A mid-sized construction materials manufacturer producing dry-mix mortars and tile adhesives faced a recurring problem: setting times slowed dramatically in low temperatures, draining productivity every winter and delaying project handovers. Employing more than 120 staff and supplying contractors across three countries, the company could not afford another season of lost output. This case study shows how switching to calcium formate solved both a technical and a commercial challenge.
The company had long relied on chloride-based accelerators to speed up setting in cold weather. Over time, however, chloride additives corroded reinforcing steel inside the products and caused efflorescence on finished surfaces. Customer complaints rose, rework costs climbed, and the manufacturer urgently needed an accelerator that performed in the cold without compromising long-term durability.
Early trials with other additives proved disappointing. Some worked only above 10°C, while others introduced unwanted side effects or doubled raw-material costs. The search was narrowed to a single requirement: a chloride-free accelerator that delivered consistent performance across the full winter temperature range.
After testing several alternatives, the company adopted calcium formate (Ca(HCOO)2), a chloride-free set accelerator supplied in 25 kg bags and 1,000 kg jumbo bags. Calcium formate accelerates the hydration of cement, shortens setting time, and increases early strength — all without introducing chlorides. Technicians found the dosage simple to adjust, allowing a smooth transition with minimal reformulation and no disruption to production schedules.
| Metric | Before | After |
|---|---|---|
| Setting time at 5°C | ~8 hours | ~4 hours |
| Early strength (24 h) | 12 MPa | 18 MPa |
| Corrosion complaints | Frequent | None |
| Winter output | Reduced | Full capacity |
The impact was immediate. Setting times fell by half, early strength rose by 50%, and corrosion-related complaints disappeared entirely. With full winter output restored, the company recovered seasonal revenue it had previously written off.
Within a single season, the manufacturer eliminated corrosion-related complaints and restored full winter output. Calcium formate has since become a standard part of its mortar and adhesive formulations — clear evidence that the right additive can deliver both durability and profitability, even in the harshest conditions.
