Application Guide

for
MasterEmaco® Repair Products
MasterEmaco® P 5000AP
MasterEmaco® N 5100
MasterEmaco® N 102
MasterEmaco® N 5200CI
MasterEmaco® S 5300CI
MasterEmaco® S 5400CI
MasterEmaco® S 5440CI
MasterEmaco® S 820CI
MasterEmaco® S 822
MasterEmaco® T 920CI
MasterEmaco® T 288
MasterEmaco® T 545
MasterEmaco® S 680
MasterEmaco® S 620
MasterEmaco® S 902

May 2018 Page 1 of 15

MasterEmaco repair products
These products are used for a variety of concrete repair applications and share some common
attributes and often some installation techniques.

PACKAGING

Product Description Packaging

MasterEmaco P 5000AP Specialty steel primer for use with repair mortars 5kg
MasterEmaco N 102 Lightweight low strength repair mortar 20Kg
MasterEmaco N 5100 Thin layer fairing mortar 20Kg
MasterEmaco N 5200CI Lightweight fast setting repair mortar 20Kg
MasterEmaco S 5300CI High build repair mortar 20Kg
MasterEmaco S 5400CI High strength repair mortar 20Kg
MasterEmaco S 5440CI High strength flowable repair mortar 20Kg
MasterEmaco S 820CI General purpose shotcrete with corrosion inhibitor 20Kg
MasterEmaco S 822 Shotcrete for cathodic protection 20Kg
MasterEmaco T 920CI Rapid setting micro concrete 20Kg
MasterEmaco T 288 Fast setting trafficable repair mortar 20Kg
MasterEmaco T 545 Fastest setting trafficable repair mortar 20Kg
MasterEmaco S 680 CAC shotcrete for aggressive environments 20Kg
MasterEmaco S 620 Hand applied acid resistant mortar 20Kg
MasterEmaco S 902 Rapid setting underwater repair mortar 20Kg

For detailed explanations of the mechanisms of concrete deterioration, inspection and

interpretation of inspections and repair technologies, a number of documents should be referred to.
Some of these include:
• Standards Australia HB 84 - 2006 “Guide to Concrete Repair and Protection” prepared by the
CSIRO and ACRA
• European Standard EN 1504:2004 “Products and systems for the protection and repair of
concrete structure”
• ICRI (International Concrete Repair Institute) Concrete Surface Profile Chips (CSP 1-10)

SURFACE PREPARATION
Preparation of the concrete substrate for concrete repairs generally involves a couple of steps.
Preparation will involve removal of the contaminated, cracked and affected concrete to create a
suitable profile as well as the cleaning of the reinforcing steel.

For the best results, a CSP profile of 5 or greater is required and to achieve this, you need an
aggressive surface preparation technique. The choice of technique will be determined by the size
and depth of the patch. Suitable techniques include:
• Hammer and cold chisel
• Kango style impact hammer
• Machine mounted impact hammer
• Hydro demolition

All loose material should be removed and the reinforcing steel exposed to the point where there is
no visible rust and a grey surface colour is observed. This indicates that the steel at this point is
still passivated and thus you are out of the current corrosion zone. The reinforcing steel should be
exposed on all sides so that you are able to fit a gloved hand behind the bar. In the event that the
reinforcing steel has lost a significant amount of its cross-sectional area (approximately 20% is
classified as significant) it may need to be replaced or additional steel installed. The replacement
should be determined by the engineer, especially in structural applications.
May 2018 Page 2 of 15
The steel should be cleaned to an SA Class 2.5 and all rust removed. For small patches this can
be done by wire brush. On larger jobs a needle gun or captive grit blasting will be effective. The
action of the hydro demolition will clean the steel well and no further preparation would be
necessary.

The edges of the patch should be square cut to a depth of 10-20mm or the minimum as specified
on the TDS, to prevent any of the repair mortar from being feather edged. Patches should be
regular in shape and it may be necessary to join a number of small irregular patches to make a
single regular patch. This will reduce the risk of cracking in the patch and the premature failure.

PRIMING

Steel
• Once the steel has been cleaned it will generally be necessary to prime the steel using
MasterEmaco P 5000AP.
• Priming stops the flash rusting resulting from the contact with the moisture in the air.
• The MasterEmaco P 5000AP is an acrylic modified cementitious coating with active corrosion
inhibition. You just mix with water and coat the cleaned reinforcing steel.
• It is an orange colour to make a simple visual evaluation of the steel that has been coated.
• This should be allowed to dry for a few hours before application of repair mortars or shotcrete.
• If application of MasterEmaco shotcrete was to proceed directly after the hydro demolition, the
need for the MasterEmaco P 5000AP is reduced and could be eliminated without creating any
issues with the longevity of the repair.
• Note: Although BASF does not sell a zinc rich steel primer the use of one is entirely compatible
with any of the MasterEmaco repair products. Care must be taken if using a zinc rich primer to
ensure none is left on the parent concrete as this will interfere with the bond of the repair
mortar.

Concrete
• The concrete substrate should be a saturated surface dry (SSD) substrate, to accept the repair
mortars, as a dry substrate will lead to surface cracking and poor bond to the substrate.
• The only exception to this is the MasterEmaco T 545 which chemically bonds with the
concrete and does not need a wetted substrate (Note: a damp substrate will not interfere with
the bonding of the MasterEmaco T 545).
• Shotcrete materials like the MasterEmaco S 820CI, MasterEmaco S 680 and MasterEmaco
S 822 only require the substrate to be wetted just prior to the beginning of spraying. This is
accomplished by spraying just water or a very thin, wet mix, as a slurry coat onto the prepared
surface and then continuing with the normal shotcrete.
• MasterEmaco P 5000AP as well as being used as a steel primer can be used as a bonding
agent for the repair mortar to the concrete. The repair mortar should be applied whilst the
MasterEmaco P 5000AP is still wet and if it dries out reapplication will be required.
• MasterEmaco P 157 is an SBR bonding agent, which can be used when wetting is impractical
and should be diluted 1:1 with water and applied generously by brush to the concrete. Apply
the repair mortar whilst the MasterEmaco P 157 is still tacky.
• Slurry coat of the repair mortar – normally a mixture of 2 parts water and 1 part dry powder of
the repair product being used is used to create a slurry coat and apply this to a wetted
substrate with a brush and apply the repair mortar whilst still wet. The benefit of this is that the
materials are all on site and more can be simply made up as required.

May 2018 Page 3 of 15

• Note: epoxy bonding agents are not recommended for vertical and overhead repairs however
some specifications may call for this and MasterBrace 1444 is compatible with all the repair
mortars. Epoxy bonding can also be considered for the MasterEmaco T 920CI or T 288 for
heavy duty pavement repairs and on horizontal surfaces, MasterEmaco 2525 would be the
appropriate bonding agent. Ensure that the epoxy bonding agent is still tacky before applying
any repair mortar. Depending upon the delay, either reapply the bonding agent if cross linking
is still possible or sand and solvent wipe prior to reapplication. In extreme cases, removal of the
cured bonding agent may be required before starting again.

MIXING
MasterEmaco N 102, N 5100, N 5200CI, S 5300CI, S 5400CI, S 5440CI, T 920CI, T 288, S 620
• Only mix full bags. Damaged or opened bags should not be used.
• Add mixing water (clean, potable water only) to a clean mixing container.
• Accurately measure the mixing water and hold back approximately 10% so that the consistency
can be adjusted to the required slump.
• Mix mortars with a helical paddle attached to a slow speed (300-600 rpm) mixer or in a forced
action pan mixer for 3 minutes until a lump free, plastic consistency is achieved. MasterEmaco
S 5440CI is best mixed with a bird cage style mixer to give a fluid consistency.
• Stop mixing during this time to scrap down the sides and continue mixing.
• Add the remaining water until the required consistency is achieved.
• Mixing water needed will vary depending on consistency required.
• See table below for water addition ranges and verify amount by checking the latest copies of
the individual technical data sheets.
• Allow the mortar to rest for 2 - 3 minutes and then remix briefly, adjusting the consistency as
required. In very hot weather the water demand will be at the high end of the range.

WATER DEMAND

Product Description Packaging Water demand

MasterEmaco P 5000AP Specialty steel primer for use with 5Kg 220-260mls per Kg
repair mortars of powder
MasterEmaco N 102 Lightweight low strength repair mortar 20Kg 3.8-4.0L
MasterEmaco N 5100 Thin layer fairing mortar 20Kg 3.0-3.5L
MasterEmaco N 5200CI Lightweight fast setting repair mortar 20Kg 3.5-4.0L
MasterEmaco S 5300CI High build repair mortar 20Kg 3.8-4.2L
MasterEmaco S 5400CI High strength repair mortar 20Kg 3.0-3.4L
MasterEmaco S 5440CI High strength flowable repair mortar 20Kg 2.2-2.5L
MasterEmaco S 820CI General purpose shotcrete with 20Kg 1.8-2.5L
corrosion inhibitor
MasterEmaco S 822 Shotcrete for cathodic protection 20Kg 1.8-2.5L
MasterEmaco T 920CI Rapid setting micro concrete 20Kg 1.7-1.9L
MasterEmaco T 288 Fast setting trafficable repair mortar 20Kg 2.6-3.0L
MasterEmaco T 545 Fastest setting trafficable repair 20Kg 1.4L
mortar
MasterEmaco S 680 CAC shotcrete for aggressive 20Kg 1.8-2.5L
environments
MasterEmaco S 620 Hand applied acid resistant mortar 20Kg 2.8-3.2L
MasterEmaco S 902 Rapid setting underwater repair 20Kg 3 L of powder with
mortar 1 L of water.

May 2018 Page 4 of 15

MIXING
MasterEmaco P 5000AP
• In a suitable container, mix MasterEmaco P 5000AP with a paddle mounted on a slow-speed
drill or by hand, until a smooth, thick consistency is achieved.
• Mixing water needed: 0.22 to 0.26 litres per kg of powder, depending upon consistency
required.
• Leave to stand for approx. 5 minutes and re-mix briefly before use.
• Adjust the consistency with water when required but without exceeding the maximum water
demand.

MIXING
MasterEmaco S 902
• Water requirements vary depending on temperature, humidity and the consistency desired.
• Mixing three volumes of MasterEmaco S 902 with approximately one volume of water will give
a stiff plastic consistency.
• Place MasterEmaco S 902 into container and add half the water, mix quickly with a short
handled trowel, add extra water as required until no white streaks are present to get the
desired plastic consistency.
• Mix only small batches at one time, as MasterEmaco S 902 must be placed within 5 minutes of
mixing.
• The MasterEmaco S 902 should be shaped quickly into spheres of about cricket ball size and
applied as soon as possible.
• Do not re-temper material which has begun to stiffen - discard material which has lost its
plasticity.

MIXING
MasterEmaco S 820CI, S 822, S 680
• These materials are applied via a dry shotcrete machine and the water is added at the nozzle
and controlled by the shotcrete operator.
• Increasing the water will reduce the rebound and dust creation.

MIXING
MasterEmaco T 545
• WATER CONTENT IS CRITICAL. A 20kg bag of MasterEmaco T 545 mixed with a maximum
1.4 litres of water
• Add all the water to a clean bucket and add the MasterEmaco T 545 and mix for
approximately 1 to 1½ minutes and place.
• Use neat material for patches less than 25mm in depth. Do not use MasterEmaco T 545 for
patches less than 13mm deep.
• For deeper patches, MasterEmaco T 545 must be extended by adding up to 12kg of properly
graded, dust-free, hard, rounded aggregate.
• Note: Do not use calcareous aggregate made from soft limestone. Test aggregate for fizzing
with 10% HCI. If fizzing occurs, aggregate is unsuitable for use with MasterEmaco T 545.
• Do not add sand, fine aggregate or Portland cement to MasterEmaco T 545.
• MasterEmaco T 545 gives off ammonia fumes when mixed with water and care should be
taken to provide adequate ventilation.

May 2018 Page 5 of 15

• MasterEmaco T 545 is slightly acidic once mixed with water and will mark aluminium,
galvanized metals and glass so care should be taken to avoid contact. The material becomes
alkaline once it hardens.
• MasterEmaco T 545 will not freeze at temperatures above -7°C.
• To obtain permanent repairs the edge of the patch should be square cut to a depth of not less
than 10mm.

APPLICATION THICKNESS

Product Description Packaging Min-max

thickness
MasterEmaco P 5000AP Specialty steel primer for use with 5kg 1-2mm
repair mortars
MasterEmaco N 102 Lightweight low strength repair 20Kg 5-100mm
mortar
MasterEmaco N 5100 Thin layer fairing mortar 20Kg 0-3mm
MasterEmaco N 5200CI Lightweight fast setting repair 20Kg 3-100mm
mortar
MasterEmaco S 5300CI High build repair mortar 20Kg 10-75mm
MasterEmaco S 5400CI High strength repair mortar 20Kg 5-50mm
MasterEmaco S 5440CI High strength flowable repair 20Kg 20-500mm
mortar
MasterEmaco S 820CI General purpose shotcrete with 20Kg 10-150mm
corrosion inhibitor
MasterEmaco S 822 Shotcrete for cathodic protection 20Kg 10-150mm
MasterEmaco T 920CI Rapid setting micro concrete 20Kg 25-200mm
MasterEmaco T 288 Fast setting trafficable repair 20Kg 10-300mm
mortar
MasterEmaco T 545 Fastest setting trafficable repair 20Kg 13-25mm (Neat)
mortar 25-150mm (filled)
MasterEmaco S 680 CAC shotcrete for aggressive 20Kg 10-150mm
environments
MasterEmaco S 620 Hand applied acid resistant 20Kg 10-50mm
mortar
MasterEmaco S 902 Rapid setting underwater repair 20Kg 20-50mm
mortar

APPLICATION
Primer – MasterEmaco P 5000AP
• Once mixed the MasterEmaco P 5000AP can be applied by stiff bristled brush when used as a
primer on prepared concrete and paint brush for coating the reinforcing steel.

Mortars - MasterEmaco N 102, N 5100, N 5200CI, S 5300CI, S 5400CI, S 620, S 488CI

• The minimum temperatures must be maintained during application and for at least 12 hours
thereafter for optimum curing of the product.
• These products can be placed using a gloved hand or trowelled onto the prepared surface.
• Apply mixed product directly to the prepared damp substrate, or wet on wet onto the primed
surface.
• A thin scratch coat or contact layer (a slurry coat of the MasterEmaco material) before building
up to the required thickness, wet on wet, will improve the wet adhesion and cohesion of the
mortar.
• Apply to the desired layer thickness (see application thickness table).
• Smoothing with a trowel and finishing by float or sponge can be done as soon as the mortar
has begun to stiffen, typically after approximately 45 - 60 minutes at 20°C. Note: At lower
temperatures and/or higher humidity these times will be extended.
May 2018 Page 6 of 15
Form and pour - MasterEmaco, S 5440CI, T 920CI, T 288
• The minimum temperatures must be maintained during application and for at least 12 hours
thereafter for optimum curing of the product.
• These products can be placed using a pump, poured from the mixing bucket and trowelled into
place onto the prepared surface.
• The formwork should be water tight and sturdy and the forms should be treated with a form
release agent like MasterFinish RL 211 or 222 to ensure they can be easily removed.
• When possible pre-wet the substrate before pumping or pouring the mortar into the form.
• Ensure that excess water is drained prior to filling form with mortar.
• Saturated surface dry or bonding agent should be considered where practical.
• Keep forms on until the material has reached the desired strength and cure the material after
removal of forms.
• MasterEmaco T 288 and T 920CI are mostly used in horizontal excavations and the
surrounding concrete becomes the form.
• Move the material to the desired places with a trowel and finish off the surface profile required.
• MasterEmaco T 288 will set relatively quickly and finishing off should be done as quickly as
possible.

MasterEmaco T 545
• MasterEmaco T 545 when mixed is a high slump mortar and cannot be placed vertically
unless behind a form.
• Surface carbonation inhibits chemical bond, so application must be done shortly after
preparation of the substrate.
• Apply an indicator (phenolphthalein) to the prepared surface to determine if carbonation is
present (carbonated concrete will show no colour and non-carbonated concrete will show up
pink)
• Into a dry recently prepared excavation pour the MasterEmaco T 545 into the void to be filled
and move into place with a trowel.
• The substrate should not be wet nor bonding agents used as the MasterEmaco T 545
chemically bonds with the concrete.
• MasterEmaco T 545 has a short open time and will generate significant heat during the
hardening process.
• MasterEmaco T 545 does not require any curing.

MasterEmaco S 902
• When applying MasterEmaco S 902 to eroded piles, the MasterEmaco S 902 "ball" should be
centred in the cavity firmly, and quickly smoothed out from the centre to the sides with both
hands, using "forward and sideways" pressure, moulding to appropriate shape and thickness.
• When applying underwater, place freshly-mixed "balls" of MasterEmaco S 902 into a wire
basket and lower steadily to diver.
• Where there is wave action or turbulence in the water, it is advisable to press the
MasterEmaco S 902 firmly in place for a moment or so before smoothing it out to shape.

Shotcrete - MasterEmaco S 820CI, S 822, S 680

• MasterEmaco S 820CI, S 822, S 680 are applied via a dry shotcrete machine and the water is
added at the nozzle and controlled by the shotcrete operator.
• Adjusting the water will influence the rebound and dust creation.

May 2018 Page 7 of 15

CURING
• All cementitious materials will benefit from curing and if possible the use of a curing compound
is advised, such as MasterKure 404.
• This is often impractical due to the requirement for the application of subsequent coatings and
in this case, the use of wet hessian or plastic should be considered.
• Thinner applied mortars such as the MasterEmaco N 102, N 5200CI need protection to reduce
the risk of surface crazing from premature drying.

Figure 1 - Cleaning out behind the reinforcing

Figure 2 - Square cutting the edges of the patch

May 2018 Page 8 of 15

Figure 3 - Shows grey colour of properly prepared steel

Figure 4 - Shows the MasterEmaco P 5000AP applied to prepared steel

May 2018 Page 9 of 15
Figure 5 Mixing the repair mortar

Figure 6 - Getting the required consistency

May 2018 Page 10 of 15

Figure 7 - Apply a slurry coat

Figure 8 - Build up repair in layers

May 2018 Page 11 of 15

Figure 9 - Screed off to give flat surface

Figure 10 - Use a sponge float to get good surface

May 2018 Page 12 of 15

Figure 11 - Finished patch ready for curing

Figure 12 - Dry shotcrete machine

May 2018 Page 13 of 15

Figure 13 - Spraying on a wall

Figure 14 - Spraying mortar onto overhead repair

Caution
For information on personnel protective equipment, first aid and emergency procedures, and water
disposal methods, refer to the product bag or Safety Data Sheet

May 2018 Page 14 of 15

 Application Guide for MasterEmaco Repair V7 0518
The technical information and application advice given in this BASF publication are based on the present state of
STATEMENT OF our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be
RESPONSIBILITY made as to a product's suitability for a particular use or application and no warranty as to its accuracy, reliability or
completeness either expressed or implied is given other than those required by law. The user is responsible for
checking the suitability of products for their intended use.

Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF either
NOTE orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since they, and not
BASF, are responsible for carrying out procedures appropriate to a specific application.
BASF Australia Ltd BASF New Zealand Ltd BASF Emergency Advice:
ABN 62008437867 Level 4, 4 Leonard Isitt Drive 1800 803 440 within Australia (24hr)
Level 12 Auckland Airport 2022 0800 944 955 within New Zealand
28 Freshwater Place Auckland, New Zealand
Southbank VIC 3006
Freecall: 1300 227 300 Freecall: 0800 334 877
www.master-builders-solutions.basf.com.au www.master-builders-solutions.basf.co.nz

May 2018 Page 15 of 15