19 December 2018

Table of Contents for Readymix Plaster





Readymix Plaster

Ready Mix Mortar – A Sustainable Alternative

 

Growing ecological concerns and a renewed thrust on finding alternative construction materials has given a tremendous boost to the drymix mortar market in the country. While it was a thriving option for global companies, dynamics are changing fast in India and leading companies have started investing in production technology to gain tremendous benefits keeping environmental guidelines in mind reports Prerna Sharma.

 

In a rapidly urbanizing India, the demand of sand will only rise because sand is the main ingredient in making concrete and cement. Though the construction sector has only witnessed a 1.7 per cent growth this year, government schemes, like Swachh Bharat Mission and Housing for All by 2022, are likely to cause a resurgence. The demand for sand in India will be 1,430 million tonnes by 2020, estimates a 2013 report by the Freedonia Group, a US-based industry market research company. But worryingly, the production of sand has been going down for the past five years. According to the Indian Minerals Yearbook 2015, published by the Indian Bureau of Mines, sand production in 2014-15 was 2.1 million tonnes. As an alternative approach, Sujit Kumar Singh, senior programme manager, environment and social assessment team of Delhi-based non-profit Centre for Science and Environment, said that sustainable sand extraction is possible only if we know the regeneration rate of sand in a river and issue leases based on that data. Apart from that, one more alternative that can aid construction players is the usage of ReadyMix Plaster.

 

 

NEED:

 

A more sustainable and environment friendly option is RMC or to move up the value chain ReadyMix Plaster, for India’s construction sector. In terms of green ecofriendly construction materials, ReadyMix Plaster and dry mix mortars are emerging as the new contenders to RMC. ReadyMix plaster is the new international standard.

 

Although there are many manufacturers offering ReadyMix products in India, the market is very cost competitive and price sensitive.

 

 

INHERENT PROPERTIES

 

Mortar is the substance that is used to join bricks when constructing a wall. Mortar is used for masonry construction, flooring, plastering, and finishing, which will be in a wet state for the application. This kind of mortar is made up of the raw materials that are needed to make a substance that can be used to make a strong brick wall. The dry mix greatly differs from job-site mortars. Readymix Construction Machinerysources inform that dry-mix mortars are accumulated in a special factory with dedicated facilities on batching and blending of all the necessary ingredients in the controlled process. In this way, different types of dry-mix mortar products with well-defined properties and performance to meet specific requirements and applications can be produced.

 

Dry mix mortar is a dry powder or granular material made by mixing of fine aggregate, cementious materials, additives, fillers, etc. Dry mortar products contain both mineral cementitious binder and a polymer binder. Factory-mixed dry mortars are delivered to the construction site, in bags or special silos, and need to be mixed only with water prior to use.According to Mordor Intelligence research, in contrast to the conventional mortar, these dry mix mortars are produced in special factories, with dedicated batching and blending facilities in a highly controlled fashion. In addition to the significantly enhancing product performance, these pre-mixed dry mortars enable a high-degree application reliability and consistency. Owing to these factors, dry mix mortar finds a wide scope of application in masonry mortars, screeds, renders, tile adhesives, and waterproofing slurries, among others in various construction activities.

 

Although developed markets have moved up to Readymix Plaster, Indian market is still struggling to adopt Ready Mix Concrete itself, which is characterised by low penetration. Moving up to the next level of RMP is proving even more difficult, because Indian Standard (IS) is significantly below International Standards (ASTM - American, BS - British and EN - European). And end-users are yet to realize its virtues to ensure its rapid market penetration.

 

Dry mix products provide excellent technical properties to meet the stringent performance requirements which are common in the current construction scenario. The use of dry mix mortar products will be cost effective by reducing the potential construction problems with the long-term integrity of structures with a simple materials approach.Today the Dry Mix Mortar is conquering the market by replacing the traditional job site mixing mortar because of its various advantages.The market for dry mix mortar has been segmented on the basis of application and end-user industry.

 

One of the major market drivers is the long-term cost-effectiveness in the construction industry. Though the dry mix mortar is priced high when brought onto the onsite construction activity, it offsets labor costs, through ready-to-mix applicability of the mortar, and benefits the overall cost involved. On the flip side, lack of scope for customization of the product onsite for specific applications is likely to hamper the market growth.

 

 

 

MARKET POTENTIAL:

 

In 2016, Asia-Pacific registered the largest regional market for dry mix mortar. Factors, such as, growing construction activities and preference to cost-effective construction techniques, are favoring the market growth. Large-scale investments in infrastructural and construction activities, in emerging economies of Asia-Pacific region, are expected to drive the market during the forecast period.

 

In one of the most striking developments, recently Chilean cement and construction materials producer, Melon SA, agreed to sell its local mortar company, Melon Morteros SA to ParexGroup, a French provider of specialty dry-mortar mix solutions for the construction industry. The mortar unit is being sold for USD 6 million.

 

 

 

PERFORMANCE CRITERIA:

 

Bricklaying mortars have found applicationsinmajor European countries. They are hugely in demand because of their ability to offer consistent quality and reduce labour on construction sites. Wall renders and plasters are also widely used dry mix mortar products. They are typically delivered in silos to the construction site. The render is sucked from the silo, through a hose, using specialized equipment meant for the purpose, and pumped onto walls. Floor screeds are another popular category. Millions of square feet of floor screed are placed globally. One of the major advantages with an hydrite superplasticizer based floor screeds are that over 200 sqm of screed can be placed without joints. This is because of their low shrinkage. Quicker surface maturity is also achieved because of their property to dry out fast.

 

Tile adhesives are another area where dry mix mortar products are now being increasingly used. Thanks to the availability of the latest dry mix mortar technology based tile adhesives, the thin-bed fixing technique is being used instead of the conventional thick-bed method. While the thin-bed method tends to cost more, it aids in superior adhesion.Due to the low shrinkage factor, it also results in savings in the long run. Moreover, joint fillers, such as tile grouts, used to fill voids in tile setting and between plasterboards, are growing segments. Powder paints, delivered in silos to the construction site and which are applied using machine spraying is also emerging as a promising category.

 

Dry mix mortar is fast finding space in the construction activities for some time now and has a greater future in times to come as well. It enhances quality and speed of construction. The Key players in this segment include companies such as Ramco Cements Ltd, Magicrete Building Solutions, Citadel, Green Built, Perlecon, Ultratech, Frigmaires Engineers, Buildmate Projects, Saint Gobain Weber. Apart from them there also firms some local players such as Dico Fix, Pneucon Process Technologies, Laxmi En-fab, The Ready Mix Construction Machinery, RobusterConstructware LLP, SF Engineering Works, 360 Degree Global Equipments, Avcon Technics, Speed Dry Mix India etc.

 

 

 

DEMAND DRIVERS:

 

Their ability to save on labor costs has been one of the biggest demand drivers. With the use of specialized application equipment, substantial improvement in workmen efficiency and output has been reported due to the use of these products. For countries like India suffering from a crunch in construction labour, adoption of this technology can be greatly beneficial. Ease of application is another important factor that works in favour of dry mix mortar products. This is one more factor that is especially important in countries like India, where a majority of the construction workers are unskilled, with very low levels of education.

 

Another important factor that can further drive the demand for dry mix mortar-based products is the pressure from various quarters to deliver buildings that are durable and require very low maintenance. Their ability to deliver on the promise of consistency of quality is what has been a major reason for the remarkable growth in demand for these products. The need to increase the sustainability quotient of buildings and ensure long-term functional durability is the demand nowadays from specifiers and dry mix mortar technology is what is they are looking towards for delivering on this key aspect.

 

 

 

RESEARCH RECOMMENDATIONS:

 

Dry mix mortar is a new material technology which has been introduced by European countries initially and now it is used in Indian from last ten years in various states such as Maharashtra, Gujarat, Tamil Nadu, Kerala, Kolkata, etc. Dry mix mortar manufacturing plants provides consistent quality mix, due to proper formulations of its major three constituents such as Ordinary Portland Cement, river sand, additives. Being fully automatic operation, production cost goes high compared to semi-automatic indigenous plants. Research finds that feasible locations of dry mix mortar plants should be nearer to the source of sand. Plant installation cost varies as per the plant capacity. Dry mix mortar plants can be used to produce other powder premixes such as wall putty, tile additives, etc. Hence installation of multipurpose plants for production of various premixes is essential. Effective working of plants with less labour may be possible. Plant working and formulations of dry mix mortar should be as per standard. Manufacturers should be supported by end users for better use of this material.

 

ReadyMix mortar has strong technical features, but it should be conveyed properly. Due to consistent dry mix quality, ReadyMix mortar is efficient, durable, free from shirk age cracks formation. As a result, compressive strength, pull off strength and other technical parameters are superior for ReadyMix mortar compared to job-site mortars. Though the manufacturing cost seems to be high but it is compensated on other side by transportation of materials, labour requirement and quality of work provided to big projects. Furthermore, the premium paid for ReadyMix mortar comparedto job-site mortar has significantly reduced over the past few years. Due to the feasibility of installation of smaller range capacity dry mix manufacturing plants, this will encourage the entrepreneur. And it may become popular like RMC. In an effort to better define norms suited to Indian climatical conditions, a group of manufacturers has begun dialogue to form a manufacturers association for ReadyMix Mortarsand attempt tofurther educate end users on the benefits.

 

 

 

GROWING EXPANSE:

 

Market research analysts at Technavio predict that the global concrete repair mortars (CRM) market will grow at a CAGR of around 8 per cent by 2021. The rising demand for polymer-modified mortar is identified as one of the primary growth factors for this market. The use of polymer-modified concrete (PMC) as a construction material in structural applications is increasing. Polymer concrete has exceptional durability properties and offers great strength to buildings. PMC is manufactured by modifying ordinary cement mortar or concrete with polymer additives such as re-dispersible polymer powders, latexes, water-soluble polymers, liquid resins, and monomers. The combination of natural polymers with inorganic materials results in the development of high strength and durable construction materials. Currently, PMC is mainly used for flooring, resurfacing, and patching. It is also used as overlays on bridges and roadways, both as new construction and in repairing existing deteriorated structures. However, PMC is also widely used in concrete structures due to their properties such as high tensile strength, bond strength, resistance to cracking, higher flexural strength, and impermeability.

 

In terms of geographic regions, APAC will be the major revenue contributor to the CRM market throughout the forecast period. The CRM market in APAC is largely driven by the growth in the end-user industries such as building and car park, road and infrastructure, and utility industries. Moreover, the rise in the repair and maintenance expenditure in leading APAC countries such as Australia, Japan, and China will also drive the demand for CRM in this region.The CRM market consists of major vendors and numerous global players. These players have a large geographical presence with huge production facilities located across the world. A considerable number of small regional vendors also operate in the market and account for significant shares. The competitive environment in the market will intensify in the coming years with technological innovations that lead to an increase in product extensions.

 

During 2016, the polymer cementitious segment accounted for the major shares of the CRM market. Properties such as the tensile strength, environment-friendly nature, and extraordinary workability will contribute to the growth of this market segment in the coming years. Additionally, benefits such as the low cost and a wide range of applications will also propel the segment’s growth in this global market.

 

According to the market research report, the building and car park segment accounted for the maximum share of the CRM market during 2016. The increase in construction projects around the world that include the construction of parking areas involving the use of polymer cementitious mortars as repairing agents and the high-volume requirement of CRM in the repair and refurbishment of residential and non-residential buildings, will be the major factors that drive the growth of the market in this end-user segment. With the slowdown in world economic growth, the Dry Mortar industry has also suffered a certain impact, but still maintained a relatively optimistic growth. The past four years, Dry Mortar market size maintained the average annual growth rate of 4.31 per cent from 23700 million $ in 2013 to 27000 million $ in 2016. In the next few years, dry mortar market size will be further expanded, and by 2021, the market size is expected to reach $32000 million.

 

The analysts forecast the global dry construction market to grow at a CAGR of 5.58 per cent during the period 2017-2021.

 

 

 

Fast facts

  • Growing environmental concerns springing huge opportunities for readymix plaster
  • Fast Application hence reduces labor cost
  • No wastage
  • Asia Pacific largest market for drymix mortar
  • Market to grow at CAGR of 8 per cent by 2021

 

 

 

Advantages

  • Reduced shrinkage cracks through better cement hydration
  • No delaminating or pop-out on smooth or concrete surface due to very good bond strength
  • Good workability and sag resistance
  • Very good compressive flexural and tensile strength than ASTM standard values
  • Good water resistance property
  • Better flexibility
  • Consistent quality
  • Easy to mix and apply
  • Better finish and surface appearance
  • Almost nil wastage of the material at site
  • Minimum space required for the storage
  • Inventory cost saving
  • No multiple raw material (sand, cement and additives)
  • Minimum supervision requires

 

 

 

Major Brands

  • Ascolite
  • Build Well
  • Dicofix
  • Kaneria Ready-Mix
  • MagicPlast
  • Ramco Block Fix
  • Renaplast
  • Roofit Mix
  • Silicoplast
  • TUFF Duroplast
  • UltraTech Readiplast
  • Weber Bloksetplus

 

 

 

 

 

“RoofitMix was the pioneer in this field, starting production in 1999 – almost a decade before any other player. RoofitMix has faced its challenges but has responded by designing products that provide economy and quality performance. Recently, noting the requirement for machine application, RoofitMix has partnered with ToolCrete, USA and will be marketing its products in India. The combination of both quality materials and automated application will further fuel the market for ReadyMix Plasters in India.”

Vinayak Motwani, Director, Robuster Constructware LLP

 

 

 

 

 

“The quality finish provided by Walplast's wall putty as well as other associated products being launched in the market captured a big market in a short span of time. The superior finish quality of product and its affordable prices also made customers go in for these professional plastering solutions. With passing time and gaining due experience of the demands of market, Walplast launched many variants of products and the consistent performance delivered over the years has helped it to enjoy status as one of largest manufacturers. ”

Ashok Mehta, Chairman, Walplast Products Pvt Ltd

 

 

 

 

“Godrej Construction is one of the first concrete manufacturers in the country to obtain the certification for Integrated Management System, which includes certifications for ISO: 9001, ISO: 14001 OHSAS: 18001 & QCI. Its products span across different types of Concrete Products, Walling and Pa AAC) blocks, Recycled concrete blocks and pavers of various types, shapes and sizes. State-of-the-art facilities and a well-equipped Central Concrete Lab with cutting edge concrete technologies and practices, enable the company to ensure consistency in quality of our products batch after batch. Tuff Easyfix block binding mortar is a thin-joint, high strength adhesive for quick & firm construction of AAC blocks. It is manufactured through a PLC controlled computerized process from cement and graded natural sand blended with polymer to impart high strength and water retention properties. Controlled manufacturing process ensures consistent quality output as per specifications across batches. It enhances build accuracy of finished walls. Similarly, Tuff Duroplast is a convenient easy-to-use plaster, which is not only stronger than traditional plastering but also looks nice and binds better. ”

 

 

 

“Ascolite is now a well-renowned brand that caters to solutions such as AAC Blocks, Block Jointing Mortar, Ready Mix Plaster, Gyplast, Wall Putty and more. Ascolite now comprises of a complete walling solution. Ascolite Ready Mix Mortar is a premixed cement-based solution to substitute for the traditional site mix wall plaster process. The solution consists of processed sand which is graded and distributed as per particle size and proportionately mixed cement and water-soluble polymers which act as additives. Also available with Alkali Resistant Glass Fibre for higher strength & durability. The application method requires mixing of water before application and the mix is ready for plastering. Ascolite Ready Mix Mortar can be used for both external and internal plastering.”

 

 

“The Renaplast Ready mix cement plaster is a mix of high quality polymer additives and binders. This cement plaster is very strong and durable. It can be used on inner walls, outer walls and stone as well as concrete surfaces. The tiling work can be completed efficiently and at faster pace using Renaplast cement plaster. Renaplast is easy to use and gives a fine finish to the tiles. We can assure superior finish and longevity with thick plaster as well as thin plaster of Renaplast. Our products go through stringent quality tests to ensure its life span. ”

R P Selvasundaram, Chairman & MD, Renaatus Procon Pvt Ltd

 

 

 

“Weberblokset plus from Saint Gobain is a high grade non-refractory mortar consisting of high performance polymers for bonding masonry units, like AAC blocks. It is a Weber proprietary formulationof blended polymers, hydration retainers, cement, mineral additives and graded fine sand to have excellent grip and adhesion strength between block to block and block to cementitious surface. weber bloksetplusis in compliance with C1660-09 ASTM standards, which is the world’s only standard for thin bed mortar for autoclaved aerated cement masonry. It is a timely setting mortar, which allows uninterrupted block mounting, which is far lower in time than conventional and ordinary mortars. Combined with qualities of good workability, spread of material and no need of curing, weber bloset plus increases the speed of construction 24- 48 hours before next stage like plastering. Additionally, it is designed to eliminate the need for any external water curing which save critical resource like water. It also helps in reducing carbon footprint”

 

 

 

 

COMPARISON

 

Conventional

ReadyMix

Environmental Sustainability

Low

Medium

Mix Design Accuracy

Low

Medium

Accountability of Material

Low

High

Particle Size Distribution

Low

Medium

Water Proofing

Low

Medium

Labor Requirement

High

Low

Material Availability

Low

Medium

Crack Prevention

Low

Medium

Strength Parameters

Low

Medium

Wastage

High

Medium

Cost

Low

Medium

Curing Requirements

High

Medium

Quality Control

Low

Medium

Application Requirements

No Special Requirements

No Special Requirements

 




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