PRECAST concrete solutions

The concrete industry is facing growing challenges due to the depletion of natural resources caused by increased construction activity. One of the most pressing issues is the scarcity of natural aggregates used in concrete mixes. To maintain production levels that meet societal demands, concrete producers—including those in the precast sector—must explore alternative raw materials.

MAPEI’s RE-CON line offers a comprehensive approach to promoting a more sustainable concrete lifecycle. Within this line, the Re-Con AGG range leverages advanced admixture technology to enable the use of challenging aggregates such as:

• Manufactured sands with high fines content and delterious material such as mica-free minerals.
• Clay-bearing aggregates..
• Recycled Concrete Aggregates (RCA) containing residual calcium compounds.

According to estimates, returned concrete accounts for around 3% of the total amount produced, or around 900 million tonnes per year at a global level. Returned concrete leads to high environmental impact and the need for disposal. Today, with Re-Con Zero EVO MAPEI makes it is possible to recover and transform returned concrete, thereby going from a linear economic model, based on the production of waste, to a more circular economic model.
Re-Con Zero EVO is used to reduce the waste generated by the concrete production processes by transforming returned concrete into aggregate that can be used in the production of new concrete.

One of the most crucial stages in precast concrete manufacturing is the demoulding phase. Releasing concrete elements from the formwork must occur within a controlled and minimized timeframe to maintain structural integrity and avoid surface defects.

Mapeform form-release agents are specifically designed to ensure clean, effortless demolding while protecting the integrity of the mold. Available in vegetable oil-based formulation, they deliver excellent surface quality, reduce imperfections and help extend the lifespan of production equipment by minimizing maintenance needs.

Key benefits:

• Ensure easy and clean demoulding
• Preserve formwork surfaces and extend reuse cycles
• Minimize air voids and improve surface finish
• Available in vegetable oil-based formulations

Fiber-reinforced concrete is one of the most promising technologies in the precast industry. Synthetic macrofibers are tridimensional reinforcement systems designed to improve the post-crack behavior, impact resistance and fatigue performance of concrete. They offer a corrosion-free alternative reinforcement in various applications, thereby enhancing the sustainability of the precast industry.

Mapei is a global leader in the engineering and manufacture of high-performance macro synthetic fiber-based reinforcement systems for concrete. As a comprehensive solutions provider, Mapei offers advanced technical support for the design and formulation of fiber reinforced concrete.

Besides, the company also offers micro fibers that improve the resistance of concrete to cracks caused by plastic shrinkage, which guarantees an easy dispersion and distribution within the concrete matrix.

Key benefits of fibers:

• Ensure post-crack tensile and flexural strength
• Improve impact resistance and fatigue performance
• Allow reduction or replacement of traditional steel reinforcement
• Simplify logistics and increase safety on-site

Planitop and Topcem high-performance cementitious and polymer-modified mortars specifically formulated to restore the appearance, durability, and structural integrity of damaged or defective concrete elements.

Ideal for vertical, overhead, and horizontal applications, Planitop and Topcem range mortars deliver excellent adhesion, workability, and mechanical strength, making them the ideal choice for efficient and long-lasting repairs.

Key benefits:

• Fast setting and drying in all seasons
• Speeds up repair work
• Durability
• Hardens without cracking
• For repair and skim coating applications
• Thickness range: from 3 mm to 40 mm
• Excellent workability and thixotropy
• Smooth, uniform finish
• CO₂ emissions fully offset

The application of elastomeric coatings and paints from the Elastocolor product line serves as an effective protective barrier for concrete surfaces, significantly avoiding the risk of carbonation and the development of microcracks or structural fissures.

Elastocolor finishes form a continuous, elastic layer that adapts to the movements of the substrate, thus reducing the risk of deterioration even in the presence of thermal or mechanical stress. They effectively inhibit the penetration of aggressive atmospheric agents such as carbon dioxide (CO₂) and sulphur dioxide (SO₂), which accelerate the deterioration of reinforced concrete. They therefore make a concrete contribution to extending the life cycle and durability of concrete. Furthermore, Elastocolor finishes can be produced in an unlimited number of colours, combining aesthetic appeal with technical performance.

MAPEI has developed grouts to anchor concrete elements and filling voids under structural baseplates. Due to their high-flow, excellent mechanical strength and superior dimensional stability, they ensure secure, durable load transfer in both dynamic and static conditions.

Key benefits:

• Fill voids under baseplates
• Anchor steel and concrete elements
• High mechanical strength at early and final stages
• Shrinkage-compensated to ensure excellent adhesion
• >Resistant to both static and dynamic stress

MAPEI has developed a wide range of epoxy adhesives that are used as bonding agents, meeting ASTM C881 for such product applications as:

• Bonding of match-cast precast segments.
• Bonding hardened concrete to hardened concrete.
• Bonding agent for screeds, toppings and repair mortar on concrete slab.
• Injection of concrete cracks and cap seal for pressure-injection epoxy grouting.
• Segmental bridge adhesive for precast elements.

Elastic sealants prevent the ingress of atmospheric agents and guarantee thermal and acoustic insulation of construction and expansion joints, even those subject to joint movements.

MAPEI offers a complete range of solutions to meet all sealing and bonding requirements. Some products in the Mapeflex range are specifically designed for sealing joints in precast elements.

To guarantee the designed durability of the structure, pre-cast concrete elements must be properly waterproofed and protected against water, moisture and weathering/chemicals, according to the specific field of application where they will be used.

Joint sealing is a key success factor for all joints between precast elements, and MAPEI offers a complete range of products to seal joints internally.
Precast elements used in tanks or other hydraulic structures also need to be waterproofed and protected against chemicals. MAPEI provides a wide variety of liquid-applied membranes, which can be applied on site when elements are placed.

Dry-mix concrete is one the most relevant solutions for manufacturing high-quality precast elements such as blocks, pavers, and pipes. Its low water content allows for rapid demoulding, excellent dimensional control, and high mechanical strength at early stage.

Thanks to the Vibromix range of concrete admixtures, the efficiency of the production process is significantly enhanced through advanced vibration and compaction technology. The resulting concrete elements are highly durable and uniform.

The use of Vibromix products helps address key challenges in dry-mix concrete production — including moisture control, mix precision, and equipment performance — enabling greater process stability and overall optimization.