Construction chemicals: Production route
Why modern superplasticisers replaced older lignin and naphthalene types
What this tab covers How it is made: the main production routes or, for product families, the main product types and technologies, compared on share of supply, inputs per tonne, plant scale, yield, co-products and unit cost.The family splits into concrete admixtures, sold to ready-mix and precast producers in bulk, and building products (waterproofing, adhesives, sealants, flooring, repair), sold through contractors and retail. Admixture chemistry moved from lignosulphonates in the 1930s-70s, to naphthalene and melamine sulphonates, to PCE since the 1990s, each giving more water reduction at lower dose. Building products are formulations of cement, sand, polymer powders, resins and bitumen. Value is in formulation for local cements, technical service on site and brand with applicators.
Routes compared
| Route | Share of supply | Inputs per tonne | Typical scale | Yield | Co-products | Unit cost |
|---|---|---|---|---|---|---|
| Polycarboxylate ether (PCE) superplasticisers | largest admixture type by value (indicative); admixtures 49.3% of market (IMARC 2025) | about 0.25-0.4 t macromonomer and 0.03-0.06 t acrylic acid per t of 40% solution (indicative); 16 MJ energy per kg (EFCA eco-profile 2002, superplasticisers) | reactor plants of 10-100 kt/yr of solution, many per region (indicative) | high conversion (indicative) | none material | tracks ethylene oxide and acrylic acid; not published |
| Older plasticisers: lignosulphonates, sulphonated naphthalene formaldehyde (SNF), melamine | not published; declining share (indicative) | naphthalene, sulphuric acid, formaldehyde for SNF (indicative) | 10-100 kt/yr (indicative) | not published | sodium sulphate (SNF) | cheaper per kg than PCE (indicative) |
| Other admixtures and cement additives | included in admixtures' 49.3% (IMARC 2025) | not published | blending plants | not applicable | none | not published |
| Waterproofing systems | about 18% of market value (indicative) | bitumen, polyols and isocyanates, acrylic emulsions, cement (indicative) | regional plants | not applicable | none | not published |
| Mortars, tile adhesives, grouts, sealants and flooring | about 29% of market value combined with repair and flooring (indicative) | about 0.3-0.4 t cement per t tile adhesive (indicative) | dry-mix plants of 50-200 kt/yr (indicative) | not applicable | none | not published |
How each route works
Polycarboxylate ether (PCE) superplasticisersA methoxy-polyethylene glycol macromonomer (made from ethylene oxide) is copolymerised with acrylic or methacrylic acid. The comb-shaped polymer adsorbs on cement grains and keeps them apart by steric hindrance, so concrete flows with much less water. Basis of high-strength, self-compacting and low-cement concrete.
Highest water reduction at 0.4-2.0% dosage; sensitive to clay in sand and to cement chemistry.
EFCA/Deutsche Bauchemie model EPD (2024); EFCA eco-profile (2002); ethylene oxide and acrylic acid tiles Older plasticisers: lignosulphonates, sulphonated naphthalene formaldehyde (SNF), melamineLignosulphonate is a pulp mill by-product. SNF is made by sulphonating naphthalene and condensing with formaldehyde. Both disperse cement by electrostatic repulsion. Still common in India, China and other price-sensitive markets.
Cheap and robust; lower water reduction; plasticiser dosage 0.2-1.6% of cement (EFCA model EPD 2024).
EFCA model EPD 2024; formaldehyde tile Other admixtures and cement additivesAccelerators (calcium nitrate, alkali-free aluminium sulphate for sprayed concrete), retarders (sugars, gluconates), air entrainers (surfactants), shrinkage reducers and cement grinding aids (amines and glycols) tune setting, durability and mill output.
Small volumes, high value in service; key to using more fly ash, slag and calcined clay.
IMARC 2025; indicative Waterproofing systemsLiquid-applied polyurethane, acrylic and polymer-modified cement coatings; bitumen, PVC and TPO membranes; crystalline additives that block concrete pores. Retail brands sell to masons and homeowners; systems sell to contractors with warranties.
Brand and applicator networks matter; poor application causes most failures.
IMARC 2025 (category); share indicative Mortars, tile adhesives, grouts, sealants and flooringDry-mix plants blend cement, graded sand, redispersible polymer powder (VAE) and cellulose ethers into bagged adhesives and repair mortars. Sealants are silicone, polyurethane or MS polymer; floors are epoxy or polyurethane resins.
Low capital, local; competition from cement majors' own mortar brands.
indicative Unit economics are indicative ranges from the sources named; costs move with feedstock and energy prices, plant size and region.