DRY MIX MORTAR (DMM)
(DRY MIX PLANT WILL CONSTITUTE OF FOLLOWING ITEMS: READY MIX PLASTER,
THIN BED MORTAR, TILE ADHESIVES (FLOOR AND WALL TILES) AND TILE GROUTS)
[CODE NO.3308] J.C.: 1386
Dry Mortar Mix is gaining eminence in modern times owing to its versatile superiority in regard to characteristics over the conventional in-situ mortars viz. better performance easy to uses easy to set and the quality of leaving no crakes and voiles. Besides it has preferably better and wider field of application as patching & repairing materials for plasting purposes and other construction works viz. internal/external plastering masonry work etc. It is a very good substitute for conventional in-situ mortars.
Various types of Ready mix dry mortar comprise internal plaster mortar, external plaster mortar masonry mortar, quick setting mortar high strength mortar repair mortar self leaving flooring mortar pre-mix RCC mortar etc.
One specific advantage regarding manufacture of these ready mix dry mortar is that they can be manufactured in a single unit by variation in composition proportions as per different formulations.
Ready mix dry mortar is particularly useful on congested siles or in road construction where little space for the mixing plant and for extensive aggregate stockpile is available but the greatest single advantage of ready mix dry mortar is that it may be made under better conditions of control than are normally possible on any large construction sites.
MORTARS
These consist of finely ground refractory grain and plasticizers that can be thinly spread on brick during construction.
For air - setting mortars sodium silicates or phosphates provide strength at room temperature. Heat setting mortars contain no additives and develop strength only when a ceramic bond is formed at high temperatures.
AIR - SETTING MORTAR
A refractory composition containing chemical agents that sure hardening at temperatures below that of ceramic bonding but above room temperature sometimes called "air hardening".
HOT-SETTING BONDING MORTAR
A refractory mortar material which requires relatively high temperature fro the development of a bond.
MASONRY CEMENTS
Masonry cements are cements fro use in mortars for masonry construction. They are formulated to yield easily workable mortars and contain special additives that reduce the loss of water from the mortar to the prours masonry units.
COST ESTIMATION
Plant Capacity : 25.00 MT./day
land & Building (2000 Sq.Mtrs) : Rs. 1.14 Cr
Plant & Machinery : Rs. 54.75 Lacs
Working Capital for 2 Months : Rs. 1,32 Cr
Total Capital Investment : Rs. 3.12 Cr
Rate of Return : 50%
Break Even Point : 45%
INTRODUCTION
MORTARS
AIR - SETTING MORTAR
HOT-SETTING BONDING MORTAR
MASONRY CEMENTS
USES AND APPLICATION
DRY MORTAR PRODUCTS:
PROPERTIES AND CHARACTERISTICS
B.I.S. SPECIFICATION
PROCESS AND EQUIPMENT MAINLY USED IN DRY MORTAR PLANT
RAW SAND RECEIVING & STORAGE:
CEMENT, FLY ASH AND ADDITIVE RECEIVING AND STORAGE:
ALL INGREDIENT EXTRACTION, WEIGHING AND DISCHARGE IN MIXER:
MIXING:
MIXER DISCHARGE AND PACKING:
PROCESS FLOW DIAGRAM
RAW MATERIALS FOR DRY MIX MORTAR
(1) BINDERS
(2) FILLERS
(3) CHEMICAL ADDITIVES
(4) PIGMENTS
PRODUCTION AND TYPES OF DRY MIX MORTAR
TYPE OF DRY MORTAR PRODUCTS
OVERVIEW OF CONSTRUCTION CHEMICAL IN INDIA
MARKET SIZE AND PAST GROWTH
FIGURE: INDIAN CONSTRUCTION CHEMICAL INDUSTRY (INR CRORES)
CONSTRUCTION CHEMICALS SEGMENTS
FIGURE: INDIAN CONSTRUCTION CHEMICAL PRODUCT SHARE (%AGE)
ADMIXTURES
FLOORING AGENTS
WATERPROOFING AGENTS
REPAIR & REHABILITATION
MISCELLANEOUS
SEALANTS
GROUTS
TILE ADHESIVES
MAJOR PLAYERS
KEY CHALLENGES
GROWTH DRIVERS AND FUTURE OUTLOOK
GROWTH IN URBAN HOUSING SECTOR:
GROWTH IN END-USE MARKET:
FIGURE: CONSTRUCTION INDUSTRY IN INDIA
INCREASING PENETRATION OF CONSTRUCTION CHEMICAL PRODUCTS:
FIGURE: SPENDING ON CONCRETE ADMIXTURES IN INDIA
INCREASING COMPLIANCE WITH INTERNATIONAL MANUFACTURING STANDARDS:
FIGURE: INDIAN CONSTRUCTION CHEMICAL INDUSTRY (INR CR)
POTENTIAL OF DRY MIX MORTAR IN INDIA
SOME OF THE DRY MIX MORTAR PRODUCTS INCLUDE
THE ADVANTAGES
FUTURE:
MARKET SURVEY (INDIAN)
RISE IN POPULARITY
APPLICATION AREAS
DEMAND DRIVERS
BUOYANT FUTURE
INCREASING PREFERENCE FOR DRY MIX MORTAR OVER TRADITIONAL
MATERIALS BODES WELL FOR THE DRY MIX MORTAR MARKET
DRY MIX MORTAR TECHNOLOGY
STANDARDS
DEFINITIONS
MARKET OUTLOOK AND ESTIMATING OF DEMAND
THE GLOBAL PRODUCTION VOLUMES
FIG. WORLD MARKET DEMAND AND DEVELOPMENT IN 2006-2011
CEMENT IN MORTARS
CAPACITIES VS. MARKET DEVELOPMENT
MAJOR MORTAR PRODUCERS
THE DRY MIX MORTAR INDUSTRY CURRENTLY SHOWS THREE REMARKABLE TENDENCIES
THE WORLD BY REGIONS
AN ATTEMPT AT MARKET CLASSIFICATION
THE MAIN DRIVERS FOR DRY MIX MORTARS IN EMERGING AND GROWING
MARKETS ECOLOGY AND PROLONGED LIFETIME
CONSISTENCY OF QUALITY
EFFICIENCY AND LOGISTICS
EASE OF APPLICATION
REGIONAL ADAPTABILITY
THE FIELDS OF GROWTH
NEW CONSTRUCTION
MAINTENANCE AND RENOVATION, WATERPROOFING
RETROFITTING FIFS
INFRASTRUCTURE
CHALLENGES TO THE DRY MIX MORTAR INDUSTRY
CEMENT AS MAIN BINDER
CHANGING STYLES AND HABITS IN ARCHITECTURE
DETERIORATION OF QUALITY
LACK OF WARRANTIES AND LEGAL REQUIREMENTS
SUMMARY AND CONCLUSIONS
PRODUCTION OF DRY MIX MORTAR
INSTALLED CAPACITY & UTILIZATION OF DRY MIX MORTAR
APPARENT CONSUMPTION OF DRY MIX MORTAR
ESTIMATED DEMAND
DEMAND SUPPLY GAP
PRESENT STATUS AND FUTURE GROWTH PROSPECT OF READY MIX CONCRETE
POTENTIAL OF FUTURE GROWTH OF RMC IN INDIA
TABLE – PROBABLE PATTERN OF CEMENT AND CONCRETE CONSUMPTION
IN NEXT THREE FIVE YEARS PLANS.
TABLE: EXPECTED GROWTH OF COMMERCIAL RMC IN INDIA
PRESENT MANUFACTURERS/SUPPLIERS OF DRY MIX MORTAR
RAW MATERIALS AND COMPOSITION OF DRY MIX MORTAR
DRY MORTAR FORMULATIONS COMPRISING
MOST PREFERRED ARE COMPOSITIONS COMPRISING
TECHNICAL DETAILS OF MORTAR MIX
COLORS
SIZES
YIELD
TECHNICAL DATA
APPLICABLE STANDARDS
PHYSICAL/CHEMICAL PROPERTIES
INSTALLATION
SURFACE PREPARATION
MIXING
INSTALLATION
CURING
PRECAUTIONS
WARRANTY
FORMULATIONS
COMPOSITIONS WITH INGREDIENTS OF DIFFERENT
READY MIX DRY MORTARS
1.INTERNAL PLASTER MORTAR
2.EXTERNAL PLASTER MORTAR
3.MASONRY MORTAR
4.QUICK SETTING MORTAR (RCC)
5.HIGH STRENGTH MORTAR
6. REPAIR MORTAR (MORTAR FOR REPAIR & PATCM WORK)
7. SELF LEVELING FLOORING MORTAR
8. PREMIX RCC MORTAR
FORMULATION OF DRY MIX MORTAR (TILE ADHESIVE)
FORMULATION OF BRICK LAYING MORTAR AND AERATED LIGHT WEIGHT
CONCRETE ADHESIVE
FORMULATION OF VOID PATCH MIX
FORMULATION OF WATER PROOF MORTAR (RCC)
FORMULATION OF HIGH STRENGTH R.C.C MORTAR
FORMULATION OF ACEATED LIGHT WEIGHT
CONCRETE ADHESIVE
FORMULATION OF CERAMIC TILE ADHESIVE
FORMULATION OF TILE GROUT
CEMENT BASED TILE ADHESIVE WITH LEVELING PROPERTIES
CEMENT BASED TILE GROUT WITH FAST SETTING PROPERTIES
FORMULATION OF CEMENTITIONS TILE ADHESIVE
FORMULATION OF THIN BED MORTAR
FORMULATION OF THIN BED AAC BLOCKS JOINTING ADHESIVE
FORMULATION OF TILE GROUT
FORMULATION -1
FORMULATION -2
PROCESS OF MANUFACTURE OF READY DRY MIX MORTAR
WORKING PROCESS OF ROTARY DRYER 126
PROCESS IN DETAILS AND EXPERIMENTAL WORK FOR PROPERTY SPECIFICATION
DRY MIX MANUFACTURING PROCESS:
MANUFACTURING PROCESS FLOW DIAGRAM OF THE PLANT
EXPERIMENTAL WORK FOR PROPERTY SPECIFICATIONS OF DRY MIX MORTAR:
COMPRESSIVE STRENGTH TEST:
TABLE AVERAGE COMPRESSIVE STRENGTH AFTER 28 DAYS IN N/MM2
CONSISTENCY -CONE PENETROMETER TEST:
WATER RETENTION-FLOW TABLE TEST:
COMPARISON WITH THE DRY MIX MORTAR SAMPLES COLLECTED FROM
THE THREE PLANTS FOR PROPERTY SPECIFICATIONS:
COMPARISON FOR COMPRESSIVE STRENGTH:
TABLE COMPARISON WITH ASTM STANDARD VALUES
COMPARISON FOR CONSISTENCY:
TABLE COMPARISON WITH ASTM STANDARD VALUES
COMPARISON FOR WATER RETENTION:
TABLE COMPARISON WITH ASTM STANDARD VALUES
TABLE ASTM C270 PROPERTY SPECIFICATION REQUIREMENTS (REF. 7)
TABLE ASTM C780 CONE PENETRATION PROPERTY SPECIFICATION
REQUIREMENTS (REF. 11)
COST COMPARISON OF DRY MIX MORTAR AND CONVENTIONAL MORTAR:
TABLE COST OF DRY MIX MORTAR
TABLE COST OF CONVENTIONAL MORTAR
PROCESS FLOW DIAGRAM
DRY MIX MORTOR TECHNOLOGY AND ITS ADVANTAGES
CEMENT (ORDINARY PORTLAND CEMENT):
RIVER SAND:
ADMIXTURES:
MIX PROPORTION:
ADVANTAGES OF DRY MIX MORTAR:
MANUFACTURING OF VARIOUS TYPES OF READY MIX DRY MORTARS IN
THE SAME PLANT
INGREDIENT USED FOR THE MANUFACTURE OF READY MIX DRY MORTARS
COST ANALYSIS OF VARIOUS TYPES OF MORTORS AND
COMPARISON WITH CONVENTIONAL IN-SITU MORTARS
ADVANTAGES OF READY MIX DRY MORTARS
OVER THE CONVENTIONAL IN-SITU MORTAR
BUSINESS PRACTICE OF READY MIX MORTAR IN INDIA THEIR PERFORMANCE
IN INDIA NCR READINESS FOR A PRODUCT LIKE THIS LOOKING AT THE
SUCCESS OF THIS PRODUCT IN UK AND USA
CONCEPT OF READY MIX MORTAR AS A SUBSTITUTE FOR THE CONVENTIONAL
IN-SITU (MADE AT SITE) MORTAR
MARKETING/ADVERTISING REQUIRED FOR THIS KIND OF BUSINESS
POSSIBILITY/VIABILITY TO SET UP THE PLANT AT A DISTANCE OF 500 TO
1000 KMS FROM THE MARKET BEING TARGETED
MARKETING OF THIS PRODUCT READY MIX DRY MORTAR VIS A VIS RETAIL
& BULK (MASS CONSTRUCTION)
GENERAL PUBLIC PERCEPTION OF PRODUCT IN INDIA
RAW MATERIALS CALCULATIONS BASIS: 1MT
1. FOR INTERNAL PLASTER MORTAR
2. FOR EXTERNAL PLASTER MORTAR
3. FOR MASONRY MORTAR
4. QUICK SETTING MORTAR
5. FOR HIGH STRENGTH MORTAR
6. FOR REPAIR MORTAR
7. FOR SELF LEVELLING FLOORING MORTAR
8. FOR PREMIX RCC MORTAR
PLANT LAYOUT
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)
BATCHING UNIT
SAND DRYER
MIXER
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)
SUPPLIERS OF RAW MATERIALS
SULPHUR
SODIUM SILICATE
PORTLAND CEMENT
CLAY
BATCHING UNIT
SAND DRYER
MIXER
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)
SUPPLIERS OF RAW MATERIALS
SULPHUR
SODIUM SILICATE
PORTLAND CEMENT
CLAY
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
