EMACO CP 10

Cementitious mortar overlay for mesh

anodes in concrete cathodic protection
Description
EMACO CP 10 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.
The product is available in two grades:
EMACO CP 10 V for applications involving vertical,
inclined and overhead applications
EMACO CP 10 H for applications involving horizontal
surfaces, such as the top surface of a bridge deck or car
park
EMACO CP 10 is a two-component system. Part 1 is a
powder component which contains a blend of Portland
cement, graded silica and special additives. Part 2 is a
liquid polymer component. The product is applied using
wet-spray concrete techniques.

Uses
EMACO CP 10 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 10 is specifically designed to be compatible with
mesh anodes.

Benefits
Durable

long track record, long lasting

vapour permeable

concrete and mesh anode compatibility

excellent adhesion
Reduced overlay thickness

less dead load on the existing structure

Easy to apply

wet-spray applied

pre-packed

Environmentally friendly

cement based, contains no toxic elements

Packaging
EMACO CP 10 is supplied pre-packed;
Part 1 is in 25kg sacks and Part 2 in 20 litre pails.
Part 2 can be made available in 220 litre drums or 1000 litre
containers, for larger projects.

Colours
Grey

Typical physical properties(a)

EMACO CP 10 V
Maximum particle size
1.2 mm
Mechanical strengths (28 days)
Compressive
36.7N/mm
Flexural
7.2N/mm
Adhesion
2.3N/mm
EMACO CP 10 H
Maximum particle size
0.8 mm
Mechanical strengths (28 days)
Compressive
42.8N/mm
Flexural
12.0N/mm
Adhesion
3.0N/mm
Freeze / Thaw resistance (SS13 72 44)
0.04kg/m
(a) : typical values. All tests were carried out under temperature
controlled conditions of 21C.

Application
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.
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 high-pressure water
jetting. Do not use vibrating or high-impact methods, 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 approved THORO 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.
Mixing
EMACO CP 10 V
Wet density
2.10 kg/dm
Pot life (at 21 C)
60 minutes
Mixing liquid :
4.15 (3.8 4.5) litres EMACO CP 10 V
Part 2 / 25 kg Part 1 powder.
EMACO CP 10 H
Wet density
2.20 kg/dm
Pot life (at 21 C)
30 minutes
Mixing liquid :
3.85 (3.5 4.2) litres EMACO CP 10 H
Part 2 / 25 kg of Part 1 powder.
Use a power mixer adding the powder to the liquid. Mix until
the powder is wet throughout and maximum dispersion of all
ingredients has been obtained. Allow the mix to fatten for 5
to 10 minutes.
Re-mix adding a little additional liquid or powder when
required, without exceeding the maximum of 4.5 litres for
EMACO CP 10 V or 4.2 litres for EMACO CP 10 H.
Do not overmix.
Application:
The ambient and surface temperature should be above 5C
during application and for at least 24 hours thereafter. Apply
EMACO CP 10 when no rainfall is expected or take the
necessary protective measures using, for example, plastic
sheets.
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 10 should be applied to surfaces that have been
well dampened but which are free from standing water.

EMACO CP 10 has been designed for spray applications

only, using wet-spray concrete techniques. Suitable spray
equipment, essential for successful application, includes
hand-held hopper guns and worm-driven equipment (such as
the Putzmeister S3 or Power Sprays PS1000). Other types
of equipment may be suitable; contact your local MBT office
for advice.
The application is carried out in two stages. Spray the first
coat 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 and not exceeding
15 mm cover for EMACO CP 10 H and not exceeding 17
mm for EMACO CP 10 V. The spraying of the first layer is
essential for all types of application.
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.
Overhead applications of THORO CP:
Overlay V
After the first coat has been broomed into the substrate,
apply in successive layers of 6 to 8 mm until the required
thickness is achieved; allow each layer to stiffen but not set
before applying the next layer.
Curing:
EMACO CP 10 is self-curing. Under poor conditions, e.g.
where rapid drying may occur (hot and/or windy conditions),
protect by covering the EMACO CP 10 with plastic sheets or
by broadcasting dry silica sand onto horizontal surfaces after
the surface film has formed.
After the final spray application, the following curing times
should be used as a guide before EMACO CP 10 H is
subjected to foot traffic:
Temperature, C
35
20
5

Time (min.), hours

24
48
72

EMACO CP 10 can be overcoated with approved THORO

CP 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 10.
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.

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.

Coverage
Coverage is dependent upon various factors, including the
method of working and substrate condition.
EMACO CP 10 V
Approximately 18.0 kg EMACO CP 10 V Part 1 and appr.
3.00 litres Part 2 will be required for 10 mm/m.
EMACO CP 10 H
Approximately 19.1 kg EMACO CP 10 H Part 1 and appr.
2.90 litres Part 2 will be required for 10 mm / m.

Storage
All materials are to be stored under cover, clear of the
ground and stacked not more than 6 sacks or 2 pails high.
Protect the materials from all sources of moisture and frost.
Rotate stock in order not to exceed the shelf life of 6 months
for sacks and 12 months for pails.

Health and safety

EMACO CP 10 Part 1 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.
EMACO CP 10 Part 2 is non toxic, but should not be
ingested as it is based on acrylic polymers.
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.
Material Safety Data Sheets are 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