DRY MIX MORTAR

Submitted in partial fulfillment of curriculum prescribed for 1ST semester

M.TECH (Structural Engineering)

From

Maulana Azad National Institute of Technology, Bhopal

By,

GOPINATH CHAPAGAIN

162111411

DEPARTMENT OF CIVIL ENGINEERING

Maulana Azad National Institute of Technology, Bhopal

 Maulana Azad National Institute of Technology Bhopal

CERTIFICATE

This is to certify that GOPINATH CHAPAGAIN bearing Scholar

number 162111411 has successfully presented a seminar and submitted the seminar report on

DRY MIX MORTAR in partial fulfillment of the curriculum prescribed for I Semester

M.TECH (STRUCTURAL Engineering) of MAULANA AZAD NATIONAL INSTITUTE OF

TECHNOLOGY, BHOPAL during the year 2016.

Dr. S. K. Dubey Dr. P.K. JAIN

(PG COORDINATOR AND PROFESSOR) (HOD, DEPARTMENT

OF CIVIL ENGINEERING)
ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude and heartfelt thanks to all the

professors of Structural Engineering, MANIT, Bhopal for their constant encouragement,

innovative ideas and guidance throughout this seminar.

I am extremely thankful to all my friends and well-wishers for their never-ending support

and encouragement.
Abstract:

Dry mix mortar is an innovative idea in civil construction industry after Ready mix concrete.

This is the product of completely dry, pre-mixed mortar for various application in ready to use

condition after mixing with water as and when required. This is produced in fully automated

mechanism with standard quality.It is also know as REVOLUTIONARY CONSTRUCTION

SOLUTION. Lime-based and gypsum-based mortars have been used for thousands of years in

the erection of building structures. In the past, these simple paste substance known as mortars

have mainly been used as bedding materials for laying stones and bricks walls. However since

1950, the mineral binder within the mortar is gradually changed from lime and gypsum to

cement as a result of easy availability of Port land cement.From that time onwards, the so-called

job-site mortar technology has been introduced and applied in the construction industry

worldwide.
TABLE OF CONTENT

1. Introduction 6

2. Historical development of dry mix mortar 9

3. Job site mortar Technology 13

4. Dry mix mortar technology 15

5. Raw materials used for fry mix mortar 21

6. Production of dry mortar 24

7. Impact of dry mix mortar on sustainability 27

8. Yield of dry mix mortar

9. Advantages and disadvantages

10. Conclusion
INTRODUCTION

Dry mix mortar is an innovative idea in civil construction industry after Ready mix concrete.

This is the product of completely dry, pre-mixed mortar for various application in ready to use

condition after mixing with water as and when required. This is produced in fully automated

mechanism with standard quality. It is also know as REVOLUTIONARY CONSTRUCTION

SOLUTION

HISTORICAL DEVELOPMENT:

Lime-based and gypsum-based mortars have been used for thousands of years in the erection of

building structures. In the past, these simple paste substance known as mortars have mainly been

used as bedding materials for laying stones and bricks walls.However since 1950, the mineral

binder within the mortar is gradually changed from lime and gypsum to cement as a result of

easy availability of Port land cement.From that time onwards, the so-called job-site mortar

technology has been introduced and applied in the construction industry worldwide.
 Fig.1 Dry mix mortar bags

JOB-SITE MORTAR TECHNOLOGY:

The main ingredients of the job-site mortars are mainly cement and sand which are transported

separately to the job sites and mixed together by hand in the appropriate ratio with the addition

of water to produce wet mortars for simple applications.The quality of the site-mixed mortar

depends on the quality of the raw materials, their correct batching ratio, the homogeneity of the

mixture, and the consistency of the fresh mortar. Under these batch and mix conditions, the

quality of the site-mixed mortars cannot easily be guaranteed. The major disadvantages of site-

mixed mortars are that the whole manufacturing process cannot be controlled easily, and the
workers who make up the mortars cannot ensure the quality due to possible errors during various

steps in preparing the mortars. With the above constraints and inconsistency, mortars based on

job-site mix technology are unable to provide highly specialized properties of consistent

performance.

DRY MIX MORTAR TECHNOLOGY:

In contrast to job-site mortars, the modern dry-mix mortars are produced in a special factory with

dedicated facilities on batching and blending of all the necessary ingredients in highly-controlled

process. Factory premixed dry mortars ensure binders, fillers and chemical additives of known

quality and are blended exactly in the same ratio as required thus ensuring high degree of product

performance and consistency.The use of premixed dry mortars not only increases product

performance significantly but also guarantees a high degree of application, reliability and

consistency.

TYPES OF DRY MIX MORTAR PRODUCTS:

Basic grade: The basic dry mortar products are manufactured to replace the traditional

job-site mixed mortars with improved quality and enhanced consistency.

Technical grade: The technical dry mortars are advanced products developed to meet

latest building requirements and usually with distinct high performance properties which

cannot be easily produced and achieved with job site mixed mortars.
THE RAW MATERIALS USED FOR PRODUCTION OF DRY MIX MORTAR:

Mineral binders

Fine Aggregates

Chemical Additives

PRODUCTION OF DRY MORTAR:

Well established dry-mix mortar production plant is normally equipped with computer controlled

batching, dosing and mixing facilities. For some sizable plants, they also have their own sand

drying and grading facilities to handle the production of graded sand.

For advanced dry mortar manufacturing plants with modern facilities, the production sequences

are almost fully automatic with all the devices controlled and monitored by electronic sensors.
The automatic dosing system is usually very precise with extremely high accuracy especially for

batching high performance chemical additives.The batching sequences and mixing cycles are

specially designed for each product to ensure the powdery ingredients are blended to form a

homogeneous mixture within the batch.For a highly efficient modern plant, the mixing time for

each batch (say 2 Tons) may be as short as 2 to 5 minutes depending on type and complexity of

the product.

SCHEMATIC DIAGRAM SHOWING AUTOMATIC

DOSING AND MIXING SYSTEM:

The primary impact of dry mix mortar on sustainability can be summarized into three main areas,

Durability

Quality

Efficiency

DURABILITY:

The extended durability offered by dry mix mortars can help to support long term performance

and low maintenance of buildings.Offering better durability can also have a huge positive impact

on cost savings.Dry mix products can be designed to meet various end-use requirements such as

different climatic conditions, temperature variations etc. and can therefore be designed to survive

different weather conditions.

QUALITY

Dry mix mortars are manufactured in plants which are automated and have good process

controls. This ensures proper weighing and dosing of various raw materials and additives and

enables homogeneous mixing. Quality control is done for every cycles of dry mortar produced,

meaning the same quality and consistency of the dry mix mortar can be guaranteed every time.

Since the dry mix mortars are modified with polymers and additives, they offer excellent

application properties, helps to ensure trouble free installation and excellent finishes.
EFFICIENCY:

One of the most important drivers for the growth of dry mix mortar was its very high efficiency.

Use of dry mix mortar enables the use of machines for application which can result in huge time

savings and more efficient use of materials, this in turn supports very high productivity.

YEILD OF DRY MIX MORTAR:

Dry mix mortars typically contain a special additive which lower the mortar density and also

helps to significantly improve the application properties.Dry mix mortars can provide better

yield and thus better coverage compared to a standard site mix mortar, meaning material

consumption will be less as compared to a standard site mix mortar. Typical site mix mortar has

a density of approximately 2.1 2.2 kg / cub m, whereas for a dry mix mortar it is approximately

1.7 1.8 kg / cub m

Here is an example on the amount of time one can save using a spray applied Cement base

plaster vs. a site mix plaster from the UAE market.

These data are for cement base plaster supplied in bags and applied by spray machines.
ADVANTAGES:

Dry mix mortar is a mixture of clean and properly proportioned ingredients, resulting in

homogeneous mixture.No additional materials are required to be added while using except

water. It reduces cracks, shrinkage and dampness on walls.It gives excellent smooth finish

and more coverage Ingredients of dry mix mortar are completely cleaned in mechanical

process and free from all foreign materials which causes dampness on walls. Use of dry mix

mortar reduces plastering time and over all construction cost. It gives uniform and better

finish. Excellent crack resistance. Easy application and no specialized skill labors are

required.

DISADVANTAGES

Construction of plant is costly. Construction of plant requires large area. Transportation cost is

required.
CONCLUSION:

Although, dry mortars cannot totally solve all the construction problems, they can at least

provide a proper or more advanced materials approach to minimize the failure and enhance the

durability of structures. Advanced dry mortars are very complicated powdery mixtures with

sophisticated chemical additives of latest technology to provide wide range of superior

performance to meet complex construction requirements.Advanced dry mortar products have

been used with proven records in Europe and Western developed countries for a long time and

the trend is still growing.

REFERENCES:

1. A. Konietzko: The Application of Modern Dry, Factory Mixed, Mortar Products, ZKG

(Zement,Kalk,Gips) ACI, 48 (1985) no. 12, 625 659.

2. U. Dilger: Ready-Mixed Mortar Production Plants, ZKG (Zement,Kalk,Gips) ACI, 38

(1985) no. 1, 2 6.

3. Y. Ohama, Handbook of Polymer-Modified Concrete and Mortars Properties and Process

Technology, Noyes Publications.

4. BS 4721 : 1981, Specifications for Ready Mixed Building Mortars, British Standards

Institution.