UNIFIED FACILITIES CRITERIA (UFC) CATHODIC PROTECTION
UFC 3-570-0128 November 2016Change 1, 14 January 2019UNIFIED FACILITIES CRITERIA (UFC)CATHODIC PROTECTIONAPPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED
UFC 3-570-0128 November 2016Change 1, 14 January 2019UNIFIED FACILITIES CRITERIA (UFC)CATHODIC PROTECTIONAny copyrighted material included in this UFC is identified at its point of use.Use of the copyrighted material apart from this UFC must have the permission of thecopyright holder.U.S. ARMY CORPS OF ENGINEERSNAVAL FACILITIES ENGINEERING COMMANDAIR FORCE CIVIL ENGINEER CENTER (Preparing Activity)Record of Changes (changes are indicated by \1\ . /1/)Change No.1Date14 Jan 2019LocationParagraphs 1-2, 1-4, 1-7, 2-2 and 2-3This UFC supersedes UFC 3-570-02A, dated March 2005 and 3-570-02N datedJanuary 2004.
UFC 3-570-0128 November 2016Change 1, 14 January 2019FOREWORDThe Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and providesplanning, design, construction, sustainment, restoration, and modernization criteria, and appliesto the Military Departments, the Defense Agencies, and the DoD Field Activities in accordancewith USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects andwork for other customers where appropriate. All construction outside of the United States isalso governed by Status of Forces Agreements (SOFA), Host Nation Funded ConstructionAgreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, theSOFA, the HNFA, and the BIA, as applicable.UFC are living documents and will be periodically reviewed, updated, and made available tousers as part of the Services’ responsibility for providing technical criteria for militaryconstruction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval FacilitiesEngineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) areresponsible for administration of the UFC system. Defense agencies should contact thepreparing service for document interpretation and improvements. Technical content of UFC isthe responsibility of the cognizant DoD working group. Recommended changes with supportingrationale should be sent to the respective service proponent office by the following electronicform: Criteria Change Request. The form is also accessible from the Internet sites listed below.UFC are effective upon issuance and are distributed only in electronic media from the followingsource: Whole Building Design Guide web site http://dod.wbdg.org/.Refer to UFC 1-200-01, DoD Building Code (General Building Requirements), forimplementation of new issuances on projects.AUTHORIZED BY:GEORGE O. LEA, P.E.JOSEPH E. GOTT, P.E.Chief, Military Engineering BranchU.S. Army Corps of EngineersChief EngineerNaval Facilities Engineering CommandEDWIN H. OSHIBA, SES, DAFDeputy Director of Civil EngineersDCS/Logistics, Engineering &Force ProtectionMICHAEL McANDREWDirector, Facilities Investment and ManagementOffice of the Deputy Under Secretary of Defense(Installations and Environment)
UFC 3-570-0128 November 2016Change 1, 14 January 2019UNIFIED FACILITIES CRITERIA (UFC)NEW SUMMARY SHEETDocument: UFC 3-570-01, Cathodic ProtectionSuperseding: UFC 3-570-02A, Cathodic Protection, March 2005UFC 3-570-02N, Electrical Engineering Cathodic Protection, Jan 2004Description: This UFC provides general design guidance for cathodic protection (CP)systems. This UFC applies to all Army, Navy, and Air Force service elements andcontractors.Reasons for Document: Update the format of the manual (more of a policy and guidance manual insteadof a technical cookbook on design) and unify UFC 3-570-02A and UFC 3-57002N. Incorporate policy, guidelines, and procedures previously identified inEngineering Technical Letters and Interim Technical Guidance Documents. Provide additional guidance to the Project Design Engineer (PDE) in managingCP design contracts and guidance on commissioning of CP systems. Incorporate information regarding new technologies and update obsoletetechnical information.Impact: Clarifies policy where CP must be provided. Provides more guidance to the PDEmanaging a CP Architect-Engineer (A-E) design contract to help improvedesigns. Previously, the manual only described technical requirements for theactual designers. Helps ensure CP provided where necessary and properlydesigned to ensure economical long-term facility/structure life cycle cost.Unification Issues \1\Para 2-2 Structures for which CP is Mandatory. Navy has relaxed this forsome structures and requires these structures to be evaluated for CPrequirements. Para 2-3 Navy has relaxed the mandatory requirement that DoD CP systemsreviewers be certified. /1/
UFC 3-570-0128 November 2016Change 1, 14 January 2019TABLE OF CONTENTSCHAPTER 1 INTRODUCTION . 11-1PURPOSE AND SCOPE. . 11-2APPLICABILITY. . 11-3GENERAL BUILDING REQUIREMENTS. . 11-4REFERENCES. . 11-5GLOSSARY. . 11-6CYBERSECURITY. . 11-7RECONCILIATION WITH OTHER UNIFIED FACILITIES CRITERIA. . 3CHAPTER 2 CATHODIC PROTECTION SYSTEMS POLICY . 42-1INTRODUCTON. . 42-2STRUCTURES FOR WHICH CP IS MANDATORY. . 42-2.1POL Facilities and Structures. . 52-2.2Underground Storage Tank System. . 52-2.3Natural Gas Pipe Lines. . 52-2.4Waterfront Structures. . 72-2.5Buried or Submerged Steel Utility Piping. . 72-2.6Ductile or Cast Iron Utility Piping. . 72-2.7Potable Water Storage Tanks. . 72-2.8Fire Protection Water Storage Tanks. . 82-3OTHER STRUCTURES FOR WHICH CATHODIC PROTECTION MUSTBE EVALUATED. . 82-4PROTECTIVE COATINGS SPECIFICIED IN CONJUNCTION WITHCATHODIC PROTECTION. . 92-5ISOLATION OF COPPER WATER PIPES FROM FERROUS PIPES. . 92-6CP PROJECT PLANNING. . 92-6.1General CP Requirements. . 92-6.2Environmental/Site Concerns. . 9CHAPTER 3 DESIGN REQUIREMENTS . 113-1INTRODUCTION. . 113-2APPLICABLE CODES AND REGULATIONS. . 113-3SYSTEM DESIGN. . 113-3.1Two types of CP systems. . 113-3.2Field Surveys and Tests. . 13i
3-3.3UFC 3-570-0128 November 2016Change 1, 14 January 2019Availability of AC Power (ICCP Systems). . 143-3.4Environmental/Site Concerns. . 143-3.5Electrical Continuity. . 153-3.6Identification of Other Structures in the Area. . 163-3.7Electrical Isolation. . 173-3.8Connecting Electrical Wires and Cables. . 173-3.9Connections and Splices. . 173-3.10Hazards Associated with Cathodic Protection. . 183-3.11Special Requirements. . 193-3.12Easement Issues. . 203-3.13CP System Protection Criteria. . 203-3.14System Maintainability. . 203-3.15Design Submittals. . 213-3.16Design Build. 223-4DESIGN FOR CONSTRUCTABILITY. . 233-4.1Identification of Issues During Design Field Survey. . 233-4.2Prevention of Damage to Existing Structures/CP System Components. . 243-4.3Commissioning. . 24CHAPTER 4 CATHODIC PROTECTION SYSTEM COMPONENTS . 264-1INTRODUCTION. . 264-2GALVANIC ANODE SYSTEMS. . 264-2.1Anodes. 264-2.2Backfill. . 274-2.3Connecting Wires. . 284-3IMPRESSED CURRENT SYSTEMS. . 284-3.1Anodes. 284-3.2Backfill. . 284-3.3Anode/Structure Lead Wires and Header Cables. . 294-3.4Deep Anode Bed Design. . 294-3.5Rectifiers and Other DC Power Supplies. . 344-4OTHER COMPONENTS. 354-4.1Electrical Continuity and Isolation. . 354-4.2Connections and Splices. . 37ii
4-4.3UFC 3-570-0128 November 2016Change 1, 14 January 2019Test Stations. . 394-4.4Permanent Monitoring Electrodes and Probes. . 404-5SPECIAL TECHNOLOGICAL CONSIDERATIONS. . 414-5.1Remote Monitoring. . 414-5.2Pre-engineered CP for Underground Storage Tanks. . 424-5.3Aboveground (on-grade) Storage Tanks. 434-5.4CP Systems for Reinforcing Steel in Concrete. . 434-5.5Water Storage Tanks. . 474-5.6Hot Water Storage Tanks. . 48APPENDIX A REFERENCES . 49APPENDIX B BEST PRACTICES . 53B-1CATHODIC PROTECTION PLANNING. . 53B-1.1Project Documentation. 53B-1.2Corrosion Control/CP System Assistance. 54B-2CP SYSTEM DESIGN CONTRACT PROCESS. . 54B-2.1Project Documentation. 54B-2.2Developing A-E Scope of Work. . 54B-2.3What Information to Provide A-E. . 55B-2.4Deliverables – What to Expect from the A-E. . 56B-2.5Common Problems/Lessons Learned with A-E Designs. 56B-3CP SYSTEM DESIGN DOCUMENTATION. . 57B-3.1DESIGN BASIS. . 57B-3.2DESIGN DRAWINGS. . 58B-3.3Specifications. 59B-3.4Common Problems/Lessons Learned with Design Documents. . 60B-4TYPES OF CP SYSTEMS. . 62B-4.1GALVANIC CP SYSTEMS. 62B-4.2IMPRESSED CURRENT SYSTEMS. . 65B-5GENERAL DESIGN PRINCIPLES. . 71B-5.1DESIGN APPROACH. . 71B-5.2DESIGN PARAMETERS AND CONSIDERATIONS. . 72B-5.3GENERAL CATHODIC PROTECTION DESIGN PROCESS. . 73B-6TYPICAL DESIGN CALCULATIONS. 78iii
B-6.1UFC 3-570-0128 November 2016Change 1, 14 January 2019Calculate Structure Surface Area to be Protected. . 79B-6.2Calculate Cathodic Protection Current Requirements. . 79B-6.3Determine CP System Circuit Resistance. 79B-7OTHER CP SYSTEM COMPONENT DESIGN CONSIDERATIONS. . 86B-7.1Connecting Wires. . 86B-7.2Connections and Splices. . 90B-7.3Bonds and Insulating Joints. . 91B-7.4Test Stations - Location and Function. 91B-8DESIGN PRACTICES THAT FACILITATE OPERATION ANDMAINTENANCE. . 95B-8.1As Built Drawings. . 96B-8.2Locate Equipment Where Readily Maintainable. . 96B-8.3Test Stations. . 97B-8.4Markers and Labeling. . 98B-8.5Test Access. . 98B-8.6Permanent Reference Electrodes (PRCs). . 98B-8.7Electrical Resistance Probes. . 99B-8.8Coupon Test Station System. . 101B-8.9Anode Current Output. . 102B-8.10Electrical Isolation Testing. . 102B-8.11Remote Monitoring. . 103B-8.12GPS Synchronizable Interruption. . 104B-9LESSONS LEARNED AND OTHER PRECAUTIONS FOR CP SYSTEMDESIGN. . 104B-9.1Common Problems and Design Deficiencies. . 104B-10SPECIALIZED CP TECHNOLOGY AND CONSIDERATIONS. . 114B-10.1Deep Anode Beds. . 114B-10.2Pre-engineered Cathodic Protection for Underground Storage Tanks. 118B-10.3CP Systems for Reinforcing Steel in Concrete. . 120B-10.4Interior of Potable Water Tanks. . 128B-10.5Hot Water Storage Tanks. . 132B-11CP SYSTEM COMMISISONING. . 135B-11.1System Commissioning Procedures. . 135B-11.2System Commissioning FAQs. . 137iv
UFC 3-570-0128 November 2016Change 1, 14 January 2019APPENDIX C GLOSSARY . 138APPENDIX D EXAMPLE CATHODIC PROTECTION DESIGN DETAILS . 143FIGURESFigure 3-1 Schematic Illustration of a GCP System . 12Figure 3-2 Schematic Illustration of a ICCP System . 13Figure 4-1 Schematic of a typical deep well anode bed . 31Figure 4-2 Small Solar Powered CP System. Solar Panels Shown in Picture on Left.Battery Bank and Control Center Shown on Right. 35Figure 4-3 Bond Wire Installed Between Two Electrically Isolated Pipe Sections . 36Figure 4-4 Exothermic Weld of CP System Wiring to the Structure . 38Figure 4-5 Mechanical Connection of Wiring to the Structure . 38Figure 4-6 STI-P3 Tank . 42Figure 4-7 Titanium Mesh Anodes Fastened to a Concrete Beam . 44Figure 4-8 Discrete Zinc Anode (Wrapped in Green Mesh) in Concrete Deck Repair.Device with Yellow Lead Wire is a Permanent Reference Electrode. . 45Figure 4-9 Discrete Zinc Anodes in Fiberglass Jacket for Pile Installation. . 46Figure 4-10 Photos Showing “Before” and “After” Installation of Integrated Pile RepairSystems . 46Figure B-3 Wenner Four Electrode Method Schematic . 75Figure B-4 Wenner Four Electrode Method for Measuring Soil Resistivity . 75Figure B-5 Measuring Soil Resistivity in a Soil Box . 76Figure B-6 Typical Ground Flush Mount Test Station . 92Figure B-7 Above Grade Test Stations. PVC Pipe Mount on the Left, Pole Mount in theCenter, and Wall Mount on the Right. . 92Figure B-8 Resistors in an Above Grade Terminal Box . 93Figure B-9 Flush Mounted Current-Potential Test Station . 94Figure B-10 Pipe Mounted Test Station. Figure on Right is a Close-Up of the TestStation “Head” or Terminal Board. . 94Figure B-11 Wall/Pole Mount Type Test Station. . 95Figure B-12 Rectifiers Located for Ease of Maintenance. . . 96Figure B-13 Test Station Marker for Flush Mount Test Station. . 97Figure B-14 Small Flush Mounted Test Station with Too Many Large Sized Wires. . 98Figure B-15 Example of an ER Probe . 99Figure B-16 Probe with Encapsulated Connector. . 101Figure B-17 Pre-Assembled Conduit System, Probe, and PRC for Submerged Use. . 101Figure B-18 Anode Junction Box . 102Figure B-19 Interference on Pipeline in Vicinity of a DC Powered Rail System. . 111Figure B-20 Interference on Foreign Pipelines in the Vicinity of a CP System. . 112Figure B-21 Placing Anodes to Minimize Interference. . 113Figure B-22 Centralizers Installed on High Silicon Cast Iron Anodes. 116Figure B-23 Anode Column Vent Pipes Run Outside of Anode Junction Box. . 117Figure B-24 Severe Corrosion of Cast Iron Cover on the Anode Well Head Box CausedBy Chlorine Gas Vented into the Box. . 117Figure B-25 STI-P3 Tank . 119v
UFC 3-570-0128 November 2016Change 1, 14 January 2019Figure B-26 Titanium Mesh Anodes Fastened to a Concrete Beam . 122Figure B-27 Discrete Zinc Anode (Wrapped in Green Mesh) in Concrete Deck Repair.Device with the Yellow Lead Wire is a Permanent Reference Electrode. . 124Figure B-28 Discrete Zinc Anodes in Fiberglass Jacket for Pile Installation. . 124Figure B-29 Photos Showing “Before” and “After” Installation of Integrated Pile Repairand CP Systems . 125Figure B-30 Typical Lifejacket Installation . 126Figure B-31 Concrete Demolished Around Entire Pile to Permit Installation of a BarWelded to Each Rebar to Establish Electrical Continuity. . 127Figure B-32 Octagonal Shaped Buoy Design. . 130Figure B-33 Umbrella-like Anode Support Structure Design. . 131Figure B-34 CP System for a Vertical Hot Water Tank with a Man-Way Access Opening. 133Figure B-35 CP System Rectifier and Anode Condulet Fitting on Side of Water Tank. 133Figure B-36 Close up of Condulet Fitting Showing Anode Rod Extending Out of theStorage Tank. 134Figure B-37 Reference Electrode Placed in Contact with Moist Wadding TemporarilyPlaced Inside of the Capillary Tube Monitoring Port. . 134Figure D-1 Example GCP Anode Installation Detail . 143Figure D-2 Example ICCP Anode Installation Detail . 144Figure D-3 Example Deep Anode Installation Detail . 145Figure D-4 Example GCP Anode Detail . 146Figure D-5 Example Seawater GCP Anode Detail . 147Figure D-6 Example ICCP Oil Cooled Rectifier Detail . 148Figure D-7 Example Anode Junction Box Detail . 149Figure D-8 Example Flush Mount Test Station Detail. 150Figure D-9 Example Flush Mount Bond Test Station Detail . 151Figure D-10 Example Soil Access Test Station Detail . 152Figure D-11 Example Dielectric Insulation Flange Detail . 153Figure D-12 Example Exothermic Weld Detail . 154Figure D-13 Example Electrical One-Line Schematic Diagram . 155TABLESTable 1-1. UFC Documents Requiring Reconciliation of CP System Requirements andCriteria . 3Table B-1. General CP System Cost Guidelines . 53Table B-2. Advantages/Limitations of GCP Systems . 63Table B-3. Advantages/Limitations of ICCP Systems. 65Table B-4. Current Density Requirements for Cathodic Protection of Bare Steel. 80Table B-5. Common Problems with GCP System Designs . 105vi
UFC 3-570-0128 November 2016Change 1, 14 January 2019CHAPTER 1 INTRODUCTION1-1PURPOSE AND SCOPE.This UFC provides policy and design requirements for cathodic protection (CP)systems. This document provides the minimum design requirements, and must beutilized in the development of plans, specifications, calculations, and Design/BuildRequest for Proposals (RFP).UFC 3-501-01, Electrical Engineering, provides the governing criteria for electricalsystems, explains the delineation between the different electrical-related UFCs, andrefers to UFC 3-570-01 for Cathodic Protection requirements. Refer to UFC 3-501-01for design analysis, calculation, and drawing requirements.1-2APPLICABILITY.Compliance with this UFC is mandatory for Department of Defense (DoD) facilitieslocated on or outside of DoD installations, whether acquired by appropriated or nonappropriated funds, or third party finance and constructed.\1\For Navy projects, third party financed and constructed projects are not required tomeet this UFC’s requirements except for provision and extension of Navy-owned orGovernment-owned systems and infrastructure that are extended to the third party'ssite. /1/1-3GENERAL BUILDING REQUIREMENTS.UFC 1-200-01, General Building Requirements, provides applicability of model buildingcodes and government-unique criteria for typical design disciplines and buildingsystems, as well as for accessibility, antiterrorism, security, sustainability, and safety.Use this UFC in addition to UFC 1-200-01 and the UFCs and government criteriareferenced therein.1-4REFERENCES.Appendix A contains a list of references used in this document. The publication date ofthe code or standard is not included in this document. In general, the latest availableissuance of the reference is used.\1\For Navy projects, the reference date is set by the contract or RFP date. /1/1-5GLOSSARY.Appendix C contains acronyms, abbreviations, and terms.1-6CYBERSECURITY.All control systems (including systems separate from an energy management controlsystem), remote monitoring units, and automated data collection units must be planned,1
UFC 3-570-0128 November 2016Change 1, 14 January 2019designed, acquired, executed and maintained in accordance with UFC 4-010-06; and asrequired by individual Service Implementation Policy.2
1-7UFC 3-570-0128 November 2016Change 1, 14 January 2019RECONCILIATION WITH OTHER UNIFIED FACILITIES CRITERIA.The CP requirements and criteria in this document will be reconciled with CPrequirements and criteria in other UFCs so that the required criteria are located in asingle location; the other UFCs and criteria documents will refer to UFC 3-570-01. Inthe event there is a conflict between these criteria and other criteria in anotherdocument, these criteria govern. The documents listed in Table 1-1 are known to beaffected by the requirements and criteria in this document.Table 1-1. UFC Documents Requiring Reconciliation of CP SystemRequirements and CriteriaDOCUMENTUFC 3-230-01UFC 3-460-01UFC 3-460-03UFC 3-570-06UFC 4-150-07UFC 4-151-10UFC 4-152-01TITLEWater Storage, Distribution and TransmissionDesign: Petroleum Fuel FacilitiesOperation and Maintenance: Maintenance of PetroleumSystemsOperation and Maintenance: Cathodic ProtectionSystemsMaintenance and Operation: Maintenance ofWaterfront FacilitiesGeneral Criteria for Waterfront ConstructionDesign: Piers and Wharves3
UFC 3-570-0128 November 2016Change 1, 14 January 2019CHAPTER 2 CATHODIC PROTECTION SYSTEM PLANNING2-1INTRODUCTON.In accordance with DoD Instruction 5000.67, Prevention and Mitigation of Corrosion onDoD Military Equipment and Infrastructure, consider corrosion prevention and control(CPC) as an integral part of the design, construction, sustainment, restoration andmaintenance o
UFC 3-570-01 28 November 2016 Change 1, 14 January 2019 . UNIFIED FACILITIES CRITERIA (UFC) NEW SUMMARY SHEET . Document: UFC 3-570-01, Cathodic Protection Superseding: UFC
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