Fosroc Galvashield Fusion T2
Second-generation self-powered dual-phase hybrid anode that fuses an impressed-current burst with maintenance-free galvanic protection in one embedded unit.
What is it?
A Type 2 hybrid cathodic-protection anode that combines a self-generated impressed-current (ICCP) phase with a long-term alkali-activated galvanic phase inside a single unit embedded in drilled holes in sound concrete.
Where is it used?
Chloride- and carbonation-attacked reinforced concrete: multi-storey car parks, bridge decks, columns and beams, marine piers, wharves and balconies across coastal and urban India.
Why use it?
It arrests active rebar corrosion with an initial current burst, then ‘fits-and-forgets’ as a galvanic anode for 30+ years with no external power, wiring transformers or ongoing maintenance access.
How is it applied?
Drill a grid of holes in sound concrete avoiding rebar, pre-wet, set the wet anode in embedding mortar with min. 20 mm cover, connect to reinforcement, then wet-cure and protect for 24 hours.
About Fosroc Galvashield Fusion T2
Fosroc Galvashield Fusion T2 is a second-generation hybrid anode for controlling corrosion in reinforced-concrete structures, supplied in India by Space Arc Engineering. Manufactured by Vector Corrosion Technologies and distributed under the Fosroc brand, it belongs to the durability and repair-rehabilitation toolkit rather than to patch-repair mortars, because its job is to stop the underlying electrochemical process that destroys rebar in the first place. In Indian conditions, where chloride-rich coastal air, de-icing-free but humid monsoon cycles, carbonated cover concrete and high-salinity groundwater drive premature corrosion in flyovers, jetties, basement car parks and sea-facing balconies, a conventional ‘cut-out-and-patch’ repair often fails within a few years. The reason is the well-documented ‘ring-anode’ or ‘incipient-anode’ effect: once you place fresh, high-alkalinity repair mortar next to old chloride-contaminated concrete, the steel at the perimeter of the patch becomes anodic and corrodes faster. Galvashield Fusion T2 is designed to break that cycle. It is a Type 2 anode, meaning it is embedded directly into holes drilled in mechanically sound parent concrete, on a designed grid, rather than being cast into a repair patch. Each unit packs two technologies into one cylinder: a self-powered impressed-current cathodic-protection (ICCP) element and an alkali-activated galvanic anode with a zinc core. When the anode is installed and connected to the reinforcement, Phase 1 delivers an intense, self-generated current that polarises the steel and passivates the active corrosion sites. The unit then automatically transitions to Phase 2, behaving as a long-life galvanic anode that supplies a maintenance-free protective current for the remaining service life. Crucially, the whole system runs without any external DC power supply, transformer-rectifier, control panel or permanent monitoring cabling, which removes the single biggest cost and reliability headache of traditional ICCP systems. For Indian asset owners and consultants, that makes it a practical durability intervention for structures where access is difficult, downtime is expensive, or long-term electrical maintenance simply will not happen. Space Arc Engineering positions Galvashield Fusion T2 as the premium option within the Fosroc corrosion-management range, used where a design life of 30 years or more is genuinely required and where the structure justifies a corrosion engineer’s grid design.
The technical insight
The defining feature is the dual-phase, single-unit architecture. Phase 1 is an internally driven impressed-current pulse that does not need an external rectifier; the unit self-generates a high current density for a defined pre-treatment period, polarising the steel to passive potentials and re-establishing a protective alkaline environment at the rebar surface. Phase 2 is classic galvanic action: a zinc core complying with ASTM B418 Type II (high-purity zinc) is encased in an activated cementitious mortar buffered to a pH of 14 or greater. That high-alkalinity backfill keeps the zinc actively dissolving (sacrificially) instead of passivating, which is the failure mode of plain zinc anodes in concrete. The mortar is formulated with no intentionally added chloride, bromide or sulphate, in line with ACI 222R, so the anode itself introduces nothing corrosive to the steel. Anode spacing and the Phase 1 pre-treatment parameters are not off-the-shelf; they are engineered by Vector Corrosion Technologies for the specific structure, in conformance with the principles of ISO BS EN 12696:2016 (the international standard for cathodic protection of steel in concrete) and NACE/AMPP design practice. Three geometries cover most cases: Fusion T2 Standard (46 x 105 mm) for large capacity, Fusion T2 Slim (29 x 135 mm) for thin sections or congested reinforcement, and Fusion T2 X (46 x 130 mm) for extreme exposure. Minimum cover over the embedded anode is 20 mm, and anodes should sit at least 100 mm from steel, ideally centred in the reinforcement grid.
Where it is used
- Corrosion control and cathodic prevention in chloride-attacked reinforced concrete
- Durability upgrade of marine piers, jetties, wharves and sea-facing structures
- Multi-storey and basement car park repair where de-icing salts or leakage drive corrosion
- Bridge decks, piers, columns and beams on coastal and estuarine crossings
- Treatment of incipient-anode (ring-anode) zones around concrete patch repairs
- Balconies, parapets and facades on coastal high-rise buildings
- Industrial RCC in aggressive environments (effluent, process, splash zones)
- Life-extension of heritage and high-value structures where external ICCP wiring is impractical
Key advantages
- Two technologies in one unit: ICCP current burst plus long-term galvanic protection
- No external DC power supply, transformer-rectifier or control panel required
- Operates automatically once installed – genuinely ‘fit-and-forget’, reducing access cost
- Design life of 30+ years of corrosion protection without routine maintenance
- Phase 1 pre-treatment can be re-run later if a refresh is ever desired
- Zinc core to ASTM B418 Type II with high-alkalinity (pH 14+) activating mortar for sustained galvanic output
- Contains no intentionally added chloride/bromide/sulphate (ACI 222R) – safe to embed near steel
- Designed to ISO BS EN 12696:2016 principles, giving consultants a recognised compliance basis
- Targets corrosion at the source, avoiding the repeated patch-repair failure cycle
- Three sizes (Standard / Slim / X) suit thin sections, congested rebar or extreme exposure
Limitations & considerations
- Not a structural product – does not repair cracks, spalls or loss of section; a structural engineer must address structural damage
- Requires a corrosion engineer’s design: anode spacing and Phase 1 parameters are project-specific, not generic
- Embedded only in mechanically sound concrete; all delaminated/unsound concrete and repairs must be completed first
- Discontinuous reinforcement must be electrically connected or deliberately isolated, verified by multimeter continuity testing
- Galvanic service life depends on steel density, concrete resistivity, chloride level, humidity and spacing – not a fixed guarantee
- Installation is skilled work: rebar location, drilling without cutting steel, embedding without air voids, and continuity checks
- Made-to-order (MTO) item with lead time; not an over-the-counter stock product
- Higher upfront unit cost than discrete galvanic ‘puck’ anodes, justified on long-life, high-value assets
Selection & best practice
Always start with a corrosion survey – half-cell potential mapping, chloride profiling and cover/carbonation testing – and have Vector/Fosroc design the anode grid and Phase 1 pre-treatment to ISO BS EN 12696:2016 before ordering. Complete all structural and concrete repairs first; Fusion T2 controls corrosion but does not restore section. Use a rebar locator to set out drill positions that avoid cutting steel, keep anodes a minimum of 100 mm from reinforcement and ideally centred in the grid, and verify steel continuity with a multimeter. Pre-wet both the drilled holes and the anodes to a saturated-surface-dry condition, then bed the still-wet unit using Galvashield Embedding Mortar (or Fosroc Renderoc HB40 / Construction Grout as advised), filling the bottom two-thirds first and pressing the anode in so the annulus fills with no air voids. Maintain at least 20 mm cover over the anode, make rebar connections with the supplied Vector connectors, confirm continuity, then wet-cure the embedding mortar (or use a curing compound) and protect from traffic for 24 hours. Store unopened units in dry conditions, use within one year of manufacture, and install within one month of opening the container.
Specifications
| Product type | Self-powered dual-phase hybrid anode (Type 2, embedded in drilled holes) |
| Protection mechanism | Phase 1 impressed-current passivation, then Phase 2 galvanic cathodic prevention |
| Galvanic core | Zinc core to ASTM B418 Type II |
| Activating mortar | Alkali-activated cementitious mortar, pH 14 or greater |
| Aggressive ions | No intentionally added chloride/bromide/sulphate (per ACI 222R) |
| Fusion T2 Standard size | 46 x 105 mm (dia. x length); min. hole 50 x 135 mm |
| Fusion T2 Slim size | 29 x 135 mm (dia. x length); min. hole 35 x 165 mm |
| Fusion T2 X size | 46 x 130 mm (dia. x length); min. hole 50 x 160 mm |
| Minimum cover over anode | 20 mm |
| Spacing from steel | Minimum 100 mm from reinforcement; ideally centred in rebar grid |
| Design life | Up to 30+ years without maintenance (exposure-dependent) |
| External power | None – no transformer-rectifier, control panel or permanent wiring |
| Design standard | ISO BS EN 12696:2016 (also NACE/AMPP practice) |
| Packaging | 20 units per box (Standard / Slim / X); made-to-order |
| Embedding mortar | Galvashield Embedding Mortar 20 kg, or Renderoc HB40 / Construction Grout |
| Shelf life / storage | Up to one year from manufacture in dry, unopened containers; install within one month of opening |
Industry use cases
Marine & Ports
Jetties, wharves and piers along Indian coastlines (Mumbai, Chennai, Kochi, Visakhapatnam) suffer chloride-driven rebar corrosion in tidal and splash zones. Fusion T2 delivers a passivating current burst then decades of galvanic protection without dragging permanent power cabling across a working berth.
Transport Infrastructure
Coastal and river-crossing bridge decks, piers and pier caps where chlorides and carbonation attack reinforcement. The grid of embedded anodes extends service life and defers costly deck reconstruction with minimal traffic disruption.
Commercial & Parking Structures
Basement and multi-storey car parks where leakage, salt carry-in and poor drainage corrode slabs, beams and columns. The fit-and-forget operation suits buildings that cannot support ongoing ICCP maintenance regimes.
Coastal High-Rise & Residential
Sea-facing balconies, parapets and facades on towers in cities like Mumbai, Goa and Chennai. Slim units fit thin, congested sections and stop the patch-repair failure cycle on visible elements.
Industrial RCC
Process and effluent structures, splash zones and aggressive-exposure plant where chloride or sulphate ingress threatens reinforcement. Fusion T2 X is specified for these extreme environments.
Repair Contractors
Used alongside Fosroc Renderoc patch-repair mortars to neutralise incipient-anode (ring-anode) corrosion around repairs, so the repair lasts instead of triggering corrosion at its perimeter.
Frequently asked questions
Does Galvashield Fusion T2 need an external power supply?
How is it different from a normal galvanic ‘puck’ anode?
What is the design life and is it guaranteed?
Can it be installed into a fresh repair patch?
Which standards does it comply with?
What sizes are available and how many per box?
Can Space Arc Engineering help with design and supply in India?
How we position Fosroc Galvashield Fusion T2
Within the Fosroc range, Galvashield Fusion T2 sits at the top of the embedded-anode hierarchy: simpler discrete galvanic anodes (the Galvashield CC/XP-style ‘puck’ anodes) are mainly for preventing incipient corrosion around patch repairs, whereas Fusion T2 adds a self-powered impressed-current phase that actively halts existing corrosion before going galvanic for the long term. It is naturally paired with Fosroc Renderoc patch-repair mortars and Galvashield Embedding Mortar, and Dekguard/Nitocote coatings for surface protection above the slab. Against the wider market, it competes most directly with Sika’s hybrid and galvanic anode systems (Sika supplies a near-identical Galvashield Fusion line under licence, plus FerroGard migrating corrosion inhibitors as a lower-cost, non-anode alternative). Generic galvanic anodes and migrating/penetrating corrosion inhibitors from MBS, STP Limited and Dr. Fixit (Pidilite) are cheaper interventions but do not deliver the targeted, self-powered passivation phase or the 30-year engineered design life of a hybrid anode. Honest positioning: Fusion T2 is the right choice for high-value, hard-to-access or actively corroding structures where a designed, low-maintenance, long-life solution is justified; for low-risk preventive work around small repairs, a discrete galvanic anode or a corrosion-inhibitor system from Fosroc or an alternative supplier may be more cost-effective. Space Arc Engineering can advise on the most appropriate tier for your structure.
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