Phil Matisak
Master Builders Solutions US & Canada
Introduction
Concrete has always been the backbone of modern construction, from highways and tunnels to warehouses and data centers. Its strength and versatility are unmatched, but so is its environmental footprint. Cement, the key binding ingredient, accounts for nearly 90% of concrete’s embodied carbon, and concrete producers are under growing pressure to deliver mixtures that perform while lowering emissions and conserving resources.
That challenge is also an opportunity. With the right mix design strategies and admixture technologies, concrete producers can build smarter, reduce waste, and conserve materials — all while maintaining or even improving strength, durability, and efficiency. The new era of concrete is being defined by two priorities: cutting carbon and conserving natural resources.
Cutting Carbon Without Compromising Strength
Reducing cement intensity is the most direct way to cut the embodied CO₂ of concrete. But the real question is: how do you reduce the cement content without compromising performance?
Strength-enhancing admixtures provide one of the most effective solutions. By accelerating hydration and boosting both early- and late-age strength, these technologies allow concrete producers to reduce cement content by 5–20%. When paired with workability-enhancing admixtures that resolve flow and finishability challenges, embodied carbon reductions of 30–50% are achievable.
The Green Sense® Concrete methodology takes this even further, combining supplementary cementitious materials (SCMs) with advanced admixtures to optimize mixture designs. In practice, this approach has achieved over 70% cement replacement and more than 50% reduction in embodied CO₂ compared to conventional concrete. And it’s not just for showcase projects — concrete producers are applying these methods today in precast operations, tilt-up construction, and large-scale infrastructure.
Conserving Resources Through Recycling and Reuse
Sustainability also means rethinking what happens when all the concrete that is ordered isn’t used. Returned concrete has long been treated as waste, often destined for disposal or carbon-intensive crushing. In the new era of concrete, the returned material is viewed as a valuable resource.
Since the late 1980s, admixture systems have enabled returned fresh concrete to remain plastic for hours or even days, allowing it to be reused in new batches of concrete. ASTM C1798/C1798M - Standard Specification for Returned Fresh Concrete for Use in a New Batch of Ready-Mixed Concrete – provides requirements for this practice. Other technologies convert returned concrete into usable backfill, aggregate, or road base. By diverting concrete from the waste stream, concrete producers conserve raw materials, reduce costs, and strengthen their own operational resilience.
Conserving Water and Energy
Water is another critical input in concrete production, and one that’s under increasing stress in many regions. For over 70 years, water-reducing admixtures have helped the industry do more with less, and their influence remains profound.
High-range water reducing admixtures provide exceptional flowability for concrete at low and very low water-to-cementitious ratios, conserving water while improving strength and durability. Mid-range water reducing admixtures help create mixtures that are more efficient in the mid-slump range of 5 in. (125 mm) to 8 in. (205 mm) without sacrificing performance. Consequently, water reducing admixtures, particularly mid- and high-range, help reduce the energy associated with consolidation and, for slabs, the finishing of concrete. Pervious Concrete technologies expand resource conservation beyond production by managing stormwater on-site, reducing runoff, and supporting groundwater recharge.
Durability: Extending Service Life
Resource conservation doesn’t stop at concrete production — it continues through the entire life of a structure. Concrete that lasts longer requires fewer repairs, less replacement material, and fewer emissions tied to maintenance.
Crack-control fibers, shrinkage-reducing admixtures, corrosion inhibitors, and waterproofing technologies all help concrete withstand aggressive environments. By extending service life, concrete producers not only deliver better performance to their customers but also contribute to a smaller carbon footprint. In this way, durability is key to sustainability.
Proving Impact with Digital Tools
For concrete producers, sustainability isn’t only about making progress — it’s about proving it. Owners, designers, and regulators increasingly require Environmental Product Declarations (EPDs), LEED documentation, and Health Product Declarations (HPDs) as part of project specifications.
Master Builders Solutions supports concrete producers with tools and services that streamline the entire process — from data collection and life cycle assessment to third-party verification. These digital tools facilitate the demonstration of embodied carbon reductions, compliance with regulatory requirements, and position concrete producers as leaders in sustainable construction.
The New Era of Concrete
The construction industry is entering a new era, one defined by cutting carbon and conserving resources. For concrete producers and contractors, this shift is not just a regulatory requirement or a customer expectation; it is a fundamental change in the industry. It’s a chance to optimize operations, reduce costs, and deliver stronger, more sustainable results.
At Master Builders Solutions, our commitment is to help the industry meet this challenge head-on with admixture technologies, recycling solutions, and digital tools that make sustainability measurable and achievable.
Explore our Sustainability Page to learn more or connect with us to schedule a free EPD consultation. Together, we can build a stronger, smarter, and more sustainable future.