The Importance of Cathodic Protection for Metal Wire

Cathodic protection is based on the components of corrosion — electrolytes, cathodes and anodes. By understanding the essential principles of corrosion, you can design a pair of metals that protect one another.

In cathodic protection, you connect one metal to a more easily corroded metal. During this process, you essentially sacrifice the newly introduced metal so that you can preserve the initial metal. In other words, the new metal acts as the anode and corrodes, while the protected metal is the cathode.

Cathodic protection supplies the metal with additional electrons and removes the possibility of corrosion. Without this added protection, metals behave as anodes and rust easily. The electric current flows into the anode from the electrolyte. Once there, the current expels onto the metal and provides a protective coating. This coating regulates corrosion and keeps it from developing on the metal.

One example of cathodic protection in action is Bezinal® XC coated wire. Numerous industries use springs for daily functions, from automotive to telecommunications. As springs are exposed to harsh elements or deformation, the Bezinal® XC coating allows the spring to resist corrosion. Due to the high protection of the coating, additional corrosion layers are unnecessary.

Bezinal® XC coated wire displays how cathodic protection can directly help industries. This coating type uses cathodic protection to shield wires from corrosion or other forms of degradation. In turn, industries can use these tools more efficiently. It lengthens the wire's lifetime, reducing time and money spent on additional coatings or replacements. The more protection your springs have, the better they protect against corrosion

There are two major types of cathodic protection — galvanic cathodic protection (GACP) and impressed current cathodic protection (ICCP). Both involve a current flow that acts as a protector to the anode, or metal. Once the electrical wave flows out of the anode and into the electrolyte, it ejects onto the metal and controls corrosion.

There are further distinctions between the two types of cathodic protection:

Many industries use cathodic protection for a variety of purposes. Cathodic protection helps prolong the life span of equipment and makes infrastructure safer to use. It's a critical method for keeping materials secure even in harsh environments.

These are frequent applications of cathodic protection systems:

• Offshore drilling: Offshore drilling is an important process for the extraction of many resources. Most offshore drilling sites reside in salt water, which can sometimes quicken the corrosion process. Corrosion can place high stress on equipment and cause it to degrade or fail altogether. Engineers use cathodic protection to preserve equipment and keep workers safe. The process can reduce corrosion and help drilling tools remain sturdy even in the saltwater environment.
• Onshore pipelines: Many onshore pipelines are susceptible to corrosion. These underground pipelines carry gas, hazardous liquids or other essential substances. Corrosion causes the pipelines to wear down, resulting in leaks, contamination or worker injuries. Because of these risks, pipeline engineers and professionals use cathodic protection to prevent corrosion from occurring.
• Renewable energy structures: Infrastructures based on renewable energy are critical developments in the face of the climate crisis. Projects like solar power panels, wind turbines and hydroelectric stations are crucial for a more sustainable future. However, these structures exist outdoors and face the limitations of corrosion. Designers use protection techniques to reduce or avoid corrosion and keep these structures secure, such as Bezinal® XC coated wire. This zinc-aluminum coating maintains its high protection levels against corrosion even amidst highly degrading atmospheres.
• Ships: Ships are essential for transportation, carrying food, medical supplies and other goods to people worldwide. Their constant exposure to salt water and outside elements makes them prone to corrosion and degradation. Corrosion can force higher maintenance costs or cause a ship's engine to fail prematurely. Cathodic protection deteriorates the sacrificial anode, instead of the crucial outer layers of the vessel.
• Concrete structures: From buildings to bridges to sculptures, concrete is found in all kinds of construction. Concrete corrosion can be caused by exposure to salt water, industrial waste or sulfates. Other bacteria also cause rapid deterioration in concrete structures. Many engineers use cathodic protection and other preventative strategies to halt the degradation.
• Transmission lines: Transmission lines carry electric power from one point to another in an electric power system. They also use cathodic protection to ensure large voltages of power get transported safely. The cathodic protection keeps the lines from corroding, enabling them to transfer electric power without any delays.
• Guy, static and messenger wires: These wire types provide additional support to standing structures. Static wires protect against lightning, while messenger and guy wires add stability to structures like power lines. Messenger wires are essential for telecommunications and transmitting data. These wires often use cathodic protection to maximize their efforts. Normally made of steel, cathodic protection helps the wires perform to their full extent even in harsh conditions.

No matter the industry, cathodic protection keeps structures safe from deterioration. Protect your workers and maintain infrastructure security when you use cathodic-protective materials. Many tools, such as wires, have shielding qualities that induce cathodic protection.

Bekaert is the leading provider of steel wires in North America. We offer many high-quality wires and wire coating solutions that utilize cathodic protection, including:

• Bezinal® XC coated wire: You can use this wire in a variety of industries, notably for alternative energy applications. Its zinc aluminum coating uses cathodic protection to protect the wire from corrosion. In turn, the wire works more efficiently and can withstand harsh temperatures and deformation.
• Anchorage rope wire: Bekaert Anchorage rope wire is perfect for offshore drilling uses. The wires help build durable ropes designed for deep-sea applications. It can endure intense water pressures and provide strength for anchors. The rope wire uses cathodic protection strategies to prevent corrosion, making it ideal for the harsh environment.
• Armoring wire: This highly durable armoring wire also uses corrosion prevention techniques. Frequently used in drilling formats, the armoring wire has extreme strength and protects against outside elements and corrosion.
• Land cable armoring wire: Bekaert land cable wire is an excellent option for underground power cables. It protects against harsh impacts and corrosion, ensuring the wire stays stable. In turn, the cables remain online and avoid damage from construction work or other interferences. Its corrosion resistance is due to cathodic protection strategies.

These wires are examples of cathodic protection in action.

Anodic protection is an additional strategy for preventing corrosion. Both cathodic and anodic protection are electrochemical processes that protect the metal from rusting and corrosion. However, anodic protection differs from cathodic protection in several key ways, such as:

• The protected metal becomes the anode: Anodic protection essentially takes the opposite approach of cathodic protection. In cathodic protection, the protected metal becomes the cathode in the electrical cell. In anodic protection systems, the opposite occurs — the protected metal acts as the anode.
• Suppresses reactivity: The goal of anodic protection is to keep the metal in a passive state. In its passivity, it does not react chemically and therefore does not corrode. Because of this, you can only use anodic protection with metals that already have relatively high passivity, such as stainless steel. In contrast, cathodic protection does not need a passive state and instead uses the current to stop corrosion from occurring.
• No different types: As discussed previously, cathodic protection has several types, such as galvanic and impressed current cathodic protection. However, anodic does not have other forms.
• Applications: Because anodic protection works only with high passivity, it is usually used for these types of metals, like steels. You can also use anodic protection for short-term solutions because it does not have the same longevity as cathodic protection. Anodic protection can withstand basic and acidic environments, so it is also useful in these applications.

Both of these are high-quality strategies for the prevention of corrosion overall. They are essential for keeping metal infrastructures safe.