20 August 2019

Readymix Plaster

Effective and sustainable



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 reports ROHAN AMBIKE.




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.




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 is hugely different from job-site mortars. 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.




The concept of dry mix mortar was conceived as dry mix factory-made products which are used for plastering, masonry, tile adhesives, flooring screed, and repair products which are based on cement being the main binder. The dry mix mortar products are available in pre-bagged form and can enable significant enhancement on building quality based on simple mix and apply operations. As a result, the adaptation of these products will be faster in the years to come.




Dry Mix Mortar 2Population growth is on the rise and non-availability of natural resources as raw materials to meet the demand in infrastructure activities is a concern. Also, green building certifications are an emerging trend and there is an increasing requirement from a durability perspective for lower maintenance. Dry mortar industry has a large role to play in this regard by developing quality assured products with hassle free application even with machines. Automated plants, sophisticated lab tests and analysis, and scientific formulations of products have made adapting to the local raw materials and standards easier.




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.




Advantages of Ready mix Mortar


The raw materials used by on-site mixed mortar are of a single species, with artificial batching employed, and free-fall mixer for stirring. Therefore, the performance of mortar is poor and the quality is unstable. Hollowing, cracking and shedding phenomena are widespread. On-site mixed mortar belongs to labor-intensive and manual workshop production, low in the productivity and single in the final product.




Although the investment is small, the product quality is unstable. Stacking materials on site occupies land. Wastewater, waste, and noise are produced in the production process, not only polluting the environment, but also not conducive to the civilized construction, so it is a phased out production method.




Ready-mixed mortar is mortar of factorization production, with professional and technical personnel in the research and development work of mortar, and the performance of mortar can be adjusted according to the needs of project, so that the quality of mortar can be guaranteed. Usually in mortar more admixtures and additives are added, fundamentally improving the performance of mortar. Mortar is of many varieties and multiple functions.




In addition, the batching of mortar uses the automated and micro-computerized control, so the product quality is stable and reliable. Thus, ready-mixed mortar is not simply moving from the site to the factory production, but high-quality mortar. Promoting ready-mixed mortar is an important technical and economic measure for the technological progress of construction, and an important technical means to guarantee the construction engineering quality, improve the modernization level of construction, and to promote the civilized construction.




In addition, the ready-mixed mortar can use the artificially machine-made sand made from construction waste, coal gangues, steel slag and other industrial solid waste to replace the natural sand, which can save natural resources, has no adverse effects on the product quality, and can consume fly ash and other industrial waste. This can not only benefit the waste utilization, but also can reduce environmental damage and achieve the purpose of energy saving and emission reduction.




Market statistics


According to a report on Dry Mix Mortar Market by Mordor Intelligence, the global dry mix mortar market is estimated to grow CAGR of 6.73 per cent, over the forecast period, 2018-2023.Increasing Construction activities in the United States and Asia-Pacific




The global construction sector is expected to expand in real terms, by an annual average of 3.2 per cent in the coming decade, to a nominal value of more than USD 6.0 trillion. The Asia-Pacific construction industry is the fastest-growing market across all regions and is expected to account for the largest share in the construction market, in the world. Rapid increase in population, in Countries like China and India, is expected to give a rise in demand for the residential construction, which, in turn, augments the usage of dry mix mortar. The key areas of expected growth are social infrastructure, schools, hospitals, government accommodation, water, defence infrastructure, and water resources.




 In the Asia-Pacific region, infrastructure accounted for 37 per cent, residential for 34 per cent, and non-residential for 29 per cent share of the construction spending in 2017. Recently, Japan has also emerged as one of the major construction markets in Asia-Pacific. In Japan, Tokyo has emerged as a top market among the rest of the countries in the Asia-Pacific region, for investments and development prospects, of which, residential sector consists of a huge part. Apart from this, the impending 2020 Tokyo Olympics is also expected to significantly increase the construction activities in providing accommodations for the Olympic athletes, which includes a sports complex and Olympic village.




This is expected to, in turn, help in the growth of the dry-mix mortar market in the region. The construction industry in the United States has not been the same in 2017, as it was in the past three years. But there is an increase in private construction spending over the years. The residential and non-residential construction in 2017 has increased significantly and is likely to grow in 2018. All these factors are expected to improve the demand for the studied market.




Render Application - a Huge Market Potential


Dry mix products provide excellent technical properties to meet the stringent performance requirements that are common in the current construction scenario. Additionally, the use of dry mix mortar products is economical as they reduce the potential construction problems with the long-term integrity of structures with a simple materials approach. Dry mixed mortar contains the precise blend of materials and only requires the addition of water to produce a suitable render.




Dry mix mortar comprises of special additives that improve the workability of renders and help them bond to the background and reduce the risk of cracking. They can be also used for decorative finishes. Rendering is done in almost all of the construction applications to achieve a smooth or deliberately textured surface. Increasing construction activities, worldwide, are expected to drive the use of dry mix mortar in renders over the forecast period.




Asia-Pacific to Dominate the Market


In 2017, Asia-Pacific registered the largest regional market for dry mix mortar. Factors, such as growing construction activities and preference for cost-effective construction techniques, are favouring the market growth in countries such as China and India. China is among the global drivers in the consumption of dry mix products, owing to the huge infrastructure and residential growth taking place in the country.




The Chinese government has rolled out massive construction plans, including making provision for the movement of 250 million people to its new megacities over the next ten years, despite efforts to rebalance its economy to a more service-oriented form. As the construction industry is dominated by state-owned and private enterprises, increased government and private spending in this regard are pushing the industry to the peak position in the world. There have been investments of CHY 823.8 billion and CHY 801.5 billion in Chinese rail infrastructure in 2015 and 2016, respectively.



In India, a cumulative total of USD 24.67 billion foreign direct investment has been made for the construction activities (including townships, built-up infrastructure and construction- development projects), between April 2000 – December 2017. The country is likely to witness an investment of around USD 1.3 trillion in housing over the next seven years, where the country is likely to witness the construction of 60 million new homes.




The availability of affordable housing is expected to rise around 70 per cent by 2024, in India. All the above-mentioned factors, in turn, expected to increase the demand for dry mix mortar in the region during the forecast period.




Experts views


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 Mortars and attempt to further educate end users on the benefits.

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