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:
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, withRE-CON ZERO and RE-CON ZERO EVO by Mapei make 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.
The precast industry is facing significant challenges. In the effort to produce more sustainable concrete, manufacturers are increasingly using low-clinker cements and lower-quality aggregates. However, they must still meet high standards for quality, performance, and cost control.
To meet these demands, water-reducing admixtures for precast concrete play a key role, ensuring strong water reduction, high early-age mechanical strength, and robustness.
The Dynamon NRG range is a complete line of water reducers based on innovative PCE (polycarboxylate ether) polymers, specifically developed to address these challenges. Unlike conventional superplasticizers, Dynamon NRG is uniquely formulated for high-slump and self-compacting concrete (SCC), delivering superior rheology with minimal viscosity: setting a new benchmark in the market.
Mapecube is a new high-tech range of strength-enhancing admixtures designed to accelerate cement hydration and promote crystalline growth, resulting in faster development of mechanical strength at early stages. These solutions are ideal for optimizing production cycles in precast plants.
Key benefits:
Sealants for moulds play a crucial role in precast production by ensuring dimensional precision, high-quality surface finishes, and effective leak prevention. These products are specifically formulated to seal joints, interfaces, and gaps between mould components preserving the integrity of the mould cavity, minimizing surface defects, and extending mould service life.
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 demoulding while protecting the integrity of the mould. Available in both water-based and vegetable oil-based formulations, they deliver excellent surface quality, reduce imperfections, and help extend the lifespan of production equipment by minimizing maintenance needs.
Key benefits:
Fiber reinforced concrete is one of the most promising technologies in the precast industry. Structural synthetic macrofibers are tridimensional reinforcement systems designed to improve post-crack behaviour, impact resistance, and fatigue performance of concrete. They offer a corrosion-free alternative reinforcement in various structural 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 guaranty an easy dispersion and distribution within the concrete matrix.
The Planitop Rasa&Ripara Zero range includes 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 Rasa&Ripara Zero range mortars deliver excellent adhesion, workability, and mechanical strength, making them the ideal choice for efficient and long-lasting repairs.
Key benefits:
The application of elastomeric coatings and paints from the Elastocolor range serves as an effective protective barrier for concrete surfaces, significantly avoiding the risk of carbonation and the development of microcracks or structural fissures.
Elastocolor coatings form a continuous, elastic layer that adapts to the substrate’s movements, thereby reducing the risk of deterioration even under thermal or mechanical stress. Furthermore, 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. By limiting the exposure to these harmful substances, elastomeric coatings contribute substantially to extending the service life and long-term durability of the concrete. Elastocolor paints can be coloured in an unlimited number of shades, ensuring a high aesthetic effect.
Alongside the Elastocolor range, Mapei offers Colorite Beton and Colorite Performance: acrylic, anti-carbonation paints that are ideal for protecting and decorating concrete elements.
Colorite Beton is a semi-hiding paint that protects the substrate and leaves an attractive finish which evens out the colour without hiding the surface structure. Colorite Performance provides concrete surfaces with an attractive finish and is available even in the most intense and bright colour shades.
Mapei developed the Mapefill ranges of grouts to anchor concrete elements and filling voids under structural baseplates. Thanks 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:
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.
In below-grade applications, surface sealing and protection can be achieved using a fully bonded, highly flexible sheet membrane choosing from:
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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.
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