Arc sprayed zinc (Zn) anode on concrete surfaces has been an emerging technology for protecting reinforced concrete structures from rebar corrosion in coastal environments. Many cathodic protection (CP) systems with arc sprayed Zn anodes will reach or exceed their design life in the near future and thus may function improperly or insufficiently, making it necessary to replace the aged anodes. However, prior to this study, little was known about the most effective profile for the concrete surface, for either new concrete or old concrete with existing Zn anodes removed. This work develops criteria to properly prepare the concrete surface before the application of new Zn anode. Experimental studies were conducted both in the laboratory and for a field structure in Oregon. Artificial neural network was used to achieve better understanding of the complex cause-and-effect relationships inherent in the Zn-mortar or Zn–concrete systems and was successful in finding meaningful, logical results from the bond strength data. The goal is to achieve strong initial bond strength of new Zn to concrete, which is essential for long-term performance of the CP system. The results from this case study suggest that it is necessary to adjust the anode removal and surface sandblasting based on the electrochemical age of the existing concrete. In all cases of sandblasting, minimize the exposure of large aggregates (e.g., those bigger than 19 mm in diameter).