OPERATION PROCEDURE

INSTALL MAGNESIUM ANODES AND CABLE

Revision : 0

INSTALL MAGNESIUM ANODES AND CABLE

PURPOSE
The following narrative describes the procedures associated with the
installation of anodes and cables. This procedure is to ensure that the
installation work is conducted properly, which is essential for the cathodic
protection system to work properly.

RESPONSIBLE PERSONS
2.1

PROJECT COORDINATOR
Project Coordinator is responsible for the installation plan and ensure
the capability of person who work.

2.2

CONSTRUCTION SUPERVISOR
Construction Supervisor is responsible to evaluation of intended work
and inspection of the work site. Monitoring job step according to the
site-specific design drawings.

2.3

SAFETY /SUPERVISOR/ OFFICER

The Safety Supervisor / Officer is responsible for carrying out periodic
checks of the work site to ensure adherence to the condition and safe
working practices.

GENERAL INSTALLATION PROCEDURES

3.1

Thermit Welding

1. The pipe coating shall be removed over an area of approximately 75 x 75

mm at top of the pipe.

2. The area shall be thoroughly cleaned using a power brush or grinder and
then roughened to bright metal using a course file. Note that it may also
be necessary to use degreaser such as xylene.
3. Strip cable sheathing and/ or insulation so as to expose the copper core
for a length appropriate to the size of mould being used.
Place metal disc within the mould, so as to obscure the hole through
the mould.

OPERATION PROCEDURE
INSTALL MAGNESIUM ANODES AND CABLE
Revision : 0

Empty powdered contents of the thermit weld charge into the mould.
Squeeze the polythene container so as to ensure discharge of the
igniter powder from the bottom of the container. Close the mould lid.
Lay the exposed cable core on the pipe and across the exposed area.
Place the carbon mould over the exposed cable core, such that it lies
in the slot at the bottom of the mould.
Hold the mould firmly in the position with one hand and ignite the
powdered charge by operating the flint gun with the other hand. Safety
goggles and gloves must be worn.
An exothermic reaction takes place in which the powder is
transformed to the molten metal and melts the metal disc and drops
onto the cable below. Allow the molten metal to cool slightly say 5
seconds, before removing the mould.
4. Test the strength of the connection by hitting the completed weld with a
500 grams copper headed hammer.
5. The connection and surrounding coating should be cleaned and primed
for re-coating all as per the project pipe coating specifications. Note that
there will be a small amount of slag that must be removed.
Following coating repair, the cable and connection area may require
holiday testing using a proprietary instrument.

3.2

Test Station
1. The subcontractor shall construct foundations for the test station in
accordance with the project drawings.
2. Test cables shall be routed through conduit connected to the appropriate
terminals within the test box.
3. Cable slack shall be provided minimum 100 mm each within the test
station.
4. When necessary, any damaged paint coating shall be repaired to the
satisfaction of the client.
5. All cables shall be marked for future identification.

3.3

Magnesium Anodes
1. The proposed location of excavation shall be checked against the contract
drawings.
2. The excavation shall be as per the project design document and be of
sufficient depth and width to accommodate the installation of the vertical
anode.
3. Soak the packaged magnesium anode in the fresh water before install the
anode.
4. Backfilling of the anode shall be as per the project drawings. The selected
backfill shall be installed around and above the anode(s) to ensure
compaction and good anode to soil interface without voids. The
installation may be wetted and tamped to compaction as per site
requirements.
5. Anode cable tail/ header cable shall be installed within soft sand as per
the project drawings and specifications. The cable shall normally be
protected by cable tiles and electrical warning tape.

OPERATION PROCEDURE
INSTALL MAGNESIUM ANODES AND CABLE
Revision : 0

6. The remainder of the excavation shall be backfilled by normal site backfill

soil and the area reinstalled to its normal condition.

TEST STATIONS AND JUNCTION BOXES

Condulet and Pole Mount

Cathodic Protection Test Stations
Rugged Designs For Long-Life
Operation
Cathodic protection systems require routine
monitoring to ensure that adequate current is
supplied to buried metallic structures. Test
stations are a simple method for conducting this
monitoring. Corrpro distributes a full line of
pole- and condulet-style test stations with
proven track records for durability and ease of
use. The stations are available in numerous
colors, shapes, and test lead configurations, and
are made from either cast iron or high-impactstrength molded plastic. To address all kinds of
applications, the stations can be constructed to
accommodate from one to eleven test lead
terminals. The terminals for all test stations
offered are composed of corrosion-resistant
nickel-plated brass to guarantee many years of
accurate readings. Various types of mounting
options are also available. The stations may be
purchased with steel conduit or UV-protected
polyethylene poses in various diameters and
lengths, or may be ordered with special adapters
for flange or vault-wall mounting.
The condulet and pole-mount test stations
offered by Corrpro are designed to be extremely
user friendly. Lids on the pole mount stations
remove easily, and the terminals are clearly
marked for quick identification. Condulet
stations do not require protective caps, and the
terminals are readily accessible for testing. Both
types of test stations can be selected with either
prong- or banana-jack terminals. Pole mount
stations are also available with built-in shunts
and locking lids.

Typical Applications
Pole- and condulet-style test stations are used to
perform various corrosion-related electrical tests
on buried metallic structures. These include
structure-to-earth potentials, and the presence of
stray currents. Pole-mount test stations, which
can be selected in various color combinations,
are typically used in areas where an identifiable
marker is necessary. Condulet-style stations are
most often installed in the vicinity of buildings
or plant facilities.

Authorized Distributor for the

Following Manufacturers
Cott Manufacturing Company
Gerome Manufacturing Company

1090 Enterprise Drive / Medina, OH 44256

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

TEST STATIONS AND JUNCTION BOXES

Condulet and Pole Mount

Cathodic Protection Test Stations

Ordering Procedure
Corrpro distributes an assortment of pole- and
condulet-style test stations. To order the
required station for your application, indicate the
brand and model desired, and specify the
quantity, terminal configuration, and mounting
style needed. An example is provided to help
illustrate this process.

Ordering Procedure Example

ITEM

EXAMPLE

Quantity
Test Station
Manufacturer
Test Station Model

200

Number of Terminals

Mounting Style
Colors:
Pole
Test Head
Locking Device

Plastic Pole

Cott
Big Fink

Test Station Ordering Information

MODEL

White
Orange
Yes

STANDARD
TERMINAL
LEADS

MAXIMUM
TERMINAL
LEADS

MOUNTING
STYLE

OTHER
OPTIONS
Flange
Mounting
Zap Guard
Terminals
Locking Lids
Flange
Mounting
Zap Guard
Terminals
Locking Lids
Banana
Terminals

COTT (Manufacturer)
Big Fink

11

Six-Foot
Polyethylene
Poles

Little Fink

Five-Foot
Polyethylene
Poles

Finklet

1, 2, 3, 4

3/4" Conduit
Polyethylene
Poles
3/4" - 2 1/2"
Conduit
1" - 2 1/2"
Conduit
3/4" - 1 1/4"
Conduit
1" - 1 1/4"
Conduit
1 1/2" - 3 1/2"
Conduit

GEROME (Manufacturer)
100 Series

700 Series

10

800 Series
(Screw Cvr)
1000 Series
(Dual Hub)
2000 Series
(Dual Hub)

(Customer
Specs)
(Customer
Specs)

Thread or Slip
Fit
Thread or Slip
Fit
Thread Fit
Thread or Slip
Fit
Thread or Slip
Fit

1090 Enterprise Drive / Medina, OH 44256

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

TEST STATIONS AND JUNCTION BOXES

Flush-To-Grade

Cathodic Protection Test Stations

Suitable For Numerous Landscapes
Cathodic protection systems are utilized on
structures located in water, on land, in rural,
urban, industrial, and residential regions. To
monitor the performance of these systems in
areas where aesthetics are important or traffic
flow is present, Corrpro offers flush-to-grade
test stations. The stations are manufactured with
tube sections made from various types of plastic
materials. These special tube sections are
lightweight, durable, corrosion resistant, and
provide a watertight area for housing test lead
terminals. Terminal boards are connected either
to the test head cap or recessed into the plastic
tube for easy access. The test boards can
accommodate from one to nine terminals, which
are made from nickel-plated brass to assure
many years of accurate readings.
The quality of the lid utilized in flush-to-grade
test stations is very important. The lids are the
only means of identifying and locating the test
stations, and provide protection against water
penetration and vandalism. Corrpro flush-tograde test stations are equipped with special
locking lids, which are clearly marked for easy
identification. The caps are made from either
cast iron or high-impact-strength plastic, and are
available with built-in magnets for locating by
electromagnetic detectors.

Typical Applications
Corrpro flush-to-grade test stations are designed
for use in areas where maintaining a landscape's
aesthetic quality is important. The stations are
also ideal for use in human or vehicle traffic
areas, such as roads, parking lots, or sidewalks.
Using the test stations, readings can be obtained
to determine structure-to-soil potentials and the
level of stray currents.

Authorized Distributor for the

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

1090 Enterprise Drive / Medina, OH 44256

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

TEST STATIONS AND JUNCTION BOXES

Flush-To-Grade

Cathodic Protection Test Stations

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

Ordering Procedure Example

ITEM

EXAMPLE

Quantity
Test Station
Manufacturer
Test Station Model

200

Number of Terminals

Cott
Flush Fink

Test Station Ordering Information

MANUFACTURER
Cott
Handley

C. P. Test
Services

MODEL
Flush Fink
Street Fink
M2
T2
T4
NM
Mini
Glenn

STANDARD
TERMINAL
LEADS
5
5
2
1, 2, 5
1, 2, 5
4, 5, 7
2
4

MAXIMUM
TERMINAL
LEADS
11
9
2
5
5
7
5
5

1090 Enterprise Drive / Medina, OH 44256

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