Cathodic Protection Prepackaged Magnesium Anode

Magnesium anode is the most common used anode for

soil application. The most negative potential of COMPOSITION & ELECTROCHEMICAL
magnesium anode will result of highest driving voltage PROPERTIES
which enable to protect steel structure at medium - high
soil resistivity (1.000 – 10.000 -cm). However,
SPECIFICATION MAGNESIUM MAGNESIUM
magnesium also can be used at sea water, if fast
STANDARD HIGH
structure polarization is required. It also can be used at
POTENTIAL
fresh water, especially if the resistivity is higher than 500
Composition (%)
-cm.
Aluminium (Al) 5.3 – 6.7 0.01 max
Zinc (Zn) 2.5 – 3.5 –
ALLOYS Manganese (Mn) 0.25 – 0.70 0.50 – 1.3
There are two common magnesium anode available : Silicon (Si) 0.10 max 0.05 max
standard magnesium alloy and high potential (high purity) Copper (Cu) 0.02 max 0.005 max
magnesium alloy. High potential alloy is having higher Iron (Fe) 0.003 max 0.01 max
(more negative) potential compare to standard alloy. Nickel (Ni) 0.002 max 0.001 max
Therefore, it is capable to be used at high soil resistivity Other Impurities 0.30 max 0.30 max
environment. Otherwise, at same soil resistivity value, Magnesium(Mg) remainder remainder
high potential alloy is having of higher driving voltage and Efficiency (%) min. 55 min. 50
therefore also higher current output. This is enable of Potential vs CSE -1.5 -1.7
longer protection range area but shorter anode life time (Volt)
compare to the standard alloy. Current Capacity avg. 1,200 avg. 1,100
(A-hr/kg)
APPLICATION Consumption Rate 7.30 7.96
The choice of anode material is also depend on the (kg/A-yr)
environment resistivity. In soil and brackish water with
high resistivity value, only magnesium anode might
assure a complete anti-corrosive protection, due to its
greatest driving potential. Depending on the soil
resistivity, the choice of the sacrificial anode is as follows:

Anode Material Soil Resistivity

(.cm)
Zinc + Backfill  1.500
Magnesium (Standard) + Backfill 1.000 ~ 4.000
Magnesium (HP) + Backfill 1.000 ~ 10.000

SHAPE
Anode’s shape is vary depend on its application,
however, the most common available anode shapes are
as follows: Bare Magnesium Anode

UNDERGROUND APPLICATION
 Cylinder/”D” c/w Cable (Bare/Pre-packaged)
 Ribbon

AQUEOUS APPLICATION
 Rectangular/Rod with Bolted Core
 Rectangular/Rod with Cranked Core Stand Off, etc.

Prepackaged Magnesium Anode

P T . S O U T H E R N T R I S T AR - Jl. Jababeka III H Block C No. 17J, Cikarang Industrial Estate, Cikarang
Bekasi 17550 Indonesia, Phone : +62-21- 8935162, Fax : +62-21-8935163, E-mail : sales@ptsts.com
 Cathodic Protection Prepackaged Magnesium Anode

APPLICATION CABLE
In medium to high resistivity soil (1.000 – 10.000 -cm), Standard cable size is stranded Red PVC 1C-6 sqmm –
only magnesium anode is suitable to protect 3 m length. Other type, size, color, and length of cable
underground/buried steel structure by using sacrificial will be provided on request.
anode system.
BARE / BACKFILL
INSTALLATION Anode can be supplied in bare or complete with rapid
Anode is completed with cable, provided for direct wetting backfill of the following composition:
thermowelding connection to the structure. The  Powder Gypsum : 75%
connection point shall be covered with Royston  Granular Bentonite : 20%
Handycaps. Alternatively, anode’s cable can be  Sodium Sulphate : 5%
connected to pipe’s cable in an aboveground test station, Anode and backfill are packaged in a cotton bag suitable
with or without a shunt resistor. for direct buried in soil.

D-SHAPE

Type Dimension (mm) Weight (kg)

Bare Package (appr) Bare Package
A B C OD L (Appr)
-1.5 V -1.7V
5D 70 76 290 305 120 500 2.3 6
7D 70 76 410 430 120 600 3.2 8
9D-1 63.5 63.5 650 670 130 800 4.1 16
9D-2 70 76 520 550 120 700 4.1 9
14D 70 76 810 850 120 1000 6.35 13
17D 90 95 620 650 150 750 7.7 17
20D 70 76 1240 1260 150 1500 9.5 20
32D 140 146 470 498 200 650 14.5 30
48D 140 145 730 765 220 1000 21.8 45

Round (“R”) shape, extruded, and Ribbon shape magnesium are available upon request.

P T . S O U T H E R N T R I S T AR - Jl. Jababeka III H Block C No. 17J, Cikarang Industrial Estate, Cikarang
Bekasi 17550 Indonesia, Phone : +62-21- 8935162, Fax : +62-21-8935163, E-mail : sales@ptsts.com
 Cathodic Protection Backfill

GENERAL

Both of impressed current and sacrificial anode
cathodic protection system for soil application
commonly need of backfill to lower the resistance
of anode groundbed. The specific function of
backfill is as follows:
 Provide of low resistivity environment around
the anodes, therefore lowering the anode to
earth resistance. This will lower the required
voltage drop at rectifier panel (ICCP system)
or enable of higher anode current output
(SACP system)
 Provides of uniform environment around the
anode therefore a uniform current discharge
and anode consumption rate can be attained
and avoiding anode from earlier failure.
 Acting as part and outer layer of impressed
current anode anode and adding the anode
dimension, therefore, extending the anode
design life time.
APPLICATION
 Sacrificial anode commonly use of gypsum-
bentonite-sodium sulphate backfill.
 Buried permanent reference electrode
commonly use of gypsum- bentonite backfill.
 Impressed current anode commonly use
carbonaceous backfill type (coke breeze,
petroleum coke, carburizer, etc)
.

GYPSUM-BENTONITE (SACRIFICIAL ANODE/REFERENCE ELECTRODE) BACKFILL

SPECIFICATION SACRIFICIAL REFERENCE PICTURE

ANODE ELECTRODE
Standard Powder Gypsum 75% 50%
Mixture Granular Bentonite 20% 50%
Sodium Sulphate 5% -
Properties Resistivity (wet) 50 .cm 250 .cm
Dry Bulk Density 850 850
(kg/m3)
Particle Size < 1 mm (100%) < 1 mm (100%)
Package Plastic Bag 25 kgs 25 kgs

COKE BREEZE (IMPRESSED CURRENT ANODE) BACKFILL

SPECIFICATION STANDARD HIGH GRADE PICTURE

GRADE
Typical Fixed Carbon 85% 98%
Analysis Ash 13% 0.3%
Volatile Matter 1.7% 0.4%
Sulfur 0.7% 0.5%
Moisture 0.9% 0.3%
Properties Resistivity (dry) 50 – 200 .cm1 – 5 .cm
Resistivity (wet) 10 – 20 .cm 1 – 2 .cm
Consumption Rate 1.0 0.5
(kg/A-Yr)
Max. Current Capacity 2.5 5.0
(Amps/m2)
Dry Bulk Density 1000 800 – 900
(kg/m3)
Particle Size 0–4 mm (90% min) 0–5 mm (90% min)
Package Plastic Bag 25 kgs 25 kgs

P T . S O U T H E R N T R I S T AR - Jl. Jababeka III H Block C No. 17J, Cikarang Industrial Estate, Cikarang
Bekasi 17550 Indonesia, Phone : +62-21- 8935162, Fax : +62-21-8935163, E-mail : tri-star@indo.net.id
 Cathodic Protection Test Station Box

APPLICATION Please specify the type of Test Station Box based

Test Station for potential, current, or resistance on the above purpose and the number of required
measurements should be provided at sufficient circuits.
locations to facilitate cathodic protection testing.  Standard : busbar/terminal blocks with link
Such locations may include but not limited to, the  Measuring : standard + shunt resistor
following: The DIMET brand has been established
Regulating in the
: Measuring Our consultant-cum-design
+ Variable Resistor team of
 Pipe casing installations
Cathodic Protection Field since 1970 and is are available to provide advice on a
 Foreign metallic structure crossings
P R O T E C T I O N

 lnsulating joints renowned worldwide. The DIMET experience of corrosion prevention, especially
 waterway crossings has given us unsurpassed knowledge in the protection.
 Bridge crossings design, manufacture, installation, commissioning
 Valve stations
 Galvanic anode installation and maintenance of the full range of sacrificial QUALITY ASSURANCE AND CONTR
 Regular spacing of pipeline anodes, impressed current cathodic protection DIMET anodes are cast in modern
systems and other corrosion prevention using only the highest purity ma
ENCLOSURE MATERIAL
methods.
Material type of enclosure is available as follows: process, spectrographic anode an
 Die Cast Aluminium performed in a well equipped com
 Painted Steel DIMET brand cathodic protection and corrosion laboratory to ensure consistant compl
 Galvanized Steel
prevention products and services are provided quality standards.
 Stainless Steel
 Glass Reinforced Polyester by Tri-Star Industries Pte Ltd in Singapore,
(GRPj
 Polycarbonate together with an extensive group of affiliates in Similar high quality standards can be
Test station is normally located at outdoor from all products and services provid
the other parts of the world.
location, either of at open area or inside of plant,
therefore, enclosure material type shall be the DIMET brand.
weatherproof and considering the environment
condition, such as corrosive or non-corrosive,
requirement of physical strength, requirement of
safety, and of course the cost.

ENCLOSURE MOUNTING
Enclosure can be fabricated for the following
C A T H O D I C

mounting methods :
 Wall mounting
 Direct conduit mounting
 Self standing frame mounting
 other as per request.

ENCLOSURE SIZE
Enclosure size shall be considering of parts
inside, including of cable entry and possibility of
heat generated by variable resistor (if applied). Anodes

COMPONENT PARTS
Component assemblied inside of enclosure is
depend on the necessity: Various CP Test Station Box
 Terminal Point - common parts
 Sliding Tap Variable Resistor - if regulating of
current flowing is required.
 Shunt Resistor - if reading of current flowing is
required either by using of portable DC
voltmeter or by pre-installed Ammeter

P T . S O U T H E R N T R I S T AR - Jl. Jababeka III H Block C No. 17J, Cikarang Industrial Estate, Cikarang
Bekasi 17550 Indonesia, Phone : +62-21- 8935162, Fax : +62-21-8935163, E-mail : tri-star@indo.net.id
 Cathodic Protection Permanent Zinc Ref. Cell

Zinc Reference electrodes are commonly used as COMPOSITION & ELECTROCHEMICAL

permanent reference electrode in seawater and PROPERTIES
underground environments. The electrode is made using
high purity zinc metal. Zinc have the longest life of any of
the permanent type reference cells. MIL-A-18001H – Zinc Reference Electrode
Chemical Composition
The DIMET brand has been established Element in the Our consultant-cum-design
Content (%) team of
APPLICATION
 Permanent reference electrodeCathodic Protection
is necessary for Field since 1970 and is
Aluminium (Al) are available
0.10 –to0.50
provide advice on a
Cadmium (Cd) 0.025 – 0.15
P R O T E C T I O N

renowned
monitoring the protection level of the worldwide. The DIMET experience
cathodic protected of corrosion prevention, especially
structure for the following condition: Automatic rectifier Iron (Fe) 0.005 max
has given us unsurpassed knowledge Lead (Pb) in the protection.0.005 max
system is applied, therefore, continuous reading of
structure potential level is neededdesign, control installation, Copper
manufacture,
by rectifier (Cu)
commissioning 0.005 max
system. Silicon (Si) 0.125 max
and maintenance of the full range of sacrificial QUALITY ASSURANCE AND CONTR
 Difficult access or way to measure by using a portable Zinc (Zn) Balance
reference electrode, such as inanodes,hazardousimpressed
area or current cathodic protection
Electrochemical Properties DIMET
in Sea anodes are cast in modern
Water, ambient
center part of bottom tank. Area with complicated
systems and other corrosion Temperature
prevention using only the highest purity ma
existing cathodic protection system, therefore" Open Circuit Potential -1.05 ± 30 mV
methods.
interference potential reading is high. In this case, true vs Ag/AgCl (Volt) process, spectrographic anode a
potential of the protected structure can be read only if a performed in a well equipped com
permanent reference electrode is put close enough with
the structure. DIMET brand cathodic protection and corrosion laboratory to ensure consistant compl
 Pavement area or very high soilprevention products
resistivity (dry POTENTIAL
sand, and services READINGquality standards.
are provided
gravel , etc.), therefore IR drop reading is high. In this The potential reading of cathodically protected structure
by Tri-Star Industries Pte measured
case, true potential of the protected structure can be
Ltd in Singapore,
by using a Zinc reference electrode is ≤ +0.25
read only if a permanent reference together with an
electrode extensive groupThis
is put volts. value is equivalent
of affiliates in with potential
Similar readingstandards
high quality value can be
close enough with the structure. -0.85 vs Cu/CuSO 4 or -0.80 vs Ag/AgCl Reference Cell.
the other parts of the world. from all products and services provid
TYPE AND SHAPE the DIMET brand.
Permanent Zinc Reference electrode type, shape and size
are varying depend on the environment and application as
below:

1. Pre-packaged Buried
 Underground Pipeline
 Underground Tank
 Bottom Part of Tank
C A T H O D I C

2. Recessed / Surface Mounted

 Ship
3. Pipe Mounted
 Jetty Pipe Piling
4. Submerged Assembly
 Intake Channel
 Water Tank
 Water Treatment Clarifier
 Steel Sheet Piling
 Pipe Piling
5. Probe / Taper Flange Anodes
 Condenser Water Box
 Heat Exchanger
 Internal Part of Cooling Water Pipe
6. Etc.

Commonly, the size, shape and assembly method of a

Permanent Zinc Reference Cell is custom made designed
based on specific condition of the protected structure.

Various Type Permanent Zinc Reference Cell

P T . S O U T H E R N T R I S T AR - Jl. Jababeka III H Block C No. 17J, Cikarang Industrial Estate, Cikarang
Bekasi 17550 Indonesia, Phone : +62-21- 8935162, Fax : +62-21-8935163, E-mail : sales@ptsts.com

Page 2
 Accurate E C S
o
E
Reliable.

We listened to you co find out what corrosion and cathodic

protection engineers want in a corrosion coupon. You said
accuncy, precision and reliability. You also said you wanted
a Lofr()5iorrcoupon tlrrL wJs co\c efleccivero use.

In developmentfor 10 years,M.C. Millerk IR-freecorrosion

coupon accuratelymeasures
the integrity ofpipeline cathodic
protection systems without the need to interrupt all currenr sources.
This revolutionary device is designed lor easy installation next to existing
test stations.It also withstands harsh field environmentsand
eliminates rhe effecrs of stray earth currents,
producing accur-atemeasurements
everyume.

Built for Accuracy...and

Precision
Easyinstallationat Unlikeothercorrosioncoupons,M.C. Miller'sIR-freecoupon
existingteststations is designedto evaluatecathodicprotectionsystenswithout
incerruptingrectifiers,foreignbonds,or sacrificialanodes.
No new teststations The couponconsisrof a bare,cold-rolledsteelcylinder
required and No. 12 strandedwires,which are
2-inch PVC tube. The PVC tube shields the reference electrode
No needto fiom pocential gradients, resulting in accurare, precise cachodic
pt all current
interru protection measurements,These neasurernents also meet
sourcesfor lR-free anticipatcd federal regulations and industry srandards for
readings consideringIR dlop in structure-to-soilporential readings.

Builtto last
Like all M.C. Miller products,our IR-freecorrosioncoupon
is built to lasr.The wire-couponinterfaceis envilonmentally
sealedro keepthe steel,copper,and soldercomponenrs
corrosion-free, makingthe couponvircuallyindestructible.

Instrumentsand Equipmentfor the CorrosionEngineer RflGMILLER*.

 EasyInstallation
Using an auger,bore a hole ro checenterline of the
pipeline, about 4 to l2 inchesawayfrom the pipeline.
Then, lower the coupon into the hole by its wires.Dtop
nativesoil in the holeuncilabout 1-112to 2 inchesofsoil
is packedover the coupon, so that it will remain outside
of the PVC tube.

Install the PVC tube 1.-1/2to 2 inchesabovethe coupon,

with the wiresoutsidethe tube.Then fill the tube with
nativesoil, which should be saturatedwith water and
thorougblypackedto removeexcess air Install the
No. 12 greenwires along the outsideof the PVC tube and
insert through a hole at the baseof the adjacenttest
station.Drill a hole in the test stationjust below grade
levelto accommodatethe wire. Then, connectone of the
greencoupon wires to chestructuretestwire by direct
connectionor through a jumper bar at the teststation box.

EasyMeasurement
After che coupon has been polarized, insert a half-cell into
che top of che PVC tube, contacting the compacted soil
above the coupon. Connect an LC-4 selectablevoltmeter
co the green coupon wire and the half cell.

An IR-free potential reading is obtained by breaking the

Our lR-fee corosion couponis designed for easy connection between the coupon wire and the structure
installation next to etiting tett stations,/asshownhere. test riiry, usually through the jumper bar, interrupting
cathodic p'rgtection to the coupon. Take a potential ./.''
. . . . - . . one
mersuremenr . . ro
- r*o second. afrer breakinp che
coupor]l connecuon.

CouponSpecifications*

ffir
Surfacearea1.34 sq. in.
wire
THHN No. 12 stranded
Silversolder
3M pottingcompound
*Couponscan be customized to your
T$,oHoles
Optionalalloy and surface
specifications.
areadesignsareencouraged.

an'-1

Instruments and Equipment for the Corrosion Engineer

 MC Miller IR-Free Coupon

COU100 Family: Carbon Steel Cylindrical Coupon with Twin THHN Wires.

• Carbon Steel ‐ AISI 1018 (ASTM A108, AMS5069)

• 10cm2 of exposed metal (1.55in2)

Includes twin cables with # 12 AWG (4mm2) stranded copper wire and THHN insulation. Insulation color and wire length
selections:

COU100‐GXX: Green wires; specify cable length, 25’, 35’, 50’

COU100‐BXX: Blue wires; specify cable length, 25’, 35’, 50’

COU100‐RXX: Red wires; specify cable length, 25’, 35’, 50’

COU100‐PXX: Purple wires; specify cable length, 25’, 35’, 50’

COU100‐YXX: Yellow wires; specify cable length, 25’, 35’, 50’

MESA PRODUCTS INC | 4445 S. 74th E. Ave., Tulsa, OK 74145 | Phone: 918-627-3188 | Fax: 918-627-2676 | www.mesaproducts.com
UNDERGROUND ELECTRICAL RESISTANCE (ER) PROBES

MODEL 620HD/650

Features

• Service Conditions – Heavy Duty

• Operation – Grounding Lead Option for Use with Cathodically Protected
Structures
• Probe Construction – Injection Molded/Epoxy (620HD)
Measure/Reference & Check Element (620HD) All Welded
Elements: Measure, Reference and Check (650)
• Cable Connection – Heavy Duty Length as Required (620HD)
Heavy Duty Length and Bonded Heat Shrink Sleeving Onto Element (650)

The Cosasco Model 620HD and 650 Electrical Resistance (ER) probes
are designed for underground and structural monitoring of pipelines,
vessels, above and below ground storage tanks and structures —
whether cathodically protected or not. The Model 620HD ER probe is a
heavy duty assembly with a check element which is suited to the
“construction site” environment. The Model 650 ER probe is
economical and durable. Its slim profile is convenient for locations with
restricted access such as concrete bridge structures and other
infrastructure applications. Both probes provide good sealing to the
reference element, and the check element provides confidence in the
continued performance of the corrosion sensor. Either probe can be
connected (or not connected) to a cathodically protected structure.
When electrically connected, the probe provides a continuous record
on the effectiveness of the Cathodic Protection (C.P.) system under all
the operating conditions.
When the probe is not connected to the structure, it monitors the
corrosivity of the soil or environment around the structure. In some
cases, it may be beneficial to monitor both the C.P. system and the
environment, which would entail the use of two probes. The probes
may be ordered with or without a grounding lead for C.P. System. The
lead may be installed at the probe or connector end, whichever is most
convenient. In most cases, a lead at the monitoring connector end is
preferred, with a separate lead running to the structure or C.P. System.
This enables connection to the C.P. System to be made as required,
even after probe installation.
MODEL 620HD/650

Typical Installations
Underground Pipeline Monitoring Above Ground Storage Tank
Monitoring

*It is recommended that the probe be bonded (electrically connected) directly to the protected structure, not at
the rectifier or galvanic anode.

Element Availability
UNS
ALLOY S10 S20 S40 T10 T20 T50 Note:
Number  Denotes availability for Model 620HD
K03005 Pipe Grade Carbon Steel        Denotes availability for Model 650
Inches .005 .010 .020 .055 .010 .025
Useful Range (mm) .127 .254 .508 .127 .254 .635
620HD Probe Type: Flush (B)
650 Probe Type: Special (D)

Dimensions
 MODEL 620HD/650

Ordering Information
Model Underground Corrosometer ER Probes
620HD Heavy Duty, Service ER Probe Assembly
650 Heavy Duty, Slim Profile Service ER Probe Assembly
Code Grounding Connection
1 Grounding Lead at Connector End
2 Grounding Lead at Probe End
Code Cable Order Length
S10 Model 620HD Only‐ Flush Strip Element, 10 mil thickness (5 mil useful probe life)
S20 Model 620HD Only – Flush Strip Element, 20 mil thickness (10 mil useful probe life)
S40 Model 620HD Only ‐ Flush Strip Element, 40 mil thickness (20 mil useful probe life)
T10 Model 650 Only ‐ 10 mil thickness (5 mil useful probe life)
T20 Model 650 Only ‐ 20 mil thickness (10 mil useful probe life)
T50 Model 650 Only – 50 mil thickness (25 mil useful probe life)
Code Element Alloy
K03005 Carbon Steel
YYYYYY Other UNS Number (Specify)
Code Cable Order Length
LL Cable Length in Feet

620HD 2 S10 K03005 100 Example

Cosasco ©Rohrback Cosasco Systems, Inc. All rights reserved

11841 East Smith Avenue
Santa Fe Springs, CA 90670, USA
Tel: 1‐562‐949‐0123
Email: sales@cosasco.com
Web Site: www.cosasco.com
The contents of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they
are not to be construed as warranties or guarantees, express or implied, regarding the products or services described wherein or their use or
applicability. We reserve the right to modify or improve the designs or specifications of our products at any time without notice.
Rohrback Cosasco Systems Corrosion Monitoring Equipment is manufactured and sold under one or more of the following US Patents:
4138878, 4238298, 4338563, 4514681, 4537071, 4587479, 4605626, 4625557, 4755744, 4839580, 4841787, 4882537 5243297

Bulletin #214‐K Rev. Date: 03/18/2016

Protection spark gap or isolating spark gap?
OBO isolating and protection spark gaps are intended
to provide galvanic isolation between electrical
installation parts that are not connected to each other
for operational purposes.
If the potential rises in one of the installation parts as
a result of a lightning strike, the isolating spark gap
guarantees a conducting connection at that time,
equalising the potential between the parts.
Spark gap applications:
- Establishing galvanic isolation of insulating flanges.
- Bridging of an unavoidable proximity with unac-
ceptably small distance in a building, across an
isolating spark gap, where the establishment of a
direct connection is not permissible.
- Avoidance of the transfer of fault voltages,
especially in the TT system.

Gas pressure controller

Isolation Isolation
spark gap spark gap

Type 480 Type 480

Type 481
EBB EBB

Gas governor station Buildings with more than one earthing

(isolating spark gap for explosion hazard
areas)
Isolating spark gap type 480 is suitable for bridging
insulating flanges or insulating fittings, especially in
explosion hazard areas.
installation
If a building has two earthing installations – a founda-
tion earthing point and a deep earthing point for
example – they can be connected via an isolating
spark gap. This prevents electrochemical corrosion of
the earthing points – unlike a direct conducting con-
nection. In addition, the entire earthing point area is
effective in the event of a direct lightning strike. TBS_GB_V0_15072002

100 Please always state the order number when ordering.

 - Degrading of one installation by another, e. g. an
information installation. For this purpose, a function
earth is provided, if necessary, in addition to the
standard building earthing point (electrical and
lightning protection).
- Connection of the earthing point with the earthing
points of the nearby building via isolating spark
gaps, especially with the TT system, in order to
make use of all the earths for lightning protection.
Fuse
Box
EBB
Overhead line connection
With an overhead line connection, the roof mast of a
low-voltage overhead line should be as far as
possible from the lightning protection installation. If
this distance is less than half a metre, an enclosed
protection spark gap must be installed. Connection to
the roof mast requires the approval of the energy sup-
ply company.
TBS_GB_V0_15072002
Please always state the order number when ordering.
- Avoidance of the transfer of fault voltages,
especially in the TT system.
- This measure avoids the need to break connections
for measurement and testing purposes.
As their name implies, isolating and protection spark
gaps contain a spark gap. The spark gap changes
from the non-conducting to the conducting state when
an arc is caused by an impulse voltage.
function earth operational earth
EBB EBB
Buildings with more than one earthing
installation
If a separate earthing installation (function earth) is
required for the operation of special electronic equip-
ment, it is recommended that the earthing installations
should be bridged with spark gaps for lightning
protection. This prevents dangerously high voltage
differences arising between the earthing installations.
A choke is also installed, to keep high-frequency volt-
ages away from the function earth.
101
 Protection and
isolating spark gaps

Isolating spark gaps 480 and 481

Operation and fields of application wear. This spark gap has (Ex) approval for use in ex-
plosion hazard areas.
Isolating spark gaps provide galvanic isolation of
electrically conducting parts of an installation that
must not be connected to each other.
Isolating spark gap 480, for instance, is used to
bridge insulating flanges and insulating fittings on
pipes. Isolating spark gap 481 may be used, for
example, to connect a lightning protection system F
with the earthing system of heavy-current installations
above 1 kV, with the auxiliary earthing points of resid-
ual current devices or with the measurement earthing
points of laboratories.
Further fields of application are the bridging of prox- Block diagram of 480/481
imity points or making connections to pipework and
tank installations which have cathodic corrosion
protection. Mounting
Both isolating spark gaps consist of two electrodes Isolating spark gaps 480 and 481 are installed with
positioned at a defined distance in an insulated hous- connecting lugs or connectors between the parts of
ing. In the event of lightning, the spark gap arcs the installation to be bridged. When installing the
through, and the two electrodes are temporarily elec- spark gaps, keep cable lengths short, since long
trically connected to each other. cables increase the risk of unnecessary stress on the
insulation due to inductive voltages.
In version 480, electrodes of tungsten-copper ensure
an extremely high resistance to erosion, as well as low

Test marks
TBS_GB_V0_15072002

Type 480

102 Please always state the order number when ordering.

 Technical data
Isolating spark gaps Parex isolating spark gap 480 Isolating spark gap 481
Explosion protection (Ex)s G 4 to VDE 0171 -
Test certificate PTB No. III B/E-29 859 -
AC clamping voltage Up (50 Hz) 1 kV (higher voltages are possible) 2.5 kV
100% lightning impulse Up 100 (1.2/50) 2 kV 5 kV
clamping voltage
Nominal discharge current In (8/20) 100 kA 100 kA
Impulse current test (10/350) with the lightning current
parameters set out in IEC 61312-1 (02.95)
Impulse current Iimp 100 kA 50 kA
Charge Q 50 As 25 As
Spec. energy W/R 2.5 MJ/Ω 0.63 MJ/Ω
Electrodes Tungsten-copper Stainless-steel
Housing Epoxy moulding compound Epoxy moulding
compound
Connecting bolt - Ø 10 mm;
Stainless-steel
Connecting lug Brass, nickel-plated, with screw, nut -
and spring washer
Connecting lead 25 mm2 Cu, NSLFF highly-flexible, -
with cable lug, screw, nut and spring washer
Screws and nuts M10 -
Steel, hot-dip galvanised
Connecting lead length L 180 mm -
L 250 mm
L 350 mm
Subject to technical alterations

Ordering data
Type Description Order no.
40

480/180 Connecting lead length 180 mm 5240 03 4

480/250 Connecting lead length 250 mm 5240 07 7 Connecting
136

480/350 Connecting lead length 350 mm 5240 06 9

82

lead length
mm

180
250
350

Type Description Order no.

481 Connection Ø 10 mm; stainless-steel 5240 08 5

170
82

ø40
TBS_GB_V0_15072002

Please always state the order number when ordering. 103

 HMWPE Cathodic Protection Cable
Single conductor, 600 Volt

Description & Features :

Cathodic Protection Cable is a stranded copper conductor insulated with a black high molecular weight
polyethlene ( HMWPE ) compound that provides exellent abrasion, crush, chemical, oil and moisture
resistance.

Application : The DIMET brand has been established in the Our consultant-cum-design team of
Suitable for direct burial for useCathodic Protection
in cathodic protectionField sincefor1970
systems and storage
pipelines is are available
tanks, to provide
pipelines, tanks, advice on
P R O T E C T I O N

pilings, well casings, cables, marine crafts and

renowned other buried
worldwide. The or waterexperience
DIMET submerged metallic structures. prevention, especially
of corrosion
has given us unsurpassed knowledge in the protection.
Construction :
Conductor design,
: Standard copper manufacture,
conductor conforminstallation, commissioning
to IEC 60228.
Insulation : High Molecularand maintenance of the full rangeconform
Weight Polyethylene (HMWPE) of sacrificial QUALITY
to ASTM D1248, TypeASSURANCE
3, Class C, AND CONTR
Category 5.
anodes, impressed current cathodic protection DIMET anodes are cast in moder
Temperature : 75 degree C
Voltage : 600 volts systems and other corrosion prevention using only the highest purity m
methods. process, spectrographic anode a
Testing : performed in a well equipped com
High voltage test (3500V, 5minutes) : Without Puncture.
DIMET brand cathodic protection and corrosion laboratory to ensure consistant comp
prevention products and services are provided quality standards.
by Tri-Star Industries Pte Ltd in Singapore,
together with an extensive group of affiliates in Similar high quality standards can be
the other parts of the world. from all products and services prov
the DIMET brand.
C A T H O D I C

Nominal Max Conductor DC Number of Wires & Nominal Nominal Nominal Overall
Conductors resistance at Diameter before insulation Cable Diameter
Area 20deg stranding thickness Weight
6mm2 3.08 Ohm/km 7X1.04/mm 2.30 mm 92 kg/km 7.80mm
10mm2 1.83 Ohm/km 7x1.35/mm 2.70 mm 148 kg/km 9.60mm
16mm2 1.15 Ohm/km 7x1.70/mm 2.70 mm 209 kg/km 10.70mm
25mm2 0.727 Ohm/km Anodes
7X2.14/mm 2.70 mm 308 kg/km 11.90mm
35mm2 0.524 Ohm/km 19X1.57/mm 2.70 mm 406 kg/km 13.20mm
50mm2 0.387 Ohm/km 19X1.78/mm 3.17 mm 551 kg/km 15.50mm
70mm2 0.268 Ohm/km 19X2.14/mm 3.17 mm 761 kg/km 17.20mm
95mm2 0.193 Ohm/km 19X2.52/mm 3.17 mm 1023 kg/km 19.10mm
120mm2 0.153 Ohm/km 37X2.03/mm 3.17 mm 1265 kg/km 21.00mm

P T . S O U T H E R N T R I S T AR - Jl. Jababeka III H Block C No. 17J, Cikarang Industrial Estate, Cikarang
Bekasi 17550 Indonesia, Phone : +62-21- 8935162, Fax : +62-21-8935163, E-mail : tri-star@indo.net.id
the contractors Choice thermOweld®

The thermOweld® Process

The thermOweld® cathodic connection process is a
simple, efficient method of welding copper to copper
or copper to steel. One advantage is that NO outside
power is required when using the thermOweld®
exothermic process. The thermOweld® process uses
high temperature reaction of powdered copper
oxide and aluminum. The reaction takes place in
a semi-permanent graphite mold. These molds
should last for approximately fifty or more welds if
proper care is given. The reaction takes place very
rapidly, therefore the total amount of heat applied '3".&
to the conductors or surfaces is considerably less
than that of brazing or soldering. This is important 45"35*/(
108%&3
to remember when welding to insulated cable or
thin wall pipe. &;-*5&¥
-*%

This system is very field friendly, since it is light and (3"1)*5&
.0-% 8&-%
.&5"-

portable and requires no outside power source. It 5"1
)0-&

45&&-
%*4$
requires very little time or skill to obtain an efficient, $"#-& 8&-%
$"7*5:
maintenance free connection when using the
thermOweld® process.
$011&3
4-&&7&

For more information visit our website @ The thermOweld® connection is a molecular
www.thermOweld.com weld. The weld has the same melting point as
copper. This factor along with the increased
cross sectional area of the connection and the
The thermOweld® process has been used to weld
following insure:
materials other than copper for electrical purposes.
1. thermOweld® connections will not be affected
Materials welded include:
by a high current surge. Tests have shown
that the electrical conductor will melt
Stainless Steel Columbium Brass
before the thermOweld® connection when
Copperweld® Plain Steel Bronze
subjected to high short circuit current.
Nichrome V Everdur® Niobium
Consult IEEE Standard 837.
Galvanized Steel Kama Chromax
2. thermOweld® connections will not loosen or
Silicon Bronze Steel Rail Cast Iron
corrode at the point of weld. There are no
Copper Clad Steel Cor-Ten® Monel
contact surfaces or mechanical pressures
involved. A thermOweld® connection becomes
When welding to galvanized steel it is recommended
an integral part of the conductor.
to resurface exposed bare steel.
3. thermOweld® connections have a current-
carrying capacity equal to or greater than
that of the conductors.

4 1-800-558-1373 • SALES • SERVICE • TECHNICAL SUPPORT • VISIT www.thermOweld.com

thermOweld® the Contractors Choice

Making a thermOweld® Connection

׌
Clean pipe before making weld.

Ø
Position conductor and mold
onto cleanded pipe, after making
sure mold is dry, by pre-heating
or making a test joint.

׎
Place metal disc in bottom of
mold crucible

Ø
Dump powder into crucible,
being careful not to loosen all
the starting powder.

א
Close lid and place a small
amount of starting powder in
the ignition pocket. Ignite the
starting powder with the Flint
Ignitor.

Ø
Remove mold and clean mold
before making next connection.

1-800-558-1373 • SALES • SERVICE • TECHNICAL SUPPORT • VISIT www.thermOweld.com 5

thermOweld® the Contractors Choice

WELD
thermOweld® Weld Metal is packaged in moisture-resistant plastic
cartridges that have tight fitting caps. These cartridges and the necessary
steel discs are then packaged in boxes that are shrink-wrapped. This
insures the weld metal arriving in good condition, always dry, and ready for a
positive ignition every time.
thermOweld® Weld Metal comes in four types; one for welding copper
to copper or copper to steel, copper to rail, copper to cast iron and one
METAL
for welding copper to steel for cathodic protection. The size and weight
(in grams) of the cartridge are marked on each individual cartridge.
thermOweld® Weld Metal is available to be shipped via ground, air or
ocean freight.

CATHODIC
STANDARD CAST IRON RAIL
PROTECTION PACKED PER
CARTRIDGE CARTRIDGE CARTRIDGE
CARTRIDGE BOX
SIZE SIZE SIZE
SIZE
#15 #15CI #15CP #15R 20
#25 #25CI #25CP #25R 20
#32 #32CI #32CP #32R 10
#45 #45CI #45CP #45R 20
#65 #65CI #65CP #65R 20
#90 #90CI ~ #90R 10
#115 #115CI ~ #115R 10
#150 ~ ~ #150R 10
#200 ~ ~ #200R 10
#250 ~ ~ #250R 10
#500 ~ ~ #500R 10
thermOweld® Weld Metal is sold in box quantities only

1-800-558-1373 • SALES • SERVICE • TECHNICAL SUPPORT • VISIT www.thermOweld.com 7

thermOweld
®

the Contractors Choice

CS-32 TYPE MOLDS

Horizontal Cable to Horizontal Steel Pipe
for Cathodic Protecion
CS-32
CS-32 Type Molds are used to terminate a horizontal copper
cable to horizontal steel pipe. Note that the cable is OFF
the surface.
Size range is 2.5 mm² through 70 mm² solid or concentric
stranded copper conductors.

• ‡ 38-4590 Sleeve/Weld Req'd

CABLE SIZE Pipe Dia. PRICE WELD HANDLE • ‡‡ 38-4588 Sleeve/Weld Req'd
MOLD #
(mm²) in mm KEY METAL CLAMPS • For sizes not listed, contact thermOweld®.
• For heavy duty molds or molds with wear plates, contact thermOweld®.
2.5, 4 & 6 up to 125 M-4146‡ 3† 15 Not Req’d • For expedited service, contact thermOweld®.
2.5, 4 & 6 over 125 M-4147‡ 3† 15 Not Req’d • Required Tools;
up to 125 M-4150‡‡ 3† 25 Not Req’d Handle Clamps w/ Flint Ignitor (see chart above for correct handles)
10 † ~ Sold complete with frame
over 125 M-4151‡‡ 3† 25 Not Req’d
up to 125 M-4146 3† 15 Not Req’d 38-0309-00 ~ Flint Ignitor
16 • Other recommended accessories;
over 125 M-4147 3† 15 Not Req’d
38-3922-00 ~ Mold Cleaning Brush (pg 40)
up to 70 M-4152 3† 25 Not Req’d 38-0135-00 ~ Cable Cleaning Brush (pg 40)
25 70 to 165 M-4153 3† 25 Not Req’d 38-0101-00 ~ Rasp (pg 41)
over 165 M-4154 3† 25 Not Req’d
up to 70 M-2833 3† 32 Not Req’d
70 to 165 M-2834 3† 32 Not Req’d
30
165 to 250 M-2835 3† 32 Not Req’d
over 250 M-2836 3† 32 Not Req’d
up to 70 M-4155 3† 32 Not Req’d
70 to 165 M-4156 3† 32 Not Req’d
35
165 to 250 M-4157 3† 32 Not Req’d
over 250 M-4158 3† 32 Not Req’d
up to 70 M-4159 3† 45 Not Req’d
70 to 165 M-4160 3† 45 Not Req’d
50
165 to 250 M-4161 3† 45 Not Req’d
over 250 M-4162 3† 45 Not Req’d
up to 70 M-4163 3† 65 Not Req’d
70 to 165 M-4164 3† 65 Not Req’d
70
165 to 250 M-4165 3† 65 Not Req’d
over 250 M-4166 3† 65 Not Req’d

CS-33 CABLE SIZE

(mm²)

2.5, 4 & 6
10
Pipe Dia.
in mm

Flat
MOLD #

M-4188‡
Surface M-4189‡‡
PRICE WELD HANDLE
KEY METAL CLAMPS

3
3
25CI Not Req’d
45CI Not Req’d
CS-33 TYPE MOLDS 16 or M-4190‡‡‡ 3 45CI Not Req’d
25 750 Dia M-4191 3 45CI Not Req’d
Horizontal Cable to Horizontal Cast Iron Pipe 35 and M-4192 3 45CI Not Req’d
for Cathodic Protecion 50 above M-4193 3 45CI Not Req’d
70 pipe M-2868 3 65CI Not Req’d
• ‡ 38-4590 Sleeve/Weld Req'd
CS-33 Type Molds are used to terminate a • ‡‡ 38-4588 Sleeve/Weld Req'd
horizontal copper cable to horizontal cast iron • ‡‡‡ 38-4589 Sleeve/Weld Req'd
• For sizes not listed, contact thermOweld®.
pipe. Note that the cable is OFF the surface. • For heavy duty molds or molds with wear plates, contact thermOweld®.
Size range is 2.5 mm² through 70 mm² solid or • For expedited service, contact thermOweld®.
• Required Tools;
concentric stranded copper conductors. Handle Clamps w/ Flint Ignitor (see chart above for correct handles)
† ~ Sold complete with frame
38-0309-00 ~ Flint Ignitor
• Other recommended accessories;
38-3922-00 ~ Mold Cleaning Brush (pg 40)
38-0135-00 ~ Cable Cleaning Brush (pg 40)
38-0101-00 ~ Rasp (pg 41)

+1-918-627-5210 • SALES • SERVICE • TECHNICAL SUPPORT • VISIT www.thermOweld.com 23

thermOweld® the Contractors Choice

ACCESSORIES

TOOL KIT
38-0302-00 ~ Tool Kit with Tools Shown except Rasp
38-0302-02 ~ Tool Kit with Tools Shown and Rasp
38-0303-00 ~ Tool Box Only

TOOLS
38-0304-00 ~ 8” File
38-0305-00 ~ Wire Brush
38-0306-00 ~ Card Cloth Brush
38-0307-00 ~ Crimping Tool
38-0308-00 ~ 6” Screwdriver
38-0309-00 ~ Flint Ignitor
38-3922-00 ~ Mold Cleaning Brush
38-0101-00 RASP
This tempered steel, curved rasp is recommended for removing
rust and mill scale from steel and cast iron surfaces. The blade is
replaceable. Specify part # 38-0101-01.
Not recommended for use on galvanized surfaces.

38-0904-00 Flint Ignitor Extension

The 38-0904-00 Flint Ignitor Extension allows the installer
to stand 36” from the mold. Flint Ignitor not included.

PACKING MATERIAL
Packing material is used to prevent the molten weld
metal from leaking out of the mold. When cable
opening becomes worn from heavy use, the packing
material may be used to prolong mold use. It is
also used around 7 strand cable to prevent leaking.
Packing material comes in a 1 lb or a 5 lb package.
Note: This packing material to be used on outside
of mold only. If packing gets into weld cavity, gassy
welds will result.
38-0309-00 Flint Ignitor
The 38-0309-00 Flint Ignitor is used to ignite
the starting powder. Each mold that is sold
with a frame has a Flint Ignitor included.
Replacement flints are available upon request.
Part #38-0309-01.

1-800-558-1373 • SALES • SERVICE • TECHNICAL SUPPORT • VISIT www.thermOweld.com 19

4102 South 74th East Ave, Tulsa OK 74145
P: 800.558.1373 • F: 800.788.1668
0000-99-5044-00 ECN 2147 REV “B” 09/07
 Handy Cap®
O t h e r P r o d u c t s

®
Royston
Technical Data Sheet

DESCRIPTION Royston Handy Cap provides quick, field applied corrosion protection to
anode and test wire leads welded onto metal substrates. The Handy Cap is
made using a durable plastic sheet that has a dome filled with a
moldable, corrosion preventing compound. The sheet is then capped with an
adhesive layer for easy and permanent application. Roybond 747 Primer is
required in order to provide sufficient adhesion.
The Handy Cap can be applied by hand or using the Royston Key Hole Tool.

RECOMMENDED USE Sealing the welded connection of an anode or test wire to a metal substrate.

SUBSTRATE COMPATIBILITY Steel, Stainless Steel, Ductile Iron, other metals, FBE, Epoxy, PE

SURFACE PREPARATION SSPC SP-3 Power Tool Cleaning or SSPC SP-6/NACE No. 3 Commercial Blast
Cleaning

PRIMER Royston Handy Cap requires a primer to allow for permanent adhesion. A 4
mil WFT of Royston Roybond 747 or Roybond 747 Aerosol should be applied
and allowed to dry prior to application of the Handy Cap. When use of a
primer is not preferred or allowed, Handy Cap IP should be considered.

1 quart of Roybond 747 can be used for 200 Handy Caps

One 16 oz can of Roybond 747 Aerosol can be used for 30 Handy Caps

SAFETY Refer to Material Safety Data Sheet: MSDS-Handy Cap

APPLICATION Refer to Application Guidelines: AG-HANDY-CAP

C h a s e C o r p o r at i o n
The information contained here is provided for product selection purposes only and is not to be
295 University Avenue
considered specification or performance data. Under no circumstance will the seller be liable for Westwood, MA 02090
any loss, damage, expense or incidental or consequential damage of any kind arising in connec-
Phone: 800-323-4182
tion with the use or inability to use its product. Specific conditions of sale and Chase's limited Fax: 781-332-0701
warranty are set out in detail in Chase Corporation Terms and Conditions of Sale. Those Terms www.chasecorp.com
and Conditions are the only source that contain Chase's limited warranty and other terms and
An ISO 9001:2008
conditions. REGISTERED COMPANY

TDS-Handy-Cap-REV1-Aug13 1
 Handy Cap®
O t h e r P r o d u c t s

Typical Technical Data

Property US Customary Metric Test Method
Overall Size 4” x 4” 101 mm x 101 mm
Plastic Sheet Size 2.75” x 4” 70 mm x101 mm
Plastic Dome Height 0.8” 20 mm
Plastic Dome Diameter 1.65” 42 mm
Total Thickness 135 mils 3.43 mm ASTM D1000
Sheet Thickness 10 mils 0.25 mm ASTM D1000
Adhesive Thickness 125 mils 3.18 mm ASTM D1000
Adhesion to Primed Steel 10 lb/in 1.75 N/mm ASTM D1000
2
Maximum Wire Size 8 AWG 8 mm
Holiday Detection Setting 5000 V 5000 V
Service Temperature Range -40°F to +165°F -40°C to +74°C

ORDERING INFORMATION
Handy Cap
Pieces Per Case Case Weight
20 5#

TDS-Handy-Cap-REV1-Aug13 2
 Corrosion Protection For
Exothermic Grounding Connections
What Is
Royston
Handy Cap?
The Royston Handy Cap
is a prefabricated
assembly specifically
designed for Cathodic
Protection leads to pipes
and tanks. When pressed
by hand into position
over the anode lead wire
weld it forms a thick,
highly resistant electrical
insulation seal over
the weld, the end of
the lead wire and the
surrounding area of
the pipe or tank.
5021 Rev. 10-14-99
Features
1.) A top plastic sheet formed with an
igloo shaped dome and entry tunnel
for the lead wire.
2.) A special elastomeric compound
in the plastic dome, which is firm
enough to resist flow at all normally
encountered application and operation
temperatures, but soft enough to mold
itself around and completely cover the
irregular welded profile.
3.) On either side of the dome are a
double row of parallel, flexibilizing
serrations to assist with conforming
around small diameter pipe.
4.) A base of Royston Tac-Coat, a black
unbacked elastomeric tape with
exceptional adhesive properties, for
bonding firmly to the metal surface,
when used with Royston Roybond 747.
Usage
The Royston Handy Cap is easily applied
and economical. They may be used on all
anode lead wire and test wire weld areas.
Royston Handy Cap is especially useful
for welds on mill coated pipe where only
a small part of the coating has been
removed to permit installation of the
thermite grounding connections.
They are ideal for use in limited access
situations, because they can be manipulated
easily and applied at arm's length.
©1999 Royston Laboratories Printed in U.S.A
Ordering
Information
Royston Handy Cap
is packed 24 per carton.
(Shipping weight is five
lbs.) Royston Roybond
747 is available in:
16 ounce aerosols-
sufficient for 30 Caps
One quart cans-
sufficient for 200 Caps.
Call your local
Royston representative
or distributor or call
Roy ston's direct at
800-245-3209 for
prices, delivery,
additional information
or technical assistance.
The technical data furnished is
true and accurate to the best
of our knowledge. However, no
guarantee of accuracy is given
or implied. We guarantee our
products to conform to our
Quality Control standards.
We assume no responsibility
for installation, coverage,
performance or injuries
resulting from use. Liability, if
any, is limited to replacement
of products determined to be
defective by our Quality
Control standards exclusive
of labor for installation and/or
subsequent damage resulting/
causing ,functional damage
either directly or indirectly,
Prompt reporting (within four
(4) working days) of suspected
defective product is required.
Prices and cost data shown
are subject to change without
prior notice.
Royston Laboratories Division ထ 128 First Street, Pittsburgh, PA 15238 ထ 412-828-1500/800-245-3209 ထ Fax 412-828-4826
Step 1
Clean all mud, dirt, grease, oil and other
contaminants from the metal surface and
any part of the mill applied coating which
is to be covered. Apply a coat of Royston
Roybond 747 and allow to dry to a
non-glossy appearance, which will take
about 5 minutes, depending on humidity
and temperature.
Step 2
Remove the release paper from the
bottom of the Royston Handy Cap.
Bend the plastic sheet inward at the
serrations when applying to small
diameter pipe. Position and place the
Royston Handy Cap on the welded
area with the tunnel over the lead wire.
Step 3
Push the dome of the cap firmly into the
weld area. Now lift the lead wire away
from the pipe and squeeze the black rubber
compound completely around and
underneath the wire. Then push the lead
wire back down on the pipe and press the
elastomeric compound into firm contact
with the pipe over the entire area.
No further protection is necessary when
Royston Handy Cap covers the entire
exposed metal area. Uncovered areas
should be protected by applying tape or
mastic, such as Royston Roskote Mastic.
When coating or wrapping the Royston
Handy Cap, remove the narrow strips of
plastic release film on the top of the cap.
This will assure maximum protection by
effecting a positive waterproof seal.
www.RoystonLab.com
 Liquid Adhesive Systems
#1027
Basic Use
Polyken liquid adhesive systems are recommended for use with only Polyken coating systems. The liquid adhesive
systems consist of butyl based elastomers blended with polymeric resins dissolved in an organic solvent system. They
can be used for machine or hand brush application, are non-toxic and non-polluting, and conform to local and national
Polyken Pipeline Coatings
standards. In addition to the excellent adhesion to the pipe substrate and cathodic disbondment resistance, the pipe
surface is protected against stress corrosion cracking with industry proven SCC inhibitors.

Polyken # 1027
Liquid adhesive system is ideal for hand brush application to rough, reconditioned, or grit-blasted pipe surfaces. It
provides a uniformly smooth, instant tack surface for Polyken coating systems.
CAUTION:
UÊ-̜ÀiÊ>Ü>ÞÊvÀœ“Ê i>ÌÊÜÕÀVi°Ê,i>`Ê>Ê>LiÊˆ˜ÃÌÀÕV̈œ˜ÃÊ«ÀˆœÀÊ̜ÊÕÃi°
UÊ*Àœ«iÀÞÊÃ̜Ài`]Ê>Ê*œÞŽi˜ÊˆµÕˆ`ÊVœ>̈˜}ÊÃÞÌi“ÃÊ >ÛiÊ>Êà ivʏˆviʜvÊÎÊÞi>ÀðÊÊ*i>ÃiÊÀiµÕiÃÌÊ>˜Ê>««ˆV>̈œ˜Ê
specification and storage guideline from Berry Plastics.
U Polyken liquid adhesive systems are FLAMMABLE MIXTURES
System Components
Description # 1027
Base Rubber/Resins
Solvent V.M. & P Naptha
Total Solids Îä¯
Weight/Gallon 7.1 lb
Weight/Liter .86 kg

DS-1027-REV7-0509
Viscosity Medium Syrup
Flash Point -4°C (40°F)
Color Black
VOC 0.59 kg/l (4.9 lbs/gal)
Maximum operating temperature 85°C (185°F)
Ordering information
Item Number Description
614401 1027 LIQUID ADHESIVE - 55 GAL-208.2L TH
È£{{äÎÊÊ Ê Ê £äÓÇÊ+1 Ê
 -6 ÊʇʣÊ
‡Î°nÊ
614402 1027 LIQUID ADHESIVE - 5 GAL-18.9L
615157 1027 LIQUID ADHESIVE - 0.95L
È£{{ÎÇÊÊ Ê Ê £äÓÇÊ+1 Ê
 -6 ÊʇʣÊ+/
®

* Contact a Berry Plastics representative for specific project requirements

Berry Plastics warrants that the product conforms to its chemical and physical description and is appropriate for the use stated on the technical data sheet when used in compliance with Berry Plastics
written instructions. Since many installation factors are beyond the control of Berry Plastics, the user shall determine the suitability of the products for the intended use and assume all risks and liabilities
in connection herewith. Berry Plastics liability is stated in the standard terms and conditions of sale. Berry Plastics makes no other warranty either expressed or implied. All information contained in
this technical data sheet is to be used as a guide and is subject to change without notice. This technical data sheet supersedes all previous data sheets on this product.

Local Distributor / Representative:

For contact details of local Distributors / Representatives

Please visit www.berrycpg.com.

www.berrycpg.com

Headquarters : Berry Plastics Tapes & Coatings Division, Franklin MA, USA
Tijuana, Mexico
Franklin, MA, USA Houston, TX, USA Tel USA +1 858 633 9797
Tel: +1 508 918 1714 Tel: +1 713 676 0085 Fax US: +1 858 633 9740 Aarschot, Belgium Baroda, India
US Toll Free: +1 800 248 0149 US Toll Free: 01 888 676 7202 Tel Mexico: +52 664 647 4397 Tel: +32 16 55 36 00 Tel: +91 2667 264721
Fax: +1 508 918 1910 Fax:+1 713 676 0086 Fax Mexico: +52 664 647 4370 Fax: +32 16 55 36 74 Fax: +91 2667 264724
CPG@berryplastics.com CPGH@berryplastics.com CPGTJ@berryplastics.com CPGE@berryplastics.com CPGIN@berryplastics.com
 #955
Mechanical Protection
Outerwrap
System Description
Polyken #955 is a protective pipeline outerwrap that is used where a complete bond of outerwrap to tape is specified.
Because it is a polyethylene film with a bonding adhesive, it stays with the tape and never disappears or disintegrates.
The adhesive assures a complete bond and eliminates the need for tie-downs on the outerwrap. Designed for machine
application at the same time the primary coating is applied, Polyken #955 is available in various thicknesses. The
standard color of #955 is white, but it is also available in black .

*Àœ`ÕVÌÊi>ÌÕÀiÃÉ i˜ivˆÌÃ
U Proven Performance UÊ >ÃÞÊ
««ˆV>̈œ˜
Polyken #955 is one of a family of Polyken outerwraps Engineered to achieve a taut, smooth machine wrap
that have proven themselves on pipeline throughout over a wide range of primary coatings, Polyken #955 is
the world over the past twenty-five years. the first choice when an adhesive bond of the
outerwrap to the primary coating is specified. Gives a
UÊ/ˆ} ÌÊ œ˜`Ê smooth, tough protection to the pipeline under all
The recommended outerwrap wherever a complete climatic conditions, in any terrain, anywhere in the
bond to tape is required. Tough, pressure-sensitive world.
adhesive means the outerwrap bonds and stays
permanently.
*Àœ`ÕVÌÊ œ˜ÃÌÀÕV̈œ˜

Backing

Adhesive

*Àœ`ÕVÌÊ*Àœ«iÀ̈iÃ
/iÃÌÊiÌ œ`Ê ˜}ˆÃ Ê Ê Ê iÌÀˆV
Total Thickness ASTM D 1000 15 20 25 30 mils 0.381 0.508 0.635 0.762
Breaking Strength ASTM D 1000 20 25 25 25 lb/in w. 3.57 4.47 4.47 4.47 kg/cm w.
Elongation ASTM D 1000 300 300 300 200 % 300 300 300 200%
Temperature Range: ASTM D 1000
Normal Application -30° to 160°F -34° to 71°C
(ambient temperature)
Normal Service -30° to 185°F -34° to 85°C

DS-955-REV5-0509
(operating temperature)

Berry Plastics warrants that the product conforms to its chemical and physical description and is appropriate for the use stated on the technical data sheet when used in compliance with Berry Plastics
written instructions. Since many installation factors are beyond the control of Berry Plastics, the user shall determine the suitability of the products for the intended use and assume all risks and liabilities
in connection herewith. Berry Plastics liability is stated in the standard terms and conditions of sale. Berry Plastics makes no other warranty either expressed or implied. All information contained in
this technical data sheet is to be used as a guide and is subject to change without notice. This technical data sheet supersedes all previous data sheets on this product.

Local Distributor / Representative:

For contact details of local Distributors / Representatives

Please visit www.berrycpg.com.

www.berrycpg.com

Headquarters : Berry Plastics Tapes & Coatings Division, Franklin MA, USA
Tijuana, Mexico
Franklin, MA, USA Houston, TX, USA Tel USA +1 858 633 9797
Tel: +1 508 918 1714 Tel: +1 713 676 0085 Fax US: +1 858 633 9740 Aarschot, Belgium Baroda, India
US Toll Free: +1 800 248 0149 US Toll Free: 01 888 676 7202 Tel Mexico: +52 664 647 4397 Tel: +32 16 55 36 00 Tel: +91 2667 264721
Fax: +1 508 918 1910 Fax:+1 713 676 0086 Fax Mexico: +52 664 647 4370 Fax: +32 16 55 36 74 Fax: +91 2667 264724
CPG@berryplastics.com CPGH@berryplastics.com CPGTJ@berryplastics.com CPGE@berryplastics.com CPGIN@berryplastics.com