Corrspray™ Metalizing Anode System

Thermally Sprayed Galvanic Protection for Reinforced Concrete

Corrspray™ is a thermally applied galvanic anode system designed for the long-term protection of steel-reinforced concrete structures. Developed through a Federal Highway Administration research initiative, Corrspray™ uses a proprietary Aluminum-Zinc-Indium (Al-Zn-In) alloy wire that is electric arc-sprayed directly onto prepared concrete surfaces.

This advanced process forms a strong, adherent metalized coating that delivers protective current through natural galvanic action, requiring no external power source, making it ideal for use in a wide range of climates and environments. Corrspray™ is especially effective in drier regions, coastal areas, and sites with fluctuating temperatures, offering high output and low-maintenance protection.

From bridges and parking garages to piers, wharfs, and balconies, Corrspray™ supports infrastructure preservation across global markets, helping owners extend the life of critical concrete assets with minimal disruption.

Features & Benefits 

The Corrspray™ Metalizing Anode offers a unique combination of performance, durability, and ease of application. Key features include:

• High Protective Current Output: Provides 2–3 times the output of pure zinc anodes, ideal for actively corroding structures.

• Superior Performance in Dry and Variable Climates: Performs more reliably than zinc in low-humidity and temperature-fluctuating environments.

• No Ongoing Power or Monitoring Requirements: Galvanic operation eliminates external power supply needs and reduces maintenance demands.

• Strong Adhesion to Concrete Surfaces: Achieves 150–350 psi adhesion depending on substrate preparation.

• Thermally Applied Using Arc Spray: Allows for rapid installation over large areas—10–15 m²/hr coverage rate.

• Aesthetic Integration: Gray/silver finish closely resembles natural concrete for discreet protection.

• Flexible Wire Options: Available in two wire diameters to meet project specifications and application requirements.

• Long Service Life: Up to 10–20 years depending on structure environment

Best Applications for Corrspray™

Corrspray™ is the preferred solution for large-scale or complex reinforced concrete surfaces that require efficient galvanic protection without deep intrusion or permanent formwork. It’s especially useful in transportation, marine, and public infrastructure projects.

Recommended Use Cases:

• Bridge Substructures and Superstructures: Columns, beams, and decks exposed to road salt or deicing chemicals.

• Parking Garages: Balconies, columns, and floor slabs subject to weather exposure and vehicular chloride tracking.

• Piers and Wharfs: Marine structures affected by tidal splash, brackish water, or salt spray.

• Prestressed Concrete Elements: Non-intrusive protection that minimizes the risk of hydrogen embrittlement.

• Urban and Coastal Infrastructure: Ideal for vertical or overhead surfaces where minimal aesthetic impact is desired.

• Balconies, Facades, and Exposed Structural Concrete: Enhances corrosion resistance while preserving architectural appearance.