EMACO CP

20
Cementitious mortar overlay for mesh
anodes in concrete cathodic protection
Description
EMACO CP 20 is a highly durable overlay specifically
developed to maximise the working life of mesh anodes for
reinforced concrete CP applications. The material is cement
based and contains special additives which impart the
qualities required for the successful long-term performance
of mesh anode CP systems, i.e. high buffer capacity against
the possible acidification around the anode during operation.
EMACO CP 20 is used for applications involving vertical,
inclined and overhead applications.
EMACO CP 20 is a one-component mortar which contains a
blend of Portland cement, graded silica and special
additives. The product is applied using wet-spray concrete
techniques or by hand for small applications.

Uses
EMACO CP 20 is a highly durable, encapsulating overlay for
use with mesh anodes in impressed current cathodic
protection (CP) of steel-reinforced structures. Suitable
applications include the control of active corrosion in
highway structures, car parks and buildings, also the
prevention of corrosion in structures at risk.
EMACO CP 20 is specifically designed to be compatible
with mesh anodes.

Benefits
Durable
vapour permeable
concrete and mesh anode compatibility
similar resistivity as concrete
excellent adhesion
Reduced overlay thickness
less dead load on the existing structure
Easy to apply
wet-spray or hand applied
pre-packed
Environmentally friendly
cement based, contains no toxic elements

Product data
4.1

Typical physical properties

(a)

Modulus of elasticity
Maximum particle size

26000 N/mm
1.5 mm

Mechanical strengths
Compressive
1d
7d
28 d
Flexural
28 d

N/mm
13
36
50
9.5

Bond strength
Coefficient of thermal expansion

> 2.5 N/mm

-6
13.6x10 mm/mmC

( a) : typical values. All tests were carried out under temperature

controlled conditions of 21C.

Packaging
EMACO CP 20 is available in 25 kg sack.

Colours
Grey

Coverage
Coverage is dependent upon various factors, including the
method of working and substrate condition.
Approximately 18.0 kg EMACO CP 20 V will be required for
10 mm/m.

Storage
EMACO CP 20 should be stored under cover, clear of the
ground and stacked not more than 6 sacks high. Protect the
materials from all sources of moisture and frost. Rotate
stock in order not to exceed the shelf life of 6 months.

Application
9.1

Substrate quality

In order to cathodically protect steel-reinforced concrete,

electrical continuity of the steel is required. For existing
structures a condition survey should be undertaken to
establish the suitability of the structure for CP.
Reference should be made to the draft CEN standard
TC262/SC2/WG2.
9.2

Substrate preparation

Preparation of the concrete substrate is vital to achieve

optimum performance and long service life from the
cathodic protection installation. Remove all surface
coatings, defective renders, foreign matter, formwork
treatments, laitance, algae and other contaminants that may
adversely affect the bond. Use abrasive blasting or highpressure water jetting. Do not use vibrating or high-impact
methods, as such methods increase the risk of inducing
micro cracks that may affect the adhesion and the long-term
durability of the anode system.
The prepared substrate should have a pull-out strength of at
least 1.5 N/mm.
Spalled or delaminated areas and cracks should be repaired
with EMACO CP 20 or other approved CP concrete repair
products. Hairline cracks may be left untreated. Under no
circumstances should any cracks be injected with materials,
which will insulate areas from the CP system. Areas of low
cover and exposed steel must be treated or the cover built
up to that required.
Mesh anodes
The type and configuration of mesh anodes are a CP design
decision. Suitable material will normally involve activated
Titanium mesh, e.g. Elgard Anode Mesh by Eltech, Titanode
by Heraeus or Lida net by DeNora Permelec. Appropriate
companies should be contacted for advice.
9.3

Mixing

Wet density
2.00 kg/dm
Pot life
30 minutes
Final setting time
6 hours
Mixing liquid
3.5 l (3.3 - 3.7 l) clean
water/25 kg powder
(The slurry coat used in hand applications to improve the
adhesion will need 10 % more water)
Mix complete sacks only. Add EMACO CP 20 powder
gradually into the water whilst stirring with a suitable paddle
in a slow-speed drill (400-600 rpm) or in an appropriate
forced-action mixer. Mix until a uniform homogeneous mass
is formed and leave to stand for approx. 3 minutes to allow
full saturation to take place. Re-mix adding more powder or
water, if required, to obtain the correct consistency. Do not
exceed the maximum water demand. DO NOT OVERMIX.
DO NOT mix more than can be placed in 30 minutes (at
21C). DO NOT re-temper.

9.4

Application

The ambient and surface temperature should be above 5C

during application and for at least 24 hours thereafter.
Under extremely hot or windy conditions it is advised that
hot substrates are cooled with potable water and that the
application should take place between sunset and sunrise.
Use sunlight-reflecting pump lines, provide wind protection
and clean equipment frequently.
EMACO CP 20 has been designed for spray applications,
using wet-spray concrete techniques. However, EMACO CP
20 can be applied by hand for small areas or local repair
work.
Suitable spray equipment includes hand-held hopper guns
and worm-driven equipment (such as the Putzmeister
TS3EVE or Power Sprays PS1000). Other types of
equipment may be suitable; contact your local MBT office
for advice.
It is strongly advised that an experienced and competent
nozzleman should carry out all spraying and that the
recognised wet-spray methods are used throughout.
Apply EMACO CP 20 to a pre-dampened surface only,
without free standing water.
The application is carried out in two stages. Spray a first
layer to a thickness of 1 to 2 mm. Immediately after
spraying, and while still wet, broom the material into the
concrete surface.
Spray the second coat immediately onto the first (still wet)
coat to the recommended thickness in accordance with the
mesh manufacturers instructions, but in any case not less
than 10 mm cover over the mesh. The application of the first
layer is essential for all types of application.
Apply in layers between 10 and 40 mm. For vertical
applications, spray from bottom to top.
Overhead applications should be limited up to 30 mm per
layer. Allow initial set to take place before applying a
subsequent layer.
When applying EMACO CP 20 by hand, a thin slurry coat (
10 % more water than for the mortar) should first be applied
to the pre-dampened surface before building up the
thickness with the mortar in its normal consistency.
Apply to a limited area only to prevent drying of the first
coat. If the first coat has dried, apply a new broom coat
before building up to the required thickness.
Under no circumstances should rebound be re-used, as it
would invariably cause a distinct fall of all mechanical
properties of EMACO CP 20.
EMACO CP 20 may be finished using wooden or steel
trowels as soon as practical, however, ensuring that no
debonding of the newly sprayed material occurs while
trowelling.

9.5

Curing

Under hot or windy conditions, fog spray all applications

after the initial set has taken place for as long as
practicable, or cover with damp hessian or polythene. In
cool conditions, cover EMACO CP 20 with an insulated
tarpaulin, polystyrene or other insulating material.
Setting and hardening times will vary , dependent upon
ambient temperatures and conditions.
Protect EMACO CP 20 against rain until setting is complete.
The use of curing compounds is not advised.
EMACO CP 20 can be over-coated with approved CP
compatible products in order to enhance the performance in
aggressive environments or for aesthetic purposes.
Preferentially this is done 7 days after the application of
EMACO CP 20.
9.6

Clean up and spillages

Not hardened material may simply be removed with water.

Cleaning of equipment and tools should be carried out as
soon as practicable well away from the application area.
9.7

Operation maintenance of the CP installation

To achieve cathodic protection of the reinforcement and

optimise the service life of the CP system, especially the
anode, it is essential that suitable design, commissioning,
monitoring, control and maintenance procedures are
followed.
Reference should be made to the draft CEN standard
TC262/SC2/WG2.

Health and safety

EMACO CP 20 is based on cement and thus can be
irritating to the skin and eyes. Gloves and eye protection
should be worn. The use of dust masks is recommended.
Accidental splashes of the material to the skin or eyes
should be immediately washed off with clean water. In the
event of prolonged irritation seek medical advice. In the
case of ingestion give water or milk to drink and treat
symptomatically. Medical advice should be sought.
A Material Safety Data Sheet for this product is available on
request
04/2001 Degussa UAE

Degussa Construction Chemicals UAE LLC

P.O. Box 37127, Dubai, UAE
Tel: +971 4 8851000

Fax: +971 4 8851002

www.degussa-cc.ae

e-mail: marketingcc.mideast@degussa.com

Whilst any information contained herein is true, accurate and

represents our best knowledge and experience, no warranty is given or
implied with any recommendations made by us, our representatives or
distributors, as the conditions of use and the competence of any labour
involved in the application are beyond our control.

Certificate No.
963680

As all Degussa technical datasheets are updated on a regular basis it is the user's responsibility to obtain the most recent issue.

Certificate No.
945787

Certificate No.
772556