facility shall be rated to safety switch 200 A DC.
m) All cabling between transformer rectifiers and all signal processing

equipment required for synchronization of the ‘INSTANT OFF’
operations shall be provided by the Contractor in accordance with
approved Contract Drawings/Documents.
2. Multiple Rectifiers/Power Supply Units
a) When there are more than one rectifier/power supply unit for the facility
or Project with multiple structures, they shall be controlled and
monitored from a common, central control unit to be placed in a location
to be agreed with the Royal Commission.
b) The communication between local units and the central unit shall be
able to utilize telephone lines, spare fiber optic cores, or wireless
communication. Necessary terminal equipment such as modems or
equal, and communication software shall be provided by the Contractor
in accordance with approved Contract Drawings/Documents.
c) The central control unit shall be able to set and/or read operating
parameters of each rectifier/power supply channel and process, time
stamp and store collected data for reporting and alarm, as a minimum
’INSTANT OFF’ and depolarization data over 24 hours, actual and set
output voltage and output current, and reference cell potentials.
d) The monitoring data shall be stored in the central unit, which shall allow
for storage of data for 3 years operation.
e) The central control unit shall have capability for communication with the
Royal Commission's remote monitoring system in accordance with
agreed communication protocols. For central control refer to
SECTION 13450.
E. Electronic Components
1. To protect against atmospheric corrosion, all electronic component assemblies

shall be encapsulated in epoxy resin or varnishes as recommended by the
component manufacturer and shall be approved by the Royal Commission.

SECTION 13113
2. Transformers shall be double-wound in accordance with BS 171 and BS 9720.

The windings shall be separated by an earthed metallic screen or mounted on
separate limbs of an earthed core. They shall be suitable for continuous use at
the specified ratings.
3. The rectifiers shall conform to BS EN 60146 and shall be silicon type with
suitable AC surge protection. Semi-conductor fuses shall be used to protect
the rectifiers on the AC side and varistors on the DC side. Rectifiers shall be
rated for continuous operation at the maximum design outputs with a peak
inverse voltage of at least 800 V. Varistors shall be compatible with the rectifier
peak inverse voltage levels.
F. Transformer Rectifier Inspection and Testing
1. All test procedures shall be submitted to the Royal Commission for approval.
Tests shall be carried out by the manufacturer and test reports and certificates
shall be submitted to the Royal Commission for approval.
2. Testing shall be conducted at manufacturer’s works to demonstrate the

compliance of transformer rectifiers with the specification and to prove full
functional compliance and fitness-for-purpose. The tests shall be arranged to
represent realistic on-site working conditions.
3. Unless otherwise specified and approved, all electrical tests shall be carried
out in the manner as proposed by the Contractor and approved by the Royal
Commission.
4. The following tests shall be performed as a minimum:
a) All power circuits and apparatus shall withstand a power frequency

voltage test at 2000 V for 1 minute between AC and earth.
b) 500 V megger insulation tests comprising:

1) Primary to secondary.
2) Primary to earth.
3) DC positive to earth.
4) DC negative to earth.
5) In all cases the measured resistances shall be greater than
1 megaohm.
c) Tests to demonstrate performance of the current interruption facility

including time to activation, and synchronization of the cyclic timers to
within 250 ms between all transformer rectifiers.
d) Any other tests to provide compliance with the specification and as

approved by the Royal Commission.
e) The Royal Commission reserves the right of deputing their

representative for witnessing the factory testing.
G. Electrical Performance Specifications

SECTION 13113
1. The current and voltage rating of the transformer rectifiers shall be as

designed and needed to meet the design protection requirements. The
transformer rectifiers shall comply to the following electrical performance
specifications:
a) Primary Power Supply: As available at power source.
a) AC Ripple in DC Output: Maximum 2% of DC output.
b) DC Current Control: Ratings to meet CP system

requirements, as appropriate. All output
controls shall be stepless.
c) DC Control Limit: At maximum DC output rating.
d) DC Control Mode: Constant current, constant voltage or

constant potential mode with manual,
automatic or switchable adjustments.
e) DC Current Stability: 2% of set current or 50 mA whichever is

the greater.
f) DC Current Measurement: Across 0.01 ohm (0.5% shunt resistor).
g) DC Voltage Measurement: Across precision resistor (0.5%) to

attenuate voltages from 50 to 2 V.
h) Overall Efficiency: Greater than 70% at maximum output

voltage and current.
i) Activation Time to Achieve Maximum 250 ms from activation to full

DC Interruption and Remake: shutdown. Maximum 500 ms from
activation to full operational current
output
j) Interruption Facility: Manual selectable switch to cover

periods of 3 to 120 seconds
independently for both ‘ON’ and ‘OFF’
cycles.
k) Recording Time: The 'INSTANT OFF' potential shall be

recorded 250 ms after DC interruption.
H. Electrical Protection
1. To avoid stray currents caused by reverse currents in the anode wire, the
power supply systems shall be electrically insulated from one another. The
insulation shall ensure that each power supply system works as an electrically
independent unit, unaffected by electrical influence from other electrical
sources. The power supply systems shall be designed to suppress external
noise. The AC input and AC terminals shall be shrouded in accordance with
IEEE Wiring Regulations to prevent accidental contact. An electrical isolation
switch shall be provided between the AC power input cable and the power
supply to allow the safe disconnection of the power supply if required.

SECTION 13113
Appropriate surge protection shall be provided in the DC output and AC input

circuits.
2.03 AC POWER SUPPLY
A. General
1. AC power supply shall be designed to feed AC power to transformer rectifiers

and AC outlets at test stations. It shall meet or better requirements of this
Specification.
2. Shop Drawings shall be submitted showing:
a) Locations of junction boxes, distribution boxes and cable routing.
b) Circuit diagrams at the source, the distribution and at the loads.
B. Voltage Stabilizers
1. Voltage stabilizers shall be provided where needed for the power supply to
meet the power input specifications for the T/R's. All stabilizers shall be of
static magnetic transformer type, rated for working at 65°C and regulation of
1% of the nominal voltage at full load current. They shall fully comply with
specifications IEEE/ANSI 449 for specialty transformers.
C. Distribution Boxes
1. Distribution boxes shall be of the dead front type, rated to meet the
requirements of this Specification. The distribution and junction boxes shall be
metal cabinet with front doors, latches and locks. All locks shall be of similar
type and shall be operable by a single key.
D. Circuit Breakers
1. Circuit breakers shall conform to BS EN 60947-2 or NEMA AB-1 molded case

quick-make, quick break bolt-on type, with thermal magnetic type overload trip.
2. All circuit breakers shall be ambient compensated to 50°C, allowing the

breaker to carry full rated current with uniform tripping characteristic. The
circuit breakers shall be in separate lockable weatherproof metal enclosures.
3. All enclosures (including junction and distribution boxes) shall be of same or

better materials and quality than that specified under par. 2.08 A.
4. For more details on circuit breakers, refer to SECTION 16410.
2.04 ANODE SYSTEM
A. The anode system shall be capable of supplying current and distributing, thus
allowing for the performance required by the CP design as specified in par. 1.09 B.

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B. The calculated or anticipated life shall be sufficient for the design life incorporated
into the design with, where necessary, planned maintenance or replacement of the
anode system or part of the system at periods designated in the design.
C. The lifetime for activated titanium anodes shall be documented by testing in

accordance with NACE Standard TM 0294.
D. The calculated and anticipated life shall be sufficient for the design life (50 years) of
the new anode system as specified in par. 1.09 D.1, with no major maintenance
requirement or replacement of anode system components required during this
period.
E. The anode system shall consist of positive cable connection devices, anode system
inclusive current distributors, anode connectors, fastening devices and overlays. The
Contractor shall submit sufficient data to enable evaluation and approval of the
performance capability of the anode system proposed. The characteristic for each of
the components is provided below.
1. The selection of the anode material shall consider likely variations in cathode
current density requirements, steel distribution, concrete electrical resistivity
and any other factors likely to result in uneven distribution of current demand
or current discharge from anode. The anode materials shall be chosen among
the following types unless otherwise agreed by the Royal Commission:
a) Activated titanium anodes comprising a substrate of titanium and an

electro-catalytic coating containing mixed metal oxides including metallic
connectors and a cementitious overlay or surround. The anode may be
shaped as expanded mesh, ribbon, tubes, rods, etc. and may be surface
installed, installed in recesses or holes or embedded within the
structure.
b) Cementitious Overlay or Surround

1) No polymer constituents are to be used which may impede
current flow.
2) The material, thickness and placement method shall be
compatible with each other and the anode material.
3) The electrical resistivity shall be within the range of 50 to 100% of
the nominal parent concrete electrical resistivity. Anode overlays
shall not exceed 100% of parent concrete electrical resistivity,
subject to a maximum of 50 kΩ.cm at ambient conditions and
subject to anode within the overlay being able to pass its design
current at the design voltage in an overlay of this resistivity. The
sufficient current distribution between, and hence sufficient
protection between, for e.g. anode mesh, shall be evaluated using
reference electrodes at maximum distance from installed anodes.
2. Current distributor shall be a solid, Grade 1 titanium bar, 15 mm width, 0.8

to 1 mm thick, or as specified in the approved Contract Drawings/Documents.
3. The anodes, primary anodes and conductor bars shall be anchored to the
concrete surface or in larger repairs to the reinforcement by means of
fasteners of non-conducting material such as plastic. The type, number and

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shape shall be as specified in the approved Contract Drawings/Documents or

as recommended by the manufacturer for the individual anodes and bars.
2.05 NEGATIVE CONNECTIONS
A. The negative connections are the return power feed connections for the cathodic
protection system. The connection shall be constructed as follows:
1. A 30 mm deep hole shall be drilled off-center in the end of an 8 mm diameter

rebar, which is 100 mm long.
2. The pre-stripped copper core of the negative cable shall be placed inside the
hole and braze welded to the rebar.
3. The connection shall be encapsulated with a suitable, mechanically strong

adhesive lined heat shrink tube extending 50 mm either side of the connection
point.
4. The rebar shall be adequately welded to the designated steel reinforcement of

the structure to be protected.
2.06 REFERENCE ELECTRODES
A. To establish and monitor the effectiveness of the CP system, potential

measurements shall be recorded using permanently embedded reference electrodes.
The reference electrodes shall be commercially available devices with a proven track
record of their use in concrete of a minimum 20 years. Details of previous
applications of the reference electrodes proposed by the Contractor shall be included
as part of the technical submittal prior to acceptance.
B. In each zone or sub-zone, the reference electrodes shall be positioned such that they
represent the most exacting geometric configuration, such as diametric opposition.
1. The electrodes shall be chosen among the following electrodes:
a) Double junction silver/silver chloride (Ag/AgCl/0.5 M KCl-gel).
b) Manganese/manganese dioxide (Mn/MnO2/0.5 M NaOH).
2. Each reference electrode shall be supplied with a calibration test certificate,

clearly indicating its calibration value as recorded in a 3% sodium chloride
solution (Ag/AgCl/0.5 M KCl-gel) or a saturated calcium hydroxide solution
(Mn/MnO2/0.5 M NaOH) at 25 ± 1°C against a calibrated laboratory standard
Calomel reference electrode. For an electrode to be acceptable, the measured
potential must be within ± 5 mV of the anticipated value.
3. The reference electrodes shall have a minimum life expectancy of 25 years.

They shall have a predicted stability of ± 30 mV for the 25-year electrode life
expectancy and shall have a tested stability of ± 3 mV over any 24-hour
period.
4. The temperature coefficient and the temperature range of operation shall also

SECTION 13113
be provided by the manufacturer. The reference electrode shall be designed to

operate in an environment between 0 and 60°C.
5. Each reference electrode shall be fitted with a suitable length of cable, such
that no splices are required within the cementitious anode overlay. The
connection between the cable and the electrode shall be completely sealed
and capable of total immersion without leakage under a water head of 1 m.
6. All reference electrodes shall be clearly and discretely marked on the electrode
case and at the cable termination point. This number shall be recorded on the
calibration test certificate and shall be recorded against its location on the As-
built Drawings.
7. Reference electrodes shall be placed in drilled holes into concrete of similar

constituents to the anode encapsulation material in such a manner that the
complete electrode is fully encapsulated. The maturity of the concrete around
the reference electrode shall exceed 28 maturity days before the CP system is
energized.
2.07 DC AND INSTRUMENT CABLING
A. DC cables shall conform to BS 6004, and shall be 600/1000 V or approved

equivalent grade cables. Minimum cross-sectional area of the cables shall be 10 mm2
for power carrying cables and 4 mm2 for monitoring cables. Insulation for the cables
shall be high molecular weight polyethylene (HMWPE). Alternate materials, which
may be considered for approval, include Cross-Linked Polyethylene (XLPE) and
Polyvinylidene Fluoride PVDF (KYNAR).
B. Positive and negative cables shall be color-coded the same for all areas. Colors are
RED for positive (anode) and BLACK for negative (reinforcement steel) in single core
cables. Reference electrode and test connection cables shall have separate colors,
not BLACK or RED. Proposed color scheme shall be submitted to the Royal
Commission for approval.
C. The reference electrode cabling for connection to embedded reference elements

shall be low noise screened cable.
D. The conductor shall be 7/0.2 mm² strand annealed copper, insulated with
polyethylene over which shall be a layer of plain copper braiding. Overall sheathing
shall be PVC.
E. The capacitance shall be less than 103 pF/m at temperatures up to 50°C. Cables
shall be color-coded for identification.
F. Reference electrode cabling from the junction box to T/R shall run in conduit and
shall be screened multi-core, multi-strand type of minimum cross-section of 1.25 mm²
per core.
G. All cables shall be terminated by crimped connectors suitable for the terminals
provided in the junction boxes. All cables and wiring shall be appropriately identified
within 25 mm of each end using permanent wire markers intended for the purpose.
Where cable identifications have been given in the Contract Drawings, these shall be
used. For termination of wires and cables, refer to SECTION 16150.

SECTION 13113
H. Cable Splices
1. Cables can only be spliced with the written approval of the Royal Commission
and the Contractor shall nominate the location of each splice when seeking
each approval prior to commencement of any splicing and physically
demonstrate the capacity of a sample of the splice to the Royal Commission.
a) As a minimum, the cables being spliced shall be joined using

compression crimp connector, the hand tool used for crimping shall be
approved by the supplier for use with their crimps. The crimped joint
shall be protected by two layers of mastic-lined heat shrink with the
second, outer layer extending at least 70 mm past either end of the first,
inner heat shrink.
b) The length of the first, inner heat shrink will be determined by the length
of the crimp and the extent of exposed inner cable insulation. Each end
of the heat shrink shall extend a minimum of 30 mm over the inner
insulation, but must not ride up over the outer cable insulation.
c) Prior to positioning the mastic-filled heat shrink, the inner insulation shall
be lightly roughened using emery paper to promote good adhesion.
Then all surfaces will be wiped down with a volatile cleaner (methylated
spirits, or similar) to remove dirt, dust, grease, etc., and the heat shrink
will be immediately positioned and applied. For the outer section of heat
shrink, the PVC cable insulation will only require cleaning prior to
applying the heat shrink.
d) The Contractor shall take care to ensure that all the components are
kept clean and dry during the splicing process and that the conductor is
not damaged when the insulating layers are being stripped.
2.08 JUNCTION BOXES
A. Junction boxes shall be constructed from fiberglass-reinforced polyester or

equivalent to comply with the relevant IP rating for the location. Minimum levels shall
be IP 55 for indoor use, IP 66 for outdoor locations subject to marine or coastal
exposure and IP 65 for outdoor locations not subject to marine or coastal exposure.
IP 67 shall be applied for those boxes anticipated to be submerged.
B. All doors shall be gasketed, lockable and stiffened. All locks shall be capable of being
opened with the same key. Cable entry shall be through suitable compression gland
or in sealed conduits. Appropriate precaution shall be taken to ensure that the cable
entry system in no way compromises the junction box IP rating.
C. The terminals shall be clearly marked with the zone/sub-zone, component type and
number as appropriate and shall also be marked with suitable identification
corresponding to each particular unit. The typical control layout for the control panel
shall be shown in the Drawings. All terminals shall be clearly labeled with their
correct function, using white engraved background on black surface. Material shall be
traffolyte or equivalent.
D. Cable connectors shall be DIN rail mounted terminals. Only 1 conductor per terminal
shall be permitted. Circuit expansion shall be achieved by standard bridging strips,

SECTION 13113
barrels, and screws.
E. Layout of terminals/panels within the junction boxes shall be shown in the detail
Drawings. The proposed layout details shall be submitted to the Royal Commission
for approval prior to commencement of work.
F. The junction box installation shall conform to BS 7671. The junction box shall be
securely and rigidly fastened in place in accordance with BS 7671.
G. The junction boxes shall be grounded in accordance with the provision of BS 7671.
For more details on Grounding and Bonding, refer to SECTION 16060.

SECTION 13113
PART 3 EXECUTION
3.01 GENERAL
A. The Contractor shall provide all equipment and labor as deemed necessary for the
proper execution of the work.
B. All work shall be performed in professional manner, in conformance with the

applicable codes and standards and the best engineering practice. Work shall be
performed by skilled workers equipped to produce satisfactory results in a safe and
substantial manner so as to avoid undue stresses.
C. The Contractor shall also provide the equipment, manufacturer’s services of a

competent and experienced Engineer to supervise the installation of the equipment,
in the correct installation, operation, service and maintenance of the equipment.
D. The Contractor shall be fully responsible for any mechanical damage upon
installation of complete cathodic protection system and their related accessories.
3.02 PREPARATION
A. Environmental Survey
1. Prior to cathodic protection application, the Contractor shall perform a survey

to familiarize himself with the Project site conditions:
a) Environmental Conditions
1) Seawater, buried, submerged, splash zone, atmospherically
exposed, industrial exposure, etc. Resistivity of environment for
submerged or buried structures.
b) Climatic Conditions
1) Humidity and temperature.
B. Verification of Reinforcement Density and Construction Geometry
1. As basis for the design calculation of the steel reinforcement area, the steel
density and geometry according to the structural reinforcement drawing shall
be verified.
C. Structural Assessment
1. Perform assessment of the concrete structures, including its material condition,

its structural integrity, and whether and how to repair it.
2. The assessment shall include:
a) Visual inspection.
b) Delamination survey by hammer testing.

SECTION 13113
c) Chloride analysis, determined in accordance with BS DD ENV 1504-9.
d) Carbonation depth measurements, determined in accordance with BS

DD ENV 1504-9.
e) Concrete cover measurements using a cover meter.
f) Verification of reinforcement size and position.
g) Steel/concrete potential measurement in accordance with ASTM C876.
h) Concrete resistivity measured on drilled cores using an AC resistivity

meter.
3. The assessment shall be carried out in accordance with BS EN 12696 and BS

DD EN 1504-9.
4. All test equipment shall have a valid calibration certificate traceable from a test
laboratory approved by the Royal Commission.
D. Electrical Continuity Assessment
1. To ensure the successful operation of the cathodic protection system, it shall

be necessary for the embedded steelwork to behave as a homogeneous
cathode. To be assured of this requirement, it shall be necessary to perform a
continuity survey between reinforcement cage and all externally mounted
steelwork and between different sections of reinforcement elements.
2. The Contractor shall perform a continuity survey to ensure that all the steel
reinforcement layers including links, tie bars saddles, etc., and any other
embedded metallic fixtures within the structure to be protected are electrically
continuous. Sufficient reinforcement shall be exposed and continuity tested at
representative locations in each unit or discrete part of the structure subject to
approval by the Royal Commission. In addition, all steel exposed during
concrete repairs or other works shall be continuity tested. The frequency of
continuity testing shall be increased in the areas were discontinuity is found.
The number of additional locations to be measured shall be approved by the
Royal Commission.
3. Unless alternative testing procedures and criteria have been selected in the
design, the electrical continuity between reinforcing steel or elements of steel
in concrete shall be tested by DC reverse polarity resistance measurement
technique. This technique measures and compares the resistance using a DC
resistance instrument and then reversing the polarity of the test leads.
4. Another technique may be the DC potential difference measurement

technique. The acceptance criteria for such testing shall be a resistance of less
than 1 ohm or a potential difference of less than 1 mV and the value stable.
The reinforcement shall be polarized by means of an auxiliary circuit followed
by a DC potential measurement. The potential difference shall be less than
1 mV.
5. The locations selected for continuity testing should represent the most
exacting geometric configurations possible, e.g. change in sections, change of

SECTION 13113
plane of concrete, diametric opposite, etc.
6. All readings shall be recorded on a plan sheet, designating each location

needed. If discontinuous steel is located, it shall be bonded to the continuous
section of reinforcement.
7. Any bar or component failing the continuity testing shall be continuity bonded
to ensure long-term resistance of less than 1 ohm. Where discontinuity exists,
electrical continuity shall be provided by tack welding or clamps.
8. Following bonding of any discontinuous steel, the continuity testing shall be

performed.
E. Repairs
1. The structure to be protected shall fulfill BS EN 12969 requirements before

installation of any CP system, unless otherwise agreed with the Royal
Commission.
2. Any discontinuous reinforcement bar shall be made continuous by tack

welding or by using clamps.
3. The repairs shall include any defects that can impair the effectiveness of the
CP system. Repairs shall be performed in accordance with SECTION 03930 or
BS EN 12696, BS DD ENV 1504-9 and BS EN 1504-10.
F. A trial installation shall be carried out - one for each anode system - to demonstrate
that the design anode performance is achieved. The trial shall include all activities
associated with the installation such as surface preparation by sand or water
blasting, any drilling or saw cutting, fixation of anodes or primary anodes, encasing in
cementitious overlay or graphite backfill, application of coating or conductive overlay
and any subsequent testing of the complete encasement, bond strength and
thickness of overlay. The methods for surface preparation, fastening, application, etc.
shall be in strict accordance with the manufacturer's guidelines. The results of the
trial installation shall be forwarded to the Royal Commission for review and approval.
3.03 INSTALLATION
A. Coordination and Protection
1. Installation of the CP system shall be coordinated through discussions with the

Royal Commission, the main Contractor and other Subcontractors and shall be
conducted in stages to ensure minimal disruption to the operation of the
designated concrete structure.
2. Special precaution and scheduling may be required to prevent damage to the

installed components by subsequent operation.
3. Consideration shall be given to the need to provide temporary protection for all
cables up to the time of final concrete installation and thereafter.
4. After installation of the cathodic protection components, all movements on the

reinforcing steel surface shall be kept minimal. Since some movement may

SECTION 13113
occur over the surface with installed anode, temporary protection

considerations shall be detailed.
B. The trial installation as specified in par. 3.01 F shall be accepted by the Royal
Commission before the installation process can proceed.
C. Anode System Installation
1. The anode system shall be installed in strict accordance with the methods
accepted by the Royal Commission as part of the trial installation. The
installation shall comply with the requirements stated below.
a) The spacing between the anode system and the reinforcing steel in the
structure shall be a minimum of 15 mm at any location. Particular care
shall be taken for the cover to the reinforcement in any slots, holes, etc.
used for succeeding anode placement.
b) The anode shall be securely attached to the reinforcing steel using

plastic reinforcement steel clips and plastic cable ties so that the
construction activity associated with the concrete pour does not cause
the anode to shift or come in contact with any part of the structural steel
assembly.
c) Special care shall be taken to ensure that no part of the anode or

connection system comes into contact with the reinforcement during
installation and that the system is sufficiently secured to ensure that the
placement of the concrete does not cause any movement of the anode
system or damage during compaction.
2. Surface Mounted Anode Mesh or Ribbons
a) The anode shall be securely attached to the thoroughly cleaned

concrete surface using non-conductive fasteners so that the activities
associated with application of the cementitious overlay do not cause the
anode to shift and to ensure that the anode is satisfactorily embedded in
the overlay.
b) The concrete surfaces for installation of an anode system shall be

prepared to present as a minimum a clean, non-friable and mud-free
surface. The requirement to the surface appearance shall be in
accordance with the manufacturer's requirements. Cleaning methods
shall be in accordance with BS DD ENV 1504-9 and BS EN 1504-10.
c) The cementitious overlay approved by the Royal Commission shall be

applied over appropriate types of installed anodes. All materials,
application methods and application shall be in accordance with BS
DD ENV 1504-9 and BS EN 1504-10.
d) Application conditions with respect to the environmental conditions such

as temperature, humidity or moisture levels shall be in accordance with
the manufacturer's requirements.
e) The thickness of the cementitious overlay shall be tested during the

application by means of a measuring stick. The thickness shall be within

SECTION 13113
a tolerance of + 2 mm. The thickness shall be documented to be in

accordance with the prerequisite in the design.
f) Bond test shall be carried out in accordance with BS EN 1542. The

average bond strength between existing concrete and overlay shall be
greater than 1.5 N/mm2 and the minimum shall be greater than
1 N/mm2, or the test failure shall be within the existing structure.
g) Any damage to the anode system during testing shall be repaired.
3. Wires, Ribbons, Rods, Tubes, etc., Placed in Recesses in the Concrete Cover
or in Holes Within the Structure.
a) The anode shall be placed in the recess in the concrete surface so that
the anode does not move during casting and hardening and ensure that
the anode is satisfactorily embedded in the cementitious material. The
installation of the anode within holes in the structure shall be conducted
so complete encasing is ensured, whether a graphite backfill is used or
a cementitious grout.
b) The cementitious surround shall be applied as demonstrated in the trial.
D. Positive Connection
1. Positive connections shall be made to each conductor bar in the following

manner. A 150 mm long, maximum 4 mm diameter titanium rod shall be
factory welded to a 150 mm long conductor strip such that the intersection
length is 75 mm. Positive cable of specified rating, color and size shall be
prepared in sufficient length to run from the positive connection to the
appropriate junction box by the specified route without a cable splice. The pre-
stripped copper core of the positive cable shall be compression crimped to the
titanium rod.
2. All titanium-to-titanium connections shall be metallurgical bonds made by

resistance welding with equipment supplied by the anode manufacturer and
used in accordance with the manufacturer's instructions. Prior to commencing
welding, the equipment settings shall be tested by welding current distributor
test strips to ensure satisfactory welds will be obtained.
3. Special care shall be taken to ensure that the cables are not damaged during
compaction or that the cables are not unintentionally cut, for e.g., outside the
framework. After placement of the concrete, the part of cables outside the
structure shall be protected until installation in the transformer rectifier.
E. Negative Connection
1. The system negative connections within each zone shall be made to the
reinforcing steel in the manner shown on the design drawings. Reliable
connections such as welding to the reinforcing steel shall be used.
2. At the location within each zone (the exact positions to be agreed with the
Royal Commission on site), the reinforcement shall be thoroughly cleaned to
expose clean bright steel around its full circumference. The system negative
cable shall then be connected to the reinforcing steel in the manner shown on

SECTION 13113
the design drawings and as described below.
3. Following installation of the system negative cables to each zone, the DC

resistance between each shall be recorded. Provided the DC resistance shall
be less than 1 ohm, the system negative connection shall be deemed
sufficient. If the recorded resistance is more than 1 ohm, an additional system
negative connection shall be installed at an approved location. The DC
resistance shall be measured again, with the process repeated until a
resistance less than 1 ohm is achieved. The results of the resistance
measurements shall be included as part of the commissioning report.
4. On acceptance of the system negative connections, the connections shall be

coated with a suitable two pack modified epoxy material.
5. Special care shall be taken to ensure that the cables are not damaged during
compaction or that the cables are not unintentionally cut, for e.g., outside the
formwork. After placement of the concrete, the part of cables outside the
structure shall be protected until installation in the transformer rectifier.
F. Reference Electrodes
1. The reference electrodes shall be installed at predetermined locations. The

reference electrodes shall be placed at the level of the reinforcing steel. At this
location, a negative test connection shall also be provided and connected to
the reinforcing steel in the manner described previously for system negative
connections.
2. Post mounted reference electrodes shall be installed in drilled holes in the

concrete surface before installation of the anode system. The holes shall be
adjusted to the reference electrode geometry. The reference electrodes shall
be embedded in a mortar with a suitable electrical resistance.
3. Special care shall be taken to ensure that the cables from the reference
electrodes are not damaged during compaction or that the cables are not
unintentionally cut, for e.g., outside the formwork. After placement of the
concrete, the part of cables outside the structure shall be protected.
G. Testing During Installation
1. Each stage of the installation shall be subject to visual, mechanical and

electrical testing. The testing shall be performed to demonstrate that the
individual components are installed properly and no failures are introduced.
2. All testing activities during installation shall be outlined in an inspection plan.

The plan shall include test object, method, frequency, acceptance criterion and
documentation. The control plan shall be submitted to the Royal Commission
for approval before installation.
3. All test instrumentation shall have valid calibration certificates from a testing
laboratory approved by the Royal Commission.
4. The electrical testing shall include, but not be limited to, the following:
a) Anode System

SECTION 13113
1) The anode system shall be tested to detect any short circuits. The
electrical resistance shall be measured by means of a DC
resistance measurement and recorded. The DC resistance shall
be greater than 1 M ohm. The tests shall be conducted between
the anode and the reinforcement and the anode and any other
metallic items before, during and after casting.
b) Negative Connection
1) The DC resistance between each connection of the reinforcing
steel shall be measured and recorded. If the measured resistance
is greater than 1 ohm, an additional system negative connection
shall be made at a location approved by the Royal Commission
until the measured resistance is less than 1 ohm.
c) Polarity Checks
1) The results for polarity check for all circuits shall be unambiguous.
d) Continuity Checks
1) Continuity checks for all circuits by DC resistance measurements.
The results of the individual circuits shall demonstrate values
within 10% of those calculated from cable and component values.
5. All testing according to the control plan shall be documented and the
documentation shall be forwarded to the Royal Commission for acceptance
before commissioning.
3.04 TESTING AND COMMISSIONING
A. All pre-commissioning checks, initial energization, performance verification, and

subsequent monitoring of the CP system shall be supervised by a specialist as
specified in par. 1.07 G. On completion of the installation of the CP system and
after a lapse of a minimum curing period of 28 days, the Contractor shall commission
the CP system in accordance with approved procedures.
B. Pre-Commissioning Checks
1. The Contractor shall submit a pre-commissioning plan and procedure to the

Royal Commission for review and approval. As a minimum, the plan and
procedures shall address the following:
a) A complete visual examination and system walk down shall be

performed prior to energization. The inspection will include all exposed
conduits, wiring, cable connections, cable terminations, etc.
b) Resistance measurements shall be required between system negative

output and all system negative and reference electrode negative
connections at the junction boxes using a DC resistance meter. Stable
resistance values of less than 1 ohm will indicate continuity of the
cathode circuit.
c) Resistance measurements shall be taken between system positive

SECTION 13113
output and all anode connections within each anode zone at the junction
boxes using a DC resistance meter. Stable resistance of less than
1 ohm will indicate continuity of the anode circuit.
d) Resistance measurements shall be taken between the anode circuit and

the system negative circuit within each anode zone at the T/R unit.
Open circuit or large resistance will indicate the required discontinuity
between the anode and the cathode. System negative connections from
the individual zones shall be connected while taking the resistance
measurements.
e) ‘As found’ potential measurements will be measured and recorded at all

locations of the embedded reference electrodes and recorded as
‘Native’ potentials.
f) With a portable voltmeter and the embedded reference electrodes,

evaluate the direction of the potential change on the reinforcement steel
when the power sources are momentarily energized (1 minute
maximum) at up to 10% maximum output to confirm that the DC output
polarity is correctly connected. Negative shift will indicate correct polarity
of the system.
g) The Contractor shall record the circuit verification results to certify that
the pre-commissioning checks have been carried out successfully and
this shall be treated as a hold point.
C. Initial Energization
1. The Contractor shall energize the CP system per approved plans and
procedures. As a minimum, the Contractor shall meet the following
requirements:
a) Using the embedded reference electrodes, the "ON" potentials of the

system shall be monitored to ensure a shift in the negative direction of at
least 150 mV.
b) The Contractor shall ensure that the anode current does not exceed the
maximum recommended current by the anode manufacturer and that
a - 1100 mV (and - 900 mV for pre-stressed concrete) versus the
Ag/AgCl reference electrode is not exceeded at any reference electrode.
c) After the system operates for 7 days, the ‘INSTANT OFF’ potential of
the reinforcing steel shall be evaluated at each reference electrode. If
necessary, adjust the current to the full design output subject to the
’INSTANT OFF’ not being more than - 1100 mV Ag/AgCl at any location.
d) The performance shall be re-evaluated after 30 days. The Contractor

shall also obtain decay potentials.
e) The data shall then be analyzed to assess compliance with the specified
criteria for cathodic protection.
f) Verification of electrical isolation is required for any item intended to be

isolated.

SECTION 13113
D. Operation
1. The Contractor shall operate the CP system for the period of time until the
Royal Commission’s initial acceptance of the Facility from the Contractor. The
system operation shall include performance monitoring and system review.
E. Performance Monitoring
1. Performance monitoring shall be carried out 3, 6, 9 and 12 month from date of

commissioning.
2. The performance monitoring shall include the following:
a) A close-up visual inspection of the system and structure.
b) Conduits and junction boxes shall be visually inspected, checking for

security of attachment and integrity of insulation.
c) The power supply shall be checked, noting the integrity of all input and
output cables.
d) The driving voltage, back EMF and applied current to each zone shall be
recorded.
e) Reinforcement potentials shall be measured at all embedded reference

electrodes under the following conditions:
1) Cathodic protection current ‘ON’.
2) Cathodic protection current ‘INSTANT OFF’
3) 4 hours and 24 hours or beyond, as required, after the Cathodic
protection current has been switched off.
f) The Contractor shall carry out any adjustment to the control settings,
which is considered to be necessary.
F. System Review
1. The system review shall be carried out at the end of the 12 month period of
operation. The system review shall include the performance monitoring
specified above. The Contractor shall review all data collected during the
12 months of operation and make recommendations on the future operation of
the system including the following:
a) Requirement for maintenance and/or modification to the system.
b) Proposed operating and monitoring criteria for the system.
c) Frequency and scope of monitoring.
2. The system review report shall be issued for comment within 28 days of the
completion of the 12-months monitoring visit.

SECTION 13113
3.05 INTERFERENCE TESTING
A. General
1. In parallel with the commissioning procedure specified in par. 3.03,

interference testing with pipelines and facilities in close proximity of the
protected structures shall also be carried out by the Contractor.
2. Anodic interference shall be deemed to be present if a steady change in

potential of the affected structure of greater than 20 mV is measured according
to BS EN 50162. The requirement for remedial measures shall be as agreed
upon by the Royal Commission.
B. Test Procedures
1. The ‘as found’ potentials of pipeline and other facilities located in close
proximity shall be measured before the commissioning of the CP system.
2. After the CP system has been commissioned, the interference testing shall
commence. The ON/OFF timer of the CP transformer rectifier(s) shall be set to
operate at 8 seconds ’ON’, 3 seconds ‘OFF’.
3. All the other facilities shall be measured by recording the potentials for a
minimum of 60 seconds during the cyclic ‘ON/OFF’ period. Interference shall
be deemed to be present if the anodic potential shift, as measured on the other
facilities during this period, is coincident with the switching of the transformer
rectifiers.
4. On completion of the interference testing, the Royal Commission transformer

rectifiers shall be reset to continuous operation.
5. The Contractor shall submit full details for carrying out interference testing for
review and approval by the Royal Commission.
C. Data Analysis and Report on Interference Testing
1. The interference data shall be reviewed by the Contractor’s Specialist

Cathodic Protection Engineer. The Contractor shall prepare an interference
test report and shall submit it to the Royal Commission within 1 week of
completing the interference testing.
2. The test report shall include all data obtained, details and location of all tests
and indicate the level (if any) of interference observed. Recommendations for
rectification shall be included. The test report shall be submitted to the Royal
Commission.
3.06 PROVISION OF OPERATION AND MAINTENANCE MANUAL
A. An Operation and Maintenance Manual shall be provided by the Contractor and shall
be a complete and comprehensive reference manual with all relevant information
within one document. The Operation and Maintenance manual shall be provided in
accordance with SECTION 01830.

SECTION 13113
B. The Contractor shall submit a procedure, as part of the Operation and Maintenance
Manual, detailing how the CP system should be managed. This management shall
include criteria, fault finding, system malfunction checks and details of storage and
presentation of data. The system shall also include other periodic tests, which do not
fall within the interference testing and ‘ON/OFF’ potential surveys.
C. The monitoring frequency shall as minimum be as follows:
1. Transformer rectifier status, output voltage and output current: Weekly
2. ‘ON’ potentials for all reference electrodes at test stations: Monthly
3. ’INSTANT OFF‘ potentials for all reference electrodes at 6 Monthly

test stations and thorough component check
(during the first year of operation also after 3 month):
4. Interference testing: Every 3 years
3.07 PROVISION OF TRAINING IN SYSTEM OPERATION
A. Description
1. As part of the works, the Contractor shall provide training to the nominated
Royal Commission staff in the operation and maintenance of the CP system,
including the system monitoring.
2. Each person trained shall be provided a full set of the course material. All
training material shall be supplied by the Contractor for training purposes.
3. The instruction course shall comprise of the following 4 parts:
a) Routine operation of the CP system and monitoring performance

(including maintenance requirements).
b) Operation of the test and inspection equipment.
c) Interpretation of test data.
d) Troubleshooting and fault diagnosis.
4. Details of the actual instruction course shall be submitted to the Royal

Commission for review and approval prior to commencement of instruction.
5. The minimum requirements for these are outlined below. Instruction may take
place in any order and at various times within the Contract period.
B. Routine Operation
1. General system operation to provide knowledge of the as-built details of the

system including location of parts, power supplies, cabling routes, anode
locations, test stations and reference cell locations. Staff shall be made
conversant with the design, As-built Drawings and all documentation.

SECTION 13113
2. Routine operation of transformer rectifiers, including AC power provision,

operation of DC outputs including the setting of controls, setting output levels
and manual recording of output voltages and currents, together with potential
measurement and record keeping.
3. Other aspects of routine operation of the system as deemed necessary by the

Contractor and/or the Royal Commission. This shall include routine fault
finding in the event of system failure or inadequate performance.
C. Interpretation of Test Data
1. The data collected from the manual monitoring system and that from periodic
surveys shall be reviewed by an experienced Cathodic Protection Engineer.
Instruction shall be provided on the trend analysis of data and the type of data
required and changes in its recorded level which may signify that the CP
system requires adjustment or some form of remedial action.
D. Troubleshooting and Fault Diagnosis
1. Instruction shall be provided on troubleshooting in order to identify possible

system mal-operation or under performance. The instruction shall be general
in nature and shall indicate the obvious actions that may be taken to ensure
continued proper operation of the system. Any serious fault or lack of
performance shall be reported to an experienced Cathodic Protection Engineer
for action.
END OF SECTION

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GUIDELINE SPECIFICATION FOR

0 15/02/06 I Issued for Use ~\-

Item No Title Page No

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.07 QUALITY CONTROL ......................................................................................... 10

1.08 HEALTH AND SAFETY CONSIDERATIONS.................................................... 11

1.09 DESIGN CRITERIA............................................................................................ 12

1.10 JOB CONDITIONS............................................................................................. 17

1.12 DELIVERY, HANDLING AND STORAGE ......................................................... 19

PART 2 PRODUCTS ....................................................................................................... 21

2.01 GENERAL .......................................................................................................... 21

2.02 POWER SUPPLY SYSTEM............................................................................... 21

2.03 AC POWER SUPPLY ........................................................................................ 26

2.04 ANODE SYSTEM............................................................................................... 26

2.05 NEGATIVE CONNECTIONS ............................................................................. 28

2.06 REFERENCE ELECTRODES............................................................................ 28

2.07 DC AND INSTRUMENT CABLING .................................................................... 29

2.08 JUNCTION BOXES............................................................................................ 30

Rev 0 i Contract No:

TABLE OF CONTENTS (Contd.)

Item No Title Page No

PART 3 EXECUTION ...................................................................................................... 32

3.01 PREPARATION ................................................................................................. 32

3.03 TESTING AND COMMISSIONING .................................................................... 38

3.04 INTERFERENCE TESTING............................................................................... 41

3.05 PROVISION OF OPERATION AND MAINTENANCE MANUAL....................... 41

3.06 PROVISION OF TRAINING IN SYSTEM OPERATION .................................... 42

Rev 0 ii Contract No:

1.01 DESCRIPTION OF WORK

1.02 SECTION INCLUDES

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 01780 Closeout Submittal

H. Section 01830 Operation and Maintenance

I. Section 03205 Reinforcement for Concrete

J. Section 03310 Structural Concrete

K. Section 03930 Concrete Rehabilitation

L. Section 13111 Impressed Current Cathodic Protection of Submerged and Buried

M. Section 13112 Sacrificial Anode Cathodic Protection of Submerged and Buried

Rev 0 1 of 43 Contract No:

N. Section 13450 Central Control

O. Section 16060 Grounding and Bonding

P. Section 16075 Electrical Identification

Q. Section 16150 Wiring Connections

R. Section 16410 Enclosed Switches and Circuit Breakers

C. ACI American Concrete Institute

1. ACI 222R Corrosion of Metals in Concrete

2. ACI 318RM Building Code Requirements for Structural Concrete

D. ASTM American Society for Testing Materials

1. ASTM B265 Standard Specification for Titanium and Titanium

2. ASTM C150 Standard Specification for Portland Cement

3. ASTM C876 Standard Test Method for Half-Cell Potentials of

4. ASTM G3 Standard Practice for Conventions Applicable to

E. BSI British Standards Institution

1. BS 89 Direct Acting Indicating Analog Electrical