CathodicProtectionTestStations

TheGood,TheBad,andTheUgly!

JeffSchramukNACECPSpecialist#7695

630‐235‐1559www.cpsolutionsinc.net

1

Post‐TypeTestStation– ThirdPartyDamage

Wasn’t it obvious?

2

HowNOTtoWiretheTerminalBoard

Is there room for any more wires?

Lost my head!

3

HowNOTtoInstalltheTerminalBoard

Can I close the test station cover without

breaking off the wires?

Will the enclosure

drain?

4

FlushTestStation– WhoWillBeAbletoReadIt?

Future Traffic Lane

5

TerminalBoardw/oRingTongueWireConnectors

Test station wires merely wrapped around terminal posts will slip off when cover is twisted to close-lock

Bad Practice!

6

“Economy”Flush‐TypeTestStation&TerminalBoard

Can you see it?

Terminal Corrosion?

Bad Practice!

7

Flush‐StyleTestStation(ConcreteFilled)

Wires encased in concrete sidewalk cavity w/o proper drainage

Bad Practice!

8

FlushTestStation(WireHousingCutOff)

Bottom shaft of test station has been cut off

Bad Practice!

9

FlushTestStation(TooManyWires)

Where’s the Decoder?

Bad Practice!

10

CPTHHN‐THWNTestStationWireFailures

11Insulation crackedPoor Splice Technique

Bad Practice!

TestStationWiresNotProperlyBuried

Test station wires exposedBad

Practice!12

13

ShoddyRingTongueConnectorsonTestWires

If ring tongue connectors are used, make sure they are properly connected to the test wires!

Bad Practice!

TypicalUSACEFlushTestStationInstallation

Two test leads (gray) are

connected to the pipe. One pipe lead is connected to the anode (red wire) via the wire shunt. The other pipe lead is

terminated separately for

testing purposes.

Good Job!

14

T.S.Head– InstalledwithoutPEMountingPost

Result: Water and Silt Accumulates within Upside-Down Test Station

Problem: No Crushed Stone Installed on Bottom of Enclosure

Problem: Terminal Board Not Installed Upright within Enclosure

Result: Water and Silt Fills Test Station Enclosure

water

silt

15

16

CPTestStationWires– Protected UptoGrade

Test Station terminal board is mounted to top

of PE pipe

CP Test WiresRed: AnodesBlue: Pipe

Yellow: Reference Electrode

PE pipe protects CP wires down to bottom of

pipe trench

17

T.S.Enclosurew/oProperDrainage–After1Year

Cap is optional!?

Just cover it up!?

Bad Practice!

Interior of Enclosure w/TS Head (Damaged)Flush Enclosure

Standing water due to poor drainage from enclosure

Enclosure is poorly placed in low spot along roadside

T.S.Enclosurew/oDrainage–RealityPoursIn

18

TestStationEnclosure– AreTestWiresOptional?

Bad Practice!

Interior of Test Station Enclosure filled with mud but no test wires19

T.S.Enclosures– Designedfor“Incidental”Traffic

Bad Practice!Test station enclosures should never be paved over

20

ProperDrainageandWiringareImportant

ITS - No Gravel Drainage CTS - Proper Gravel Drainage

Disconnected wire from ring tongueMud fills bottom of enclosure21

AnodesWorkBetterWhenTheyAreConnected

Test Station w/Cover Removed

Terminal Board Front Terminal Board Back

Note: No wire shunt connection is installedbetween bonded 2 x #8 anode cables (red)and 1 x #8 structure (blue) cable

Wet sand fills bottom of enclosure22

Properly‐WiredAnodeTSTerminalBoard

Screw Terminals (Shunt & Shorting Bar) Binding Posts (All Incoming TS Wires)

23

InstalltheCorrect(Specified)TestStation

The test station cover is not suitable for teststations set within a flush enclosure since thecap’s “locking tab” cannot be easily released.

24

25

ASuitablePost‐TypeCPTestStationInstallation

Shown w/cap removed

Good Job!

26Concrete pad is optional per owner

Terminal board is mounted to PE Pipe

Crushed gravel provides drainage

Good Job!

SuitableFlush‐TypeCPTestStationInstallation

27

MoreFlush‐TypeCPTestStationInstallations

Good Job!

Note siltation - gravel allows thorough drainage

Marker Post is Optional

28

JeffSchramukNACECPSpecialist#7695

630‐235‐1559www.cpsolutionsinc.net

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