Cathodic Protection Design for Steel in Concrete Structures

Module DD - Cathodic Protection Practical Measurement Demonstration

Welcome to Module DD: Cathodic Protection Practical Measurement Demonstration, an essential core component of the Fundamentals of Design for Cathodic Protection of Steel in Concrete Structures course.

This video-driven module provides definitive practical proof of the electrochemical engineering concepts established across your initial training pathway. Operating in direct sequence after Module D1 (Pre-Design Investigation), Module D2 (Introduction to Design Requirements), Module D3 (Introduction to Cathodic Protection), and Module D4 (Methods of Providing Cathodic Protection Energy), this unit functions as the visual bridge connecting dense corrosion theory to real-world performance metrics.

Through detailed, pre-recorded laboratory testing videos, you will witness exactly how galvanic protection networks and impressed current cathodic protection (ICCP) systems react to shifting environmental exposures. The curriculum bypasses abstract math to show you real-time physical diagnostic testing. You will observe precise steel-to-steel continuity testing in Ohms and millivolts (mV), baseline "as found" potential tracking, mixed or ON potentials, and accurate instant-off potential recording following circuit disconnection.

The module also delivers a rare visual breakdown of advanced electrochemistry, demonstrating how adding electrolyte salinity spikes total current flow, how an external 1.5V battery acts as an ICCP driving voltage, and how a reversed polarity connection actively forces a more noble metal (steel) to corrode to provide ICCP to a less noble metal (zinc).

To maximise field-ready diagnostic knowledge, this module integrates downloadable measurement sheets, laboratory results, and test objectives for your informational reference. You will learn how to plot these experimental findings directly onto standard and reversed Evans diagram corrosion models, enabling you to master polarisation decay analysis, evaluate thermodynamic shifts, and confidently audit system health in the field.

What You Will Learn

This video-driven module steps through the physical testing sequence to contrast standard galvanic protection with reversed-series impressed current behaviour.

Part 1: Pre-Test Validation & Baseline Metrics

  • Preceding Sequence Reinforcement: Validate core concepts from Modules D1 through D4 via observed laboratory testing.
  • Electrical Continuity Measurements: Observe multimeter checks to verify steel-to-steel continuity using resistance in Ohms and voltage in mV.
  • As Found Potential Tracking: Study open-circuit baseline potentials measured against a stable reference electrode.


Part 2: Galvanic System Dynamics (Standard Approach)

  • Standard Galvanic Protection: Observe electrons flowing naturally from a zinc sacrificial anode to protect steel.
  • Salinity Environmental Impacts: Witness how adding 100g of salt drops resistance and spikes corrosion current.
  • Standard Evans Diagram Mapping: Plot downward cathodic shifts for steel and upward anodic shifts for corroding zinc.


Part 3: Impressed Current, Series Reversal & Polarity Risks

  • Impressed Current Driving Voltages: Analyse how an external 1.5V battery safely boosts protective current to the steel.
  • Galvanic Series Reversal: See an external DC voltage completely override and flip the natural electrochemical hierarchy.
  • Reversed Series Protection: Learn how an external DC voltage connection can be used for the application of ICCP by forcing a more noble metal (steel) to protect a less noble metal (zinc).
  • Polarity Error Risks: Examine the catastrophic field risks where inverted wiring forces the steel structure to actively corrode.
  • Reversed Evans Diagram Mapping: Chart the thermodynamic energy shifts of a reversed circuit where steel is forced anodic, and the zinc is provided with ICCP.


Part 4: Post-Test Analysis & Reference Documentation

  • Mixed ON & Instant OFF Values: Measure combined (Mixed or On) potentials and capture Instant-Off potentials following current disconnection.
  • Informational Lab Documentation: Utilise downloadable measurement and results sheets to review data validation methods.

Who This Course Is For

This practical demonstration module scales fluidly to meet you at your current level of industry practice. It bridges the foundational concepts from Modules D1 through D4 with real-world laboratory visualisation, making it essential for:

  • Entry-Level Engineers & Corrosion Technicians: Newcomers who need to transition from the basic concepts of electron flow (Module D3) and energy methods (Module D4) to observing physical field-testing equipment, multimeter settings, and baseline potential tracking in action.


  • Concrete Repair Contractors & Site Inspectors: Trade experts who want to move beyond standard concrete patching (Module D8) and structurally observe how continuity faults, concrete electrolyte changes, and reversed polarity errors directly alter system longevity and asset protection.


  • Intermediate Designers & Project Managers: Professionals responsible for planning long-life mitigation projects who need to see how the concepts of structure assessment (Module D1) and detailed design requirements (Module D2) translate into verifiable laboratory performance data.


  • Senior Specialists & Corrosion Experts: Experienced practitioners aiming to validate complex configuration layouts, audit field data variations against standard and reversed Evans diagram corrosion models and reinforce criteria specified in global BS EN ISO 12696 benchmarks.


  • Asset Owners & Civil Infrastructure Managers: Stakeholders managing concrete bridges, marine structures, or civil assets who require a transparent, visual understanding of how galvanic and ICCP systems operate to optimise maintenance budgets and maximise service lifespans.

Course Delivery & Requirements

To maintain strict compliance and ensure professional-level mastery, this course utilises an integrated learning framework:

  • On-Demand Video Lessons: Watch step-by-step practical laboratory setups.


  • Comprehensive Downloads: Complete access to downloadable practical laboratory objectives and lab recording sheets with results (PDF) for offline reference.


  • Direct Expert Q&A: Submit technical questions directly through the online learning platform to John Paul Segers (MSc, CEng, FICorr, FIMMM, BS EN ISO 15257 Level 5 CP Expert).


  • Progression Gate: Learners must complete all video lessons and review all documentation before unlocking subsequent modules.


  • Members have access to the On-Demand Video Lessons and Quiz for 1 year from the date of registration, and complete access to downloadable slides (PDF) and the module overview (PDF) for offline reference.

Course Structure and Content

This element of the course has been extracted from the complete Fundamentals of Design for Cathodic Protection of Steel in Concrete Structures course as follows:

    1. Welcome and Course Overview - Video

    2. Purchasing Cathodic Protection Standards - Video

    1. Cathodic Protection Practical Measurement Demonstration - Overview

    2. Cathodic Protection Practical Measurement Demonstration - Lab Sheets

    3. Cathodic Protection Practical Measurement Demonstration - Part 1 Galvanic - Video

    4. Cathodic Protection Practical Measurement Demonstration - Part 2 ICCP - Video

    5. Cathodic Protection Practical Measurement Demonstration - Lab Results

About this course

  • £155.00
  • 7 lessons
  • 0.5 hours of video content

Module DD - Learning Outcomes

At the end of this module, you will have developed an understanding of:

  • A typical galvanic anode cathodic protection setup.
  • The impact of salt on the current flow and corresponding corrosion rate. 
  • The impact of an external voltage on the current flow of a galvanic cathodic protection system.
  • A typical impressed current cathodic protection system. 
  • How to measure electrical continuity.
  • How to measure the As Found Off potential of an anode and cathode.
  • How to measure the mixed On potential of an anode and cathode circuit.
  • How to measure an Instant Off potential of an anode and cathode circuit following cathodic protection. 
  • How to measure current flowing when the anode is connected to the cathode in a cathodic protection circuit.
  • How to plot the findings on an Evans diagram.
  • How an Evans diagram can be used to assist with understanding galvanic and impressed current cathodic protection.


Frequently Asked Questions (FAQ)

  • How does this practical demonstration fit into the overall course structure?

    Module DD bridges the gap between theory and practice, functioning as the direct visual validation of the electrochemical concepts taught in Modules D1, D2, D3, and D4. It acts as the necessary capstone to the initial sequence before you advance to later modules.

  • Do I need to perform physical laboratory experiments or submit test sheets?

    No, you do not need your own equipment. The module consists of high-quality, pre-recorded laboratory testing videos where an expert walks you through every step. The included measurement sheets, test objectives, and results are provided for your informational reference to help you study the data.

  • What specific parameters are visualised during the video lessons?

    You will watch real-time digital multimeter and reference electrode testing. This includes steel-to-steel continuity testing in Ohms and millivolts (mV), As-Found baseline open-circuit potentials, mixed or ON potentials, connected current flow spikes, and precise instant-off potentials captured upon circuit disconnection.

  • How does the demonstration illustrate the differences between galvanic and ICCP systems?

    The videos contrast a self-powered sacrificial zinc anode setup against an externally powered impressed current network. You will see how environmental factors like adding 100 grams of salt lower the concrete electrolyte resistance to drive up galvanic current, and how an external 1.5V battery safely acts as an ICCP driving voltage.

  • What is the benefit of demonstrating a reversed ICCP polarity connection?

    By intentionally reversing the DC battery connection, the video provides a powerful visual warning regarding field installation errors. You will learn the exact thermodynamics of how a reversed setup overrides the galvanic series, forcing a more noble metal (steel) to actively corrode while providing unintended cathodic protection to a less noble metal (zinc).

  • How are Evans diagrams used in this module?

    The module teaches you how to map recorded experimental data points directly onto graphical Evans diagram corrosion models. This allows you to visually track polarisation decay, chart shifting thermodynamic energy thresholds, and confidently interpret standard versus reversed-circuit behaviours.

Module DD - Cathodic Protection Practical Measurement Demonstration

Module DD is the fifth of ten modules which form the complete Fundamentals of Design for Cathodic Protection of Steel in Concrete Structures course.

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Continue with your Learning and Personal Development

Individual modules do NOT provide CPD hours. To unlock your 50-Hour Certified CPD Certificate, you must complete all 10 modules.

Module DD is the fifth of ten modules which form the complete Fundamentals of Design for Cathodic Protection of Steel in Concrete Structures course.

Completion of all modules of the full Fundamentals of Design for Cathodic Protection of Steel in Concrete Structures course provides you with a Continued Professional Development (CPD) completion certificate worth 50 hours.

I encourage you to continue with your learning and personal development to help identify that corrosion management can be used as an effective tool to support sustainable and low-carbon development now and in the future.