At a gathering in Venice late last month, the Construction Chemicals Division of Degussa Construction Chemicals unveiled a new system aimed at reducing energy consumption in precast operations. Master Builders, Inc., the Cleveland-based admixture operating unit of Degussa Construction Chemicals in the Americas, contributed to the technology and will promote it to customers throughout North America.

The Zero Energy System was developed by researchers, scientists and concrete experts from the Degussa Construction Chemicals worldwide organization. The system combines Glenium polymer-based chemical admixtures, self-compacting Rheodynamic concrete, and the knowledge and support of technical service personnel to assist precast producers in optimizing processes to achieve a variety of energy savings — in the form of productivity, power, and efficient use of resources.

Glenium high-range, water-reducing admixtures are used in the Zero Energy System to produce high early strength. Because of this rapid yet controlled strength development, precasters can now eliminate or reduce heat-curing requirements without sacrificing performance and durability, developers note.

The system leverages the self-consolidating features of Rheodynamic concrete to allow precast producers to eliminate external vibration while improving surface appearance and engineering properties of precast elements. Energy savings are realized in the form of reduced power and equipment requirements for vibration, and reduced manpower energy needed for production processes, maintenance and repairs. Gains in safety are achieved by reducing the hazards and noise associated with vibration.

The Zero Energy System can be tailored to meet individual precast producer needs, Master Builders reports. Precast producers can strive to achieve total Zero Energy production, or they can use combinations and elements of the Zero Energy System to realize specific benefits.

“We have responded to challenges faced by precast producers who are concerned about reducing energy consumption, increasing safety at their operations, and optimizing their production cycles,” notes Master Builders President and CEO Mike Shydlowski. “The new polymer is truly innovative and has the potential to dramatically influence how precast concrete is manufactured in the future. We are constantly working to develop ‘green’ products and technologies and to help our customers implement environmental improvements they desire in their plants and products.”

Specialists in modifying and enhancing the properties of concrete by means of chemical admixtures, he adds, Master Builders personnel were instrumental in the development of the new technology. They worked with precast concrete producers to ensure the new technology would help achieve substantial benefits in terms of production and the durability and aesthetics of finished precast concrete elements.