Category Archives: Linear Anodes

Linear Anode Color Coding for Easy Field Identification

Linear Anode Color CodingIn February 2020, MATCOR revamped our SPL-FBR Linear Anode Product Line Offerings and introduced color coding for easy identification of different product ratings. Furthermore, MATCOR eliminated the 16 mA/ft, 50 mA/ft, 150 mA/ft, and 250 mA/ft from our standard offering.  All of our SPL-FBR anode ratings are based on a 25-year continuous operation. The output ranges available are color-coded using different tracer wire coloring as shown in the chart below:

SPL-FBR Linear Anode Color Coding

CURRENT OUTPUT RATINGCOLOR CODE
25 mA/ftYellow
100 mA/ftWhite
200 mA/ftRed
400 mA/ftWhite and Red

MATCOR continues to offer, for specific projects or applications, custom anode output ratings on an as-needed basis.

MATCOR continues to be the world’s leading manufacturer of linear anode products, utilizing our patented Kynex® connection technology. With our product color coding, it is easier for our clients to identify the current output of their linear anodes.


To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question, or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.

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Cathodic Protection Connections: Exothermic Welding vs Pin Brazing


Exothermic welding and pin brazing are two methods to connect a cathodic protection system to the protected steel structure. These connections route back to the rectifier to complete the circuit for an impressed current cathodic protection system. Or they connect to the anode lead cable in a galvanic anode system. They are an essential part of any cathodic protection system.

Exothermic welding and pin brazing cathodic protection connections resulted from historical needs in the railroad industry. In addition, both have a long history of use in the cathodic protection industry.

MATCOR has the experience and capability to use either connection technology depending on the client’s specifications or requirements. In the absence of a customer preference, MATCOR generally defaults to pin brazing for CP applications.

pipeline ac corrosion as290850090

Exothermic Welding for CP

The older of the two technologies is Exothermic or Thermite welding. More prevalent in United States specifications, this technology utilizes the heat generated from the reaction when you ignite a mixture of Aluminum powder and Iron Oxide III (ferric oxide Fe2O3). The resulting reaction is vigorously exothermic, generating temperatures more than 2000 C – sufficient to create molten iron.

Initially developed by German Chemist Hans Goldschmidt in 1893, exothermic welding connected steel rails on the Essen train line. In the 1930s, the technology gained widespread use for connecting bonding cables to railroad ties. This was thanks to the efforts of Charles Cadwell, a physicist for the Electric Railroad Improvement Corporation (ERICO.)

The Cadweld connection process has changed very little over time. It involves cleaning the structure surface down to the bare metal and laying the connector attached to the structure in a graphite mold. Next, you place an appropriately sized cartridge containing the aluminum powder and ferric oxide ready for igniting in the mold. Finally, using an ignitor sparks the reaction. As a result, an iron slug melts and flows over the copper conductor, welding it to the steel surface.

Cathodic Protection Connections: Exothermic Welding vs Pin Brazing

Pin Brazing for CP

Like exothermic welding, the railroad industry developed the second standard cable-to-structure technology—pin brazing.

In Sweden in the 1950s, high heat from thermite welding caused grain growth in the copper cable. As a result, connections to the rails were subject to fatigue failures from cyclical stresses associated with the movement of the rails as trains passed.

To solve this issue, the railroad industry developed lower-temperature joining technology using brazing. Brazing uses a range of silver-based filler metals to achieve the bond. These filler metals have a melting temperature between 620 and 970 C – well below the temperatures reached during exothermic welding.

Commonly specified in European standards, the pin brazing process has remained fundamentally the same since the 1950s, with some refinements to the equipment.

The pre-assembled welding pin and the pin brazing gun are the keys to pin brazing. The pin consists of a stud with a defined amount of flux encapsulated in the brazing metal. When you press the trigger, current flows through the pistol via the pin to the steel pipe. At the same time, an electromagnet is energized, drawing the pin holder and pin away from the steel surface, forming an electric arc. The arc heats the steel and starts to melt the tip of the pin. As a result, it causes the flux to melt and flow onto the steel. The electromagnet de-energizes when the current flow ceases, and the spring forces the molten stud onto the fluxed pipe surface. With the arcing stops, solidification is very rapid.

Comparing Exothermic Welding and Pin Brazing for Cathodic Protection Connections

Safety

Both methods are safe procedures when trained personnel follow the correct procedures. Neither method poses any environmental threat, although users should be sure to properly store and handle the thermite powder charges. For thermite welding, the process can be sensitive to moisture which could vaporize on contact with the molten iron slug. As a result, the potentially dangerous hot metal can be spat out of the mold. For this reason, you should conduct the pin-brazing process in damp environments and offshore applications.

Cathodic Protection Connection Reliability

Both connections have been used extensively and are widely accepted in cathodic protection. Unfortunately, no published data detailing the reliability of either connection technology exists, and reports of Cathodic Protection connection failures are infrequent and anecdotal. Lab testing on tensile load indicates that pin brazing is a slightly stronger bond; however, the loads at failure far exceeded any load possible in regular service. Nevertheless, both techniques will provide reliable, low-resistance connections when properly performed.

Metallurgical Effects

Both processes are thermal and will affect the metallurgical condition of the pipe. Many piping codes typically advise that the design consider the impact of any changes in the parent metal due to localized heating during the attachment process. Microhardness testing has shown that both connections are safe for the normal range of carbon steel pipe; however, some consideration must be given to thin-walled structures. Pin brazing results in lower temperatures and greater process control and should be considered for all thin-walled steel and alloyed piping.

Effects of Cathodic Protection Connections on Internal Coating and Fluids

Using thermal bonding to the exterior pipeline wall of a pipeline filled with highly flammable hydrocarbons requires some consideration. In addition, where internal coatings exist, it is reasonable to question whether or not thermite welding or pin brazing might damage the interior coating. Based on testing, the inner wall temperature rises more with thermite welding than with pin brazing; however, neither method’s results were sufficient to give any reason for concern.

If you need assistance with a cathodic protection assessment, please contact us. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.

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At What Distance Does Cathodic Protection Continue to be Effective?

This article explores the answer to a question posed by a student about the length of pipeline protected by a cathodic protection system.


What length of pipeline is protected by a cathodic protection system?

We recently received a question from our website from someone who self-identified as a Student. We love when people ask technical questions and are pleased that students visit the MATCOR website–we have always strived to have a content-rich website to help share CP knowledge. The question is as follows:

“For installed impressed current CP systems with 15 anodes, what would be the approximate radius/length of a 200-mile petroleum metal pipe that would be protected?”

So before diving into the answer, let’s frame this question with an assumption, identify some unknowns and provide a definition.

Assumption

The 15 anodes are part of a single anode bed. The anodes are electrically remote from the pipeline and connect to an appropriately-sized DC power supply (transformer/rectifier, solar power/battery unit, thermoelectric generator, etc.)

Unknown #1: Pipeline Details

Before doing any detailed engineering, there are a few details that must be specified:

  • Pipeline diameter and material of construction
  • Coating type and condition
    • The layout of the pipeline (location of pumping stations, valve stations, and metering stations)

Unknown #2: Soil Conditions

Understanding soil resistivity in terms of location, frequency, and spacing, is critical when designing cathodic protection systems for long-length pipelines.

Definition of Attenuation

a lessening in amount, force, magnitude, or value according to Merriam-Webster

When discussing at what distance cathodic protection continues to be effective along a pipeline, you must consider the attenuation of the CP current. At some point, the current diminishes along the length of the pipeline, becomes insufficient, and can no longer protect the pipeline.

The Answer: Impressed Current CP Systems are Complicated

We can effectively use attenuation calculations for signals generated on a uniform conductor and transmitted through a uniform environment.

In this case, the pipeline is not a uniform conductor; unless it is bare, it is anything but uniform. The coating has less than perfect effectiveness and an unknown number of defects distributed in an unknown manner. The environment is equally non-uniform; soil resistivities change based on location and weather changes. The more non-uniformity, the more inaccurate the results will be for any attenuation calculations.

It is virtually impossible to model mathematically for older pipelines with insufficient coatings. The only effective strategy is to collect data by installing a temporary current source to measure the effective current throw in each direction in multiple locations along the pipeline.

For new pipelines with very good coatings, it is possible to perform some attenuation calculations and empirically determine a reasonable separation distance between anode stations.

The math starts with determining something called the propagation or attenuation constant. To calculate this, take the square root of the resistance per unit length of the structure divided by the leakage conductance per unit length.

In Simple Words…

How hard is it for the current to travel along the pipeline versus how easy it is for the current to jump onto the pipeline?

The smaller this number, the further current will spread. Key factors affecting the attenuation constant include earth resistivity (higher resistivity soils mean further current spread) and coating quality (better coating means further current spread). Armed with this, there are six simultaneous equations that we can use, and that include hyperbolic sine and cosine functions.

Larger, new construction pipeline projects require you to consult with a professional engineer. A brief newsletter article will not adequately cover the mathematical gymnastics involved. We did say that the math is complex.

Well-coated, newer pipelines in moderate to high-resistivity soils can typically be protected for 20+ miles in each direction from an anode bed. Poorly-coated or bare pipelines in low-resistivity soils may require anodes every quarter mile or less.


Need more information? Please contact us at the link below.

MATCOR Successfully Completes Tank CP Project In Mexico

JA Electronics explosion-proof rectifiers for tank CP project in Mexico.

MATCOR recently completed a significant tank CP project in the Mexican port city of Altamira along the Gulf of Mexico. The project consisted of design, detailed engineering, supplying materials, providing installation supervision, and commissioning and testing the systems upon completion of the installation for nine above-ground storage tanks.

Tank CP Project Utilizes Linear Anodes

The cathodic protection system utilized MATCOR’s SPL Linear Anode Concentric Ring tank system that consists of individual, factory assembled, and tested anode segments. This approach facilitates a simple installation that does not require cutting, splicing, or joining anode assemblies in the field. The anode rings utilize a redundant anode cable feed system that assures reliability. This cost-effective solution protects the bottom of tanks on projects across the United States and around the globe.

Explosion Proof Rectifiers

MATCOR also supplied customized explosion-proof oil-cooled rectifiers (pictured above) for each of these tanks from our sister company, JA Electronics. These rectifiers are used in Class 1 Div 2 hazardous areas. Additionally, cast aluminum Class 1 Div 2 junction boxes were also manufactured and supplied by JA Electronics.


Click below to get a quote for your tank CP project, or learn more about MATCOR’s cathodic protection solutions.

Linear Anodes for Hard-to-Reach Places [Rusty Talks]

Rusty and Josh Johnston chat about a recent project and case study involving the use of linear anodes for hard to reach places.


This month, MATCOR exhibited at the AMPP Central Area Conference held in Kansas City. MATCOR’s Mr. Josh Johnston, along with Mr. Chad Farris of Energy Transfer, jointly presented a paper—a case story using linear anodes as a shallow horizontal anode bed installed along two pipelines in central Kansas.

Rusty: Josh, tell us how it felt to finally be in a real-life conference interacting with people in person after the last year and half of cancelled conferences and virtual conferences.

Josh: It is always great to get to interact with our friends and industry colleagues, clients, suppliers and competitors to share information and discuss the challenges that our industry faces—especially given the events of the past couple of years. Presenting this paper was a great opportunity to highlight the use of linear anodes to protect hard to reach areas on older pipelines.

Rusty: Can you describe the problem that you covered in your presentation?

Josh: Energy Transfer had two older pipelines that were not meeting criteria in a rural location. As is typical in a lot of pipeline cathodic protection applications, the pipelines were being protected by impressed current anodes located at road crossings where power was readily available. The roads ran parallel to each other and were located one mile apart. The pipeline traversed these two roads and the area in between was mostly farmland. As a result of the age and coating condition, the shallow horizontal anode beds, located at the road crossings, were not able to project much more than a ¼ mile from each end, leaving approximately ½ mile in the center under protected. This was clearly identifiable in the close interval survey (CIS) data.linear anodes hard to reach places

Rusty: Couldn’t they simply increase the current output of the existing shallow ground beds at each end of the pipeline to drive more current to the center section in between?

Josh: They tried that approach, and it did not work, raising concerns that driving excessive current onto these older pipelines could actually make the situation worse by further disbanding any coating close to the existing ground beds.

Rusty: So where did MATCOR come into this project

Josh: MATCOR proposed linear anodes be installed parallel to each of the pipelines in the area between the two roads. MATCOR developed the very first MMO (mixed metal oxide) linear anodes over 30 years ago and we have the most experience designing linear anode CP systems.

Rusty: So it sounds easy, you take a couple of ½ mile segments of linear anode, trench them in parallel to pipeline and run a couple of long extension cord cables back to the road where there is power.

Josh: Well it does sound easy; however, in practice it is critical that any linear anode design carefully addresses voltage drop, and that the power feed cabling is configured so that each anode segment output is balanced. If this is not engineered properly, you could have a large disparity in the voltage being applied on one end of the anode segment relative to the other end. This would result in a very uneven distribution of current. Discussing the design considerations for the power feed cabling was the primary focus of this presentation.

Rusty: So how did it work out?

Josh: MATCOR was able to use some creative cabling analysis and routing to assure that the voltage difference from one end of an anode segment to the other was no more than a 10% variance. The post installation and commissioning CIS data delivered an outstanding current distribution.

Rusty: Thanks for providing a very quick overview of your presentation—any final thoughts or comments?

Josh: When designed properly, linear anodes can be a real problem-solving solution for older pipelines with current distribution and attenuation issues.

Oh yeah, Kansas City BBQ still rocks!

Have questions or need a quote for linear anodes or installations services? Contact us at the link below. For immediate assistance, please call +1-215-348-2974.

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Better Tank Cathodic Protection

Looking for a better tank cathodic protection system?

Find our article in the April 2020 Storage Terminals Magazine. “No More Gridlock—Take the Ring Route” is a comparison of grid anode systems vs concentric ring systems for tank bottom cathodic protection.

Cathodic Protection of the external tank bottom for large diameter above ground storage tanks has been adopted as good engineering practice around the world.

Unfortunately, many existing grid anode systems have experienced premature failures, resulting in excessive tank bottom corrosion and costly replacement.

A recent MATCOR article published in Storage Terminals Magazine provides an overview of these grid CP systems and an alternative concentric ring linear anode system (link to the full article below). Here are just a few key points:

Grid Tank Anode Systems

  • Consist of field assembled MMO ribbon anodes and titanium conductor bars
  • Require flawless design and installation
  • Subject to poor welding and other concerns
  • Failures can be catastrophic

Concentric Ring Linear Anode System

  • Factory assembled—no field cutting or splicing required
  • Easy, fast and reliable installation
  • Coke backfilled sock protects the anode
  • Redundant—each ring segment has two feeds
  • Long life compared to the grid systems of the 1990s

If you have questions, or for information on MATCOR’s above ground storage tank cathodic protection solutions, please contact us at the link below.

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Rethink Your Shallow Horizontal Anode Bed Design – The Case For Linear Anodes

A common cathodic protection system approach is the use of a shallow horizontal anode bed. These are typically defined as an anode system consisting of a series of multiple individual anodes installed either vertically or horizontally at a depth of less than 15m (50ft) and connected to a single power source. These are particularly effective in areas where drilling deep anode beds is not feasible or practical.

The typical anode used in shallow anode bed applications is an impressed current anode. These can be high silicon cast iron, graphite anodes or mixed metal oxide tubular anodes.  The anodes may be pre-packaged in a canister filled with coke backfill, or they can be installed in a vertically drilled/augured hole or a continuous horizontal trench with backfill installed around the bare anode. The anodes can be installed in parallel to a common header cable or can have individual leads all routed to a cathodic protection junction box and connected in parallel inside the junction box.

Shallow Horizontal Groundbed-Individual Anodes
Shallow Horizontal Anode Bed with Individual Anodes

A New Approach: Continuous Linear Anodes

Another approach that is gaining acceptance in the corrosion industry is the use of a single continuous linear anode as an alternative to multiple individual discreet anodes that are field connected to form an anode bed.  There are several advantages to using a single continuous linear anode to create a shallow horizontal anode bed:

Shallow Horizontal Groundbed-Linear Anodes
Shallow Horizontal Anode Bed with a Single Linear Anode

Advantages of linear anodes for shallow horizontal anode beds

  • Ease of installation
    The use of a single continuous linear anode assembly can significantly reduce installation time by eliminating numerous field splice connections of multiple individual anodes to a header cable.
  • Reliability
    The entire linear anode assembly is factory manufactured and tested with internal factory connections that are more reliable than a field connection.  The assembly is designed with an internal header cable for redundancy and can be manufactured with an integral external return header cable, eliminating all field splicing and connections.
  • HDD Installation
    The use of a linear anode for shallow anode bed design allows for the use of HDD (horizontal directional drilling) to install the continuous anode assembly.  This can significantly minimize the installation footprint and greatly reduce installation time and costs.  This also allows for a deeper installation to facilitate locations where surface activities such as deep tilling farming operations might preclude a shallower anode system installation.
  • Cost Effectiveness
    The use of linear anodes can be extremely cost effective, resulting in a much lower cost installation. This is especially true when considering the overall cost per amp year given the longer design life of mixed metal oxide based linear anode systems.

MATCOR has extensive experience designing and installing shallow horizontal anode beds, including the use of our HDD installation crews and state-of-the-art equipment to minimize surface impact in sensitive areas.


Contact us at the link below to find out if a linear anode cathodic protection system is right for your application.

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Replaceable Anode System Success: A First for Critical Middle East Tank Assets

Last month, MATCOR successfully completed the first ever HDD tank cathodic protection system installation in the Middle East, utilizing a replaceable anode system.

Replaceable Anode System Installation

Background—Initial Recommendation for HDD Cathodic Protection System

Equate Petrochemicals is one of the world’s largest producers of Ethylene Glycol. They initially contacted MATCOR in 2012 to discuss options for cathodic protection on a critical service Ethylene storage tank at their flagship Kuwait petrochemical facility. This tank was originally constructed in 1995, and the initial CP system installed with the tank was no longer providing sufficient current to achieve NACE Criteria. At the time, MATCOR suggested installing anodes directly under the tank using horizontal directional drilling technology. The plant’s engineering and operations team had significant reservations about this approach. The tank was critical to the plant’s operation and could not be taken out of service. Should the HDD operations result in damage to the structural integrity of the tank, the results would be catastrophic.

Perimeter Anodes—An (Unsuccessful) Alternative Approach

As a result of Equate’s concerns in 2012, they attempted an alternate approach, suggested by others, using perimeter anodes. Discreet anodes were installed offset around the perimeter of the tank—thus avoiding any possible risk to the tank during the anode installation. The use of perimeter anodes around larger diameter tanks is generally not a good idea. This is because it is very difficult to drive current to the center area of the tank, often resulting in adequate protection levels only for the outer edges of the tank bottom. For the Ethylene Storage Tank, the presence of heating pipes below the tank bottom only exacerbated the current distribution challenges. Ultimately, the results were not satisfactory.

In 2018, the plant engineering team reached back out to MATCOR to discuss our HDD solutions.

Replaceable Anode System Solution

Replaceable Anode SystemMATCOR provided the plant with a detailed proposal to design and install a complete cathodic protection system using MATCOR’s Replaceable Tank Anode system. The RTA system is based on installing MATCOR SPL linear anode assemblies in a series of parallel slotted PVC pipes that have coke backfill pneumatically blown into the PVC pipe as part of the anode system installation. In addition to the linear anode segments and coke backfill, the slotted PVC pipes have a venting system to allow gases produced during the cathodic protection reaction to vent. This prevents gas buildup and blockage inside the PVC anode pipe.

Replaceable Anode System Installation Drawing

One of the key advantages of the RTA system is that once the PVC tubes are installed, it is possible to flush out the anode assemblies and coke backfill should the anode assemblies fail and/or they are at the end of their design life making this a replaceable anode system that will assure cathodic protection for the entire service life of the tank.

Additionally, a slotted Reference Cell Tube would be installed to allow for two calibrated fixed cathodic protection reference electrodes to be inserted for full polarized and non-polarized potential measurements across the entire tank bottom. This would allow for testing of the CP system with calibrated reference electrodes for the life of the tank.

Experienced HDD Installation—Assuring a Safe Installation

Horizontal Drilling Anode InstallationWhile the plant conceptually agreed with MATCOR’s solution from a technical perspective, there remained a significant concern within the plant’s operation and safety groups about drilling under this critical service tank and the possibility of a catastrophic event should the drill head drift up to the tank bottom. MATCOR put together a thorough installation procedure including detailed information on the sophisticated drill head tracking systems being utilized to assure that the drill head location was being continuously monitored throughout the bore. Utilizing an experienced local HDD drilling sub-contractor, MATCOR deputed its senior HDD installation drilling supervisor to Kuwait for the installation. Our Senior HDD Drilling Supervisor has completed hundreds of tank HDD installations in the United States and his on-site presence, along with the advanced electronic tracking package being used, assured that each bore went as planned.

Replaceable Anode System Installation Complete!

In December of 2019, MATCOR, working with our local Kuwaiti sub-contractor and the client’s engineering, construction and safety teams, successfully completed the installation of the replaceable anode system. The initial commissioning results showed that the anodes were installed properly. Each anode was distributing current as expected, and the polarization levels were meeting appropriate NACE criteria. The system has been left to operate and fully polarize. A subsequent visit by MATCOR’s technical team is scheduled in early 2020 to make final adjustments to the anode system current output and to confirm that the system continues to meet NACE criteria.

Conclusion

MATCOR’s successful installation in Kuwait of a horizontal directional bored CP system under an existing critical service tank is a first for the Middle East Region. The innovative MATCOR design, combined with the technical knowledge and operational expertise, makes this an interesting and viable option for other tank owner/operators worldwide to consider for their existing tanks with CP systems that are not performing properly.


To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.

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Have Extra 2019 Budget Monies?

MATCOR can help.

This is the time of year when thoughts turn to Thanksgiving and Christmas vacations, using up all your remaining vacation and wondering what to do with any leftover 2019 cathodic protection budget monies.  More than likely, it is too late to schedule and complete new projects.  MATCOR along with most of our competitors have full construction schedules and adding additional commitments is quite difficult.

So what to do with that leftover budget monies that may reset in 2020?  Many of our clients look to stock up on materials for their anticipated 2020 projects.  It is not too late get MATCOR’s Mitigator® Engineered AC Mitigation System, SPL™ Impressed Current Linear Anodes, Durammo® Deep Anode System, MMP™ Prepackaged MMO Canister Anodes and other ancillary materials into this year’s budget.

Click HERE to get in touch with your MATCOR account manager for more information, to ask a question or get a quote. Or, complete our contact form at the link below and we will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.

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MATCOR Ships Over a Half Million Feet of Linear Anodes to Africa

The richest man in Africa, Aliko Dangote, undertakes $12B project including 153 ASTs

Chalfont, PA (April 2019) – MATCOR, Inc., the trusted full-service provider of proprietary cathodic protection products, systems, services and corrosion engineering solutions announced that it recently completed shipment of over 500,000 linear feet (150+ km) of its SPL™-FBR linear anode product along with other ancillary materials for 153 above ground storage tanks (ASTs) in Africa.

Tank anode system materials prepped for export at MATCOR’s Chalfont PA facility. Over 520 reels of anode material have been shipped to Nigeria.

The anodes, which will prevent tank bottom corrosion, are part of an ambitious refinery project undertaken by Aliko Dangote, Africa’s richest man. The tanks are being erected on over 6,000 acres of swampland outside of Lagos, Nigeria.

MATCOR was selected for this project due to quick delivery and the company’s unique linear anode design, which does not require field splicing and saves significantly on installation time and costs.

“The ability to manufacture the large quantity of custom length linear anode segments in a very compressed time frame was key to meeting the tank contractor’s needs,” noted Ted Huck, Director of Manufacturing and Quality Assurance for MATCOR. “Our team handled a very complex order with a very tight delivery schedule while maintaining world class quality.”

Learn more about the project in our recent blog post.

About MATCOR

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CONTACT

Ted Huck
215-348-2974
Dana Baedke
Key Marketing Communications
844-545-3481, x700
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