Product Data Sheet Safety Data Sheet Show all documents
Sika® Galvashield® XP
Sika® Galvashield® XP
Sika® Galvashield® XP
Sika® Galvashield® XP
Sika® Galvashield® XP
Sika® Galvashield® XP

Sika® Galvashield® XP

Type 1A Discrete Embedded Galvanic Anode Range for Corrosion Prevention

Sika® Galvashield® XP Range is available in five sizes: Compact / XPT / XP2 / XP4 / XPX embedded galvanic anodes are used in concrete repair and rehabilitation to prevent the formation of new corrosion sites adjacent to completed patch repairs. Designed for optimum performance and ease of installation, the alkali-activated (Type 1A) anodes are comprised of high purity zinc core that is activated by the surrounding specially formulated cementitious mortar with an internal pH of >14 which keeps the zinc active over the life of the anode. The anode is quickly and easily fastened to the exposed reinforcing steel using the contractor-friendly One-and-Done™ single-wire connecton. Once installed, the zinc core corrodes preferentially to the surrounding reinforcement, thereby providing galvanic corrosion prevention to the adjacent reinforcing steel and mitigating ‘ring anode corrosion' or the 'halo effect'.

  • Proven technology - supported by independent test programme.  
  • Sika® Galvashield® XP is the original embedded galvanic anode with an extensive 20-year track record.
  • Type 1A anode - alkali-activated to maintain activity of the zinc; meets building code requirements that prohibit intentionally added constituents that are corrosive to reinforcement with the repair area. 
  • Easy to install - innovative single wire One-and-Done™ connection can be installed twice as fast as traditional two wire connections, saving up to 50% on installation labour costs.  
  • Focused protection - provides localised corrosion protection where it is needed the most, at the interface of the repair and the remaining contaminated concrete.
  • Cast zinc core - provides high anode utilisation and a secure long-term connection between the zinc and the integral lead wire. 
  • BarFit™ design - grooved edges on Sika® Galvashield® XP2, XP4 and XPX anodes assist with secure anode placement. 
  • Steel connection wires - provides dependable steel-to-steel contact with no intermediate materials (e.g. galvanising) that may impede the long-term electrical connection. 
  • Economical - provides localised protection where it is needed the most, at the interface between the repair and the remaining contaminated concrete.
  • Versatile - effective in chloride-contaminated and carbonated concrete containing chlorides. Can be used for both conventionally reinforced and prestressed or post-tensioned concrete.
  • User friendly - installation is quick and easy, requiring no special equipment or training.
  • Low maintenance – requires no external power source or system monitoring.
  • Measurable – anode performance can be easily monitored if required.
  • Does not cause hydrogen embrittlement.
  • ICRI CSP-3 (Concrete Surface Profile) - raised ridges provide increased surface profile to promote mechanical bond between repair mortars and concrete. 
  • Does not cause hydrogen embrittlement.
  • Long lasting – minimum 20 year anode service life* when using standard design tables, reduces the need for future repairs.
  • Full System – can be used in conjunction with Sika® FerroGard® and Sikagard® technologies to offer a total corrosion management system.
 
  • Independent testing - indicates concrete repair service life can be extended by more than 400%.
         * As with all galvanic protection systems, service life is dependent upon a number of factors including reinforcing steel density, concrete conductivity, chloride concentration, humidity and anode spacing. 
Sika® Galvashield® XP
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Product Data Sheet Safety Data Sheet Show all documents

Usage

Sika® Galvashield® XP anodes may only be used by experienced professionals. 
  • Patch repairs. 
  • Interfaces between new and existing concrete. 
  • Slab replacements. 
  • Expansion joint repairs. 
  • Repair of epoxy-coated rebar. 
  • Bridge widening and other structural modifications. 
  • Repair of pre-stressed and post-tensioned concrete. 
  • Mitigates ring anode formation (i.e. the 'halo effect') in concrete repairs. 
  • Extends the life of concrete and joint repairs. 
 

Advantages

  • Proven technology - supported by independent test programme.  
  • Sika® Galvashield® XP is the original embedded galvanic anode with an extensive 20-year track record.
  • Type 1A anode - alkali-activated to maintain activity of the zinc; meets building code requirements that prohibit intentionally added constituents that are corrosive to reinforcement with the repair area. 
  • Easy to install - innovative single wire One-and-Done™ connection can be installed twice as fast as traditional two wire connections, saving up to 50% on installation labour costs.  
  • Focused protection - provides localised corrosion protection where it is needed the most, at the interface of the repair and the remaining contaminated concrete.
  • Cast zinc core - provides high anode utilisation and a secure long-term connection between the zinc and the integral lead wire. 
  • BarFit™ design - grooved edges on Sika® Galvashield® XP2, XP4 and XPX anodes assist with secure anode placement. 
  • Steel connection wires - provides dependable steel-to-steel contact with no intermediate materials (e.g. galvanising) that may impede the long-term electrical connection. 
  • Economical - provides localised protection where it is needed the most, at the interface between the repair and the remaining contaminated concrete.
  • Versatile - effective in chloride-contaminated and carbonated concrete containing chlorides. Can be used for both conventionally reinforced and prestressed or post-tensioned concrete.
  • User friendly - installation is quick and easy, requiring no special equipment or training.
  • Low maintenance – requires no external power source or system monitoring.
  • Measurable – anode performance can be easily monitored if required.
  • Does not cause hydrogen embrittlement.
  • ICRI CSP-3 (Concrete Surface Profile) - raised ridges provide increased surface profile to promote mechanical bond between repair mortars and concrete. 
  • Does not cause hydrogen embrittlement.
  • Long lasting – minimum 20 year anode service life* when using standard design tables, reduces the need for future repairs.
  • Full System – can be used in conjunction with Sika® FerroGard® and Sikagard® technologies to offer a total corrosion management system.
 
  • Independent testing - indicates concrete repair service life can be extended by more than 400%.
         * As with all galvanic protection systems, service life is dependent upon a number of factors including reinforcing steel density, concrete conductivity, chloride concentration, humidity and anode spacing. 

Packaging

Sika® Galvashield® XP Compact

50 units per box

6.8 kg box

Sika® Galvashield® XPT

50 units per box

9.1 kg box

Sika® Galvashield® XP2

40 units per box

10.2 kg box

Sika® Galvashield® XP430 units per box12.0 kg box
Sika® Galvashield® XPX20 units per box13.6 kg box

Product Details

Product Information

Shelf Life

24 months

Storage Conditions

Store in original unopened, sealed and undamaged packaging in dry and cool conditions. Avoid extremes of temperature and humidity. 

Dimensions

Product Names

Anode Types

Anode Dimensions (nominal)

Zinc Masses (g)

Sika® Galvashield® XP CompactType 1A25 mm x 31 mm x 64 mm40

Sika® Galvashield® XPT

Type 1A

24 mm x 28 mm x 100 mm

60

Sika® Galvashield® XP2

Type 1A

32 mm x 34 mm x 100 mm

100

Sika® Galvashield® XP4

Type 1A

33 mm x 35 mm x 130 mm

160

Sika® Galvashield® XPXType 1A33 mm x 35 mm x 170 mm330

Anode Type:
First character indicates where the anode is installed: 1) Embedded in concrete repairs; or 2) Embedded into sound concrete. 
Second character denotes the type of zinc activation utilised: A) Alkali-activated using high pH; or H) Halide-activated using corrosive salts.
System information

System Structure

Sika® Galvashield® XP anodes are part of a Concrete Repair System in accordance with the guidelines of BS EN 1504-9. 

Bonding Primer

  • Sika® MonoTop®-1010: Bonding primer and reinforcement coating (normal applications). 
  • SikaTop® Armatec®-110 EpoCem®: Bonding primer and reinforcement coating (demanding requirements). 

Repair Mortar

  • Sika® MonoTop®-4012: Class R4 Hand and wet spray applied repair mortar (low resistivity - can be used for anode embedment). 
  • Sika® MonoTop®-615: Class R3 Hand and wet spray applied high build repair mortar. 
  • Sika® MonoTop®-614 F: Class R4 Pourable repair mortar. 
  • Sika® MonoTop®-4052: Class R4 Pourable concrete repair mortar for horizontal applications (low resistivity - can be used for anode embedment). 
  • Sika® MonoTop®-630 Rapid: Class R4 Hand applied fast setting repair mortar. 
  • SikaCem®-133 Gunite Range: Class R4 Dry spray applied repair mortars. 

Smoothing Coat

  • Sika® MonoTop®-3020: Smoothing / levelling / fairing coat. 

Corrosion Inhibitor

  • Sika® FerroGard®-903+: Active corrosion inhibitor. 

Embedding Mortar

  • Sika® Galvashield® Embedding Mortar: Mortar for embedding Sika® Galvashield® XP Compact / XPT / XP2 / XP4 / XPX. 

         

NOTE: For optimum performance, use an ionically conductive, cement-based repair mortar or concrete. In accordance with ISO 12696, electrical resistivity and mechanical properties of the repair material shall be compatible with the original concrete. Repair materials typically should have an electrical resistivity of half to two times the resistivity of the parent concrete when measured under the same exposure conditions. If repair materials with a saturated bulk resistivity of 50,000 Ω·cm or greater are to be used, pack Sika® Galvashield® Embedding Mortar, Sika® MonoTop®-4012 or Sika® MonoTop®-4052 (or another repair mortar with a resistivity of 15,000 Ω·cm or less) between the anode and the substrate to provide an ionically conductive path to the substrate. Sika® MonoTop®-4012 and Sika® MonoTop®-4052 can be used to embed anodes and complete the concrete repair.
Technical Information

Design Considerations

Table 1 - Design Criteria: 

Corrosion Risk Category

Chloride Content***

Minimum Current Density at 20 Years

Low to Moderate

<0.8%

0.4mA/m2

High

0.8 to 1.5%

0.8mA/m2

Extremely High

>1.5%

1.6mA/m2

*** Chloride content is calculated as a percentage by weight of cement. 

Anode Spacing

The following anode spacing guidelines are based on achieving the minimum current density for the appropriate corrosion risk category 20 years after installation.

NOTE: In warmer or more demanding conditions (such as marine environments), Sika® Galvashield® XPX anodes are recommended to achieve the 20 year anode life. 

Table 2 - Maximum Anode Spacing for New Construction and Carbonated Concrete:

Steel Density Ratio*

Sika® Galvashield® XPT / Sika® Galvashield® XP Compact**

Sika® Galvashield® XP2

Sika® Galvashield® XP4 / XPX

<0.3700 mm700 mm700 mm
0.31 to 0.60700 mm700 mm700 mm
0.61 to 0.90580 mm700 mm700 mm
0.91 to 1.20500 mm700 mm700 mm
1.21 to 1.50440 mm680 mm700 mm
1.51 to 1.80400 mm600 mm700 mm
1.81 to 2.10370 mm560 mm700 mm

* Steel surface area / concrete surface area.

** Sika® Galvashield® XP Compact may have reduced life due to reduced zinc mass (40g). 

       

Table 3 - Maximum Anode Spacing for Low to Moderate Corrosion Risk (Chloride Content <0.8%***):

Steel Density Ratio*Sika® Galvashield® XPT / Sika® Galvashield® XP Compact**Sika® Galvashield® XP2Sika® Galvashield® XP4 / XPX
<0.3675 mm700 mm700 mm
0.31 to 0.60450 mm700 mm700 mm
0.61 to 0.90350 mm575 mm700 mm
0.91 to 1.20300 mm475 mm625 mm
1.21 to 1.50275 mm425 mm550 mm
1.51 to 1.80250 mm375 mm500 mm
1.81 to 2.10225 mm350 mm475 mm

* Steel surface area / concrete surface area.

** Sika® Galvashield® XP Compact may have reduced life due to reduced zinc mass (40g). 

*** Chloride content is calculated as a percentage by weight of cement. 

       

Table 4 - Maximum Anode Spacing for High Corrosion Risk (Chloride Content 0.8% to 1.5%***):

Steel Density Ratio*

Sika® Galvashield® XPT / Sika® Galvashield® XP Compact**

Sika® Galvashield® XP2

Sika® Galvashield® XP4 / XPX

<0.3450 mm700 mm700 mm
0.31 to 0.60300 mm475 mm625 mm
0.61 to 0.90250 mm375 mm500 mm
0.91 to 1.20200 mm325 mm425 mm
1.21 to 1.50175 mm275 mm375 mm
1.51 to 1.80150 mm250 mm350 mm
1.81 to 2.10125 mm225 mm325 mm

* Steel surface area / concrete surface area.

** Sika® Galvashield® XP Compact may have reduced life due to reduced zinc mass (40g). 

*** Chloride content is calculated as a percentage by weight of cement. 

     

 

Table 5 - Maximum Anode Spacing for Extremely High Corrosion Risk (Chloride Content >1.5%***):

Steel Density Ratio*

Sika® Galvashield® XPT / Sika® Galvashield® XP Compact**

Sika® Galvashield® XP2

Sika® Galvashield® XP4 / XPX

<0.3300 mm475 mm625 mm
0.31 to 0.60200 mm325 mm425 mm
0.61 to 0.90175 mm250 mm350 mm
0.91 to 1.20150 mm225 mm275 mm
1.21 to 1.50125 mm175 mm250 mm
1.51 to 1.80100 mm150 mm225 mm
1.81 to 2.10N/A125 mm200 mm

* Steel surface area / concrete surface area.

** Sika® Galvashield® XP Compact may have reduced life due to reduced zinc mass (40g). 

*** Chloride content is calculated as a percentage by weight of cement.

        

NOTE: Spacing should be reduced for continuously wet substrates to extend the expected service life of the anode. Where stirrups in beams or columns are exposed, place a Sika® Galvashield® XPT / XP2 / XP4 / XPX anode at each stirrup location. Spacings are based on an average annual temperature of 10°C. 

Application

Application steps

APPLICATION

Substrate Quality and Preparation

Concrete
Break out the concrete from around and behind the reinforcement steel in accordance with the requirements of the Product Data Sheet for the appropriate BS EN 1504-3 Classification concrete repair mortar.

        

Steel Reinforcement
Rust, scale, mortar, concrete, dust and other loose and deleterious material which reduces bond or contributes to corrosion shall be removed to a minimum standard of SA 2½. The whole circumference of the exposed reinforcement shall be uniformly cleaned except where structural considerations prevent it. Reference should also be made to BS EN 1504-10 for specific requirements.

Steel preparation may be carried out by removing loose rust by very thorough scraping, hand or machine wire brushing, abrasive paper / cloth, grinding or other appropriate techniques to achieve the required final surface condition.

Method and choice of cleaning shall take into account bar congestion, contact between bars, proximity to concrete substrate, etc.

Extra preparation of the steel should be carried out in the area of the anode tie wire connection to provide a bright steel finish to ensure a good electrical connection. Alternatively drill a small hole in the reinforcement at both ends of the anode position to accept a mild steel self tapping screw and wrap the anode tie wires around the screws.

After removal of the rust to the required standard. Clean the steel reinforcement with a dry clean brush.

The anodes and repair materials should be installed immediately following preparation and cleaning of the steel reinforcement. 

         

Bonding Primer / Reinforcement Coating

Bonding Primer:
When a bonding primer is required, apply Sika® MonoTop®-1010 (normal applications) or SikaTop® Armatec®-110 EpoCem® (demanding applications, such as high chloride locations).

Reinforcement Coating:
Where a reinforcement coating is required apply Sika® MonoTop®-1010 (normal applications) or SikaTop® Armatec®-110 EpoCem® (demanding applications, such as high chloride locations).
IMPORTANT

When Sika® MonoTop®-1010 or SikaTop® Armatec®-110 EpoCem® is used as a reinforcement coating or bonding primer, it is important not to allow the coating to get inbetween the connection wire and steel, as this will act as an insulator from the zinc core.

        

Application Method

  • The location and spacing of the anodes shall be as specified by the designer (for more information refer to Design considerations above).
  • Anodes are typically tied on the side or beneath the exposed reinforcement as close as practical to the edge of the surrounding concrete, making sure that enough space is left to fully encapsulate the anode with the Sika® Galvashield® Embedding Mortar, Sika® MonoTop®-4012 or Sika® MonoTop®-4052 (or another suitable mortar). 
  • Minimum cover over the anodes / embedment mortar must be 20 mm, or the minimum thickness of the concrete repair material for trafficked areas; 10 mm, or minimum thickness of the concrete repair material, for non-trafficked areas.
  • A 20 mm minimum clearance on sides adjacent to repair edge should be maintained. Where chloride contaminated concrete remains in contact with reinforcement, place Sika® Galvashield® XPT / XP2 / XP4 / XPX anodes along the length of reinforcement, or in grid pattern at spacings recommended in the appropriate Tables above.
  • Securely fasten the anodes on the side beneath the exposed rebar, as close as practical to the surrounding concrete (preferably within 100 mm) while ensuring that enough space remains to fully encapsulate the anode in the repair. The minimum cover of the repair material over the anodes should be 20 mm. 
  • Wrap the tie wires around the clean reinforcing steel at least one full turn in opposite directions.
  • Bring the two free ends together and twist tight.
  • Anode-to-steel continuity and steel-to-steel continuity within the repair cavity should be verified with an appropriate meter; discontinuous steel should be tied to continuous bars using steel tie wire and retested. A value between 0 and 1Ω should be achieved.
  • If the repair procedures require the concrete surface to be saturated with water, do not damage the anode nor allow the anode units to be soaked for greater than 20 minutes.
  • With the anodes securely in position, begin the repair process by packing the embedment mortar between the anode and the substrate to provide a conductive path to the substrate.
  • Allow the embedment mortar to sufficiently harden around Sika® Galvashield® XP Compact / XPT / XP2 / XP4 / XPX anode before applying concrete repair mortar.
  • Complete repair with the appropriate BS EN 1504-3 Classification concrete repair mortar and, where applicable, a cementitious bonding primer.

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