TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING
PURWANCHAL CAMPUS, DHARAN-8

MODELLING AND FABRICATION OF AUTOMATIC WALL

PLASTERING MACHINE

SUBMITTED BY:

ASHOK KUMAR THAKUR (072/BME/06)

BIKESH PRASAD JAISWAL (072/BME/12)

NABIN KUMAR MANDAL (072/BME/20)

SUMAN PANDIT (072/BME/43)

SUNDAR KUMAR YADAV (072/BME/44)

UNDER THE SUPERVISION OF

Er. BHAROSH KUMAR YADAV
(Assistant. Professor)

A PROJECT REPORT
SUBMITTED TO THE DEPARTMENT OF MECHANICAL ENGINEERING IN
PARTIAL FULLFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF
BACHELOR IN MECHANICAL ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
PURWANCHAL CAMPUS, DHARAN-08
Dec, 2019
 COPYRIGHT

The author has agreed that the library, Department of Mechanical engineering, Purwanchal
Campus, Institute of engineering may make this report freely available for inspection.
Moreover, the author has agreed that permission more extensive copying of this project for
scholarly purpose may be granted by the professor who supervised the project recorded herein.
It is understood that recognition will be given to the author of this report and to the Department
of Mechanical engineering Purwanchal Campus, Institute of Engineering in any use of the
material of this project report. Copying or publication or the other user of this report for
financial gain without approval of the Department of Mechanical engineering, Purwanchal
Campus, Institute of Engineering and authors’ written permission is prohibited.

Request for permission to copy or to make any other use of the material in this report in whole
or in part should be addressed to:

Head of the Department

Department of Mechanical engineering

Purwanchal Campus, Institute of Engineering

Dharan, Sunsari

Nepal

ii
 APPROVAL

TRIBHUVAN UNIVERSITY
INSTITUTE OF ENGINEERING
PURWANCHAL CAMPUS
DEPARTMENT OF MECHANICAL ENGINEERING

The undersigned certify that they have read, and recommended to the Institute of Engineering
for acceptance, a project report entitled MODELLING AND FABRICATION OF
AUTOMATIC WALL PLASTERING MACHINE submitted by Ashok Kumar Thakur,
Bikesh Prasad Jaiswal, Nabin Kumar Mandal, Suman Pandit, Sundar Kumar Yadav in partial
fulfilment of the requirements for the Bachelor’s degree in Mechanical Engineering.

Supervisor, Er. Bharosh Kumar Yadav External Examiner, Er. Lal Babu Prasad

Department of Mechanical Engineering Department of Mechanical Engineering

Purwanchal Campus, Dharan-08 Purwanchal Campus, Dharan-08

HOD, Er. Anu Shrestha Campus Chief, Er. Om Prakash Dhakal

Department of Mechanical Engineering Purwanchal Campus, Dharan-08

Purwanchal Campus, Dharan-08

Date of Approval: ……/……/………..

iii
 ACKNOWLEDGEMENT

We wish to express my sincere thanks to our supervisor Asst. Prof. Er. Bharosh Kumar Yadav
(deputy, HOD). He, who took our interest and introduced our innovation new ways to think
about advantages along with importance of AWPM in mechanical world. We want to thank
him for guiding us through our undergraduate final year project work and for providing
critical feedback that improved on our research writing skills, initiating us to safety expertise
in AWPM experimental techniques.

Our biggest appreciation goes to HOD Er. Anu Shrestha for his enthusiastic support, candid
attitude and willingness to allow us to the research on this project.

Finally, and significantly to the final submission of this project research is our regards and
thoughtful respect to the TU, IOE, Purwanchal Campus for their understanding and kind
encouragement while administering the campus policy

Project members:

ASHOK KUMAR THAKUR (072/BME/06)

BIKESH PRASAD JAISWAL (072/BME/12)

NABIN KUMAR MANDAL (072/BME/20)

SUMAN PANDIT (072/BME/43)

SUNDAR KUMAR YADAV (072/BME/44)

iv
 ABSTRACT

The aim of this project is modeling and fabrication of automatic wall plastering machine.
This project was driven by specific objective which are to examine for plastering wall with
good finishing surface of uniform thickness by the help of trowel mechanism. Different types
of mechanical machine element such as; pulley system is used for lifting mechanism,
conveyor for mortar feeding. The main power source of this machine is AC and wiper motor
were used for dc power with the help of SMPS. The modelled and fabricated AWPM
experimental result shows that it saves man power, raw material, cycle time and cost as
compared to manually plastering. Additionally, this AWPM can be used as a finishing
technology for both interior and exterior walls made from bricks like masonry bricks, thermal
bricks &other bricks. This plastering machine experimentally shows that labor cost can be
saved up to 85%, productivity can be increased by 4-5 times and quality finishing in less
time. We eventually, the AWPM machine could play significant role in overall construction
projects to reduce project net accomplishing time and increases the net profits.

Keywords: Modelling, Plastering Machine, Pulley, Conveyor, Trowel, Chain, Sprocket.

v
 LIST OF FIGURES

Figure 1. 1. Smooth trowel ....................................................................................................... 2

Figure 1. 2. Felt trowel ............................................................................................................. 2
Figure 3. 1. Fabricated prototpe of machine ............................................................................ 9
Figure 3. 2. Chain & sprocket ................................................................................................ 10
Figure 3. 3. Conveyor belt ...................................................................................................... 11
Figure 3. 4. Pulley .................................................................................................................. 12
Figure 4. 1 Isometric view of prototype ................................................................................. 14
Figure 4. 2 Base and Top........................................................................................................ 17
Figure 4. 3 Vertical Column ................................................................................................... 18
Figure 4. 4 Slider .................................................................................................................... 18
Figure 4. 5 Pulley ................................................................................................................... 19
Figure 4. 6 Conveyor .............................................................................................................. 19
Figure 4. 7 Trowel .................................................................................................................. 20
Figure 4. 8.Sliding box ........................................................................................................... 20

vi
 LIST OF TABLES

Table 3.1 Selection of materials and cost ............................................................................... 13

Table 5.1 Result Obtained ...................................................................................................... 22

vii
 LIST OF SYMBOLS

A Area to be Plastered

d Diameter

ρ Density of Mortar

N Speed of Rotation

T Teeth of Sprocket

σ Stress

V Volume of Mortar

M Mass of Mortar

viii
 LIST OF ABBREVIATIONS & ACRONYMS

AWPM Automatic Wall Plastering Machine

WPM Wall Plastering Machine

IOE Institute of Engineering

TU Tribhuvan University

DPDT Double Pole Double Throw

MS Mild Steel

CI Cast Iron

Rpm Revolution per minute

C.G. Centre of gravity

SMPS Switched-mode Power Supply

FOS Factor of Safety

ix
 TABLE OF CONTENTS

COPYRIGHT ........................................................................................................................ ii

APPROVAL ......................................................................................................................... iii

ACKNOWLEDGEMENT ................................................................................................... iv

ABSTRACT ........................................................................................................................... v

LIST OF FIGURES ............................................................................................................. vi

LIST OF TABLES .............................................................................................................. vii

LIST OF SYMBOLS .........................................................................................................viii

LIST OF ABBREVIATIONS & ACRONYMS ................................................................ ix

TABLE OF CONTENTS ..................................................................................................... x

CHAPTER 1: INTRODUCTION ........................................................................................ 1

1.1 Background ..................................................................................................................... 1

1.1.1 Types of plastering method ...................................................................................... 1

1.1.2 Trowel ...................................................................................................................... 1

1.1.3 Types of Plastering .................................................................................................. 2

1.2 Problem statement .......................................................................................................... 3

1.3 Objectives ....................................................................................................................... 3

1.4 Organization of project ................................................................................................... 4

CHAPTER 2: LITERATURE REVIEW............................................................................ 5

2.1 History of AWPM........................................................................................................... 5

CHAPTER 3: METHODOLOGY....................................................................................... 9

3.1 Construction of Prototype of Wall Plastering Machine .................................................. 9

3.2 Working of the Prototype ............................................................................................. 10

3.3 Mechanisms involved in Automated Wall Plastering Prototype .................................. 10

3.3.1 Chain and sprocket mechanism.............................................................................. 10

3.3.2 Conveyor mechanism............................................................................................. 11

x
 3.3.3 Lifting mechanism ................................................................................................. 12

3.4 Selection of materials and costing of AWPM .............................................................. 13

CHAPTER 4: CAD MODELLING AND FABRICATION OF AWPM ....................... 14

4.1 CAD Model .................................................................................................................. 14

4.2 Modelling Numerical Calculation ................................................................................ 15

4.3 Fabrication .................................................................................................................... 17

4.4 Assembly ...................................................................................................................... 21

4.5 Preliminary Testing ...................................................................................................... 21

CHAPTER 5: RESULT AND DISCUSSIONS ................................................................ 22

5.1 Results........................................................................................................................... 22

5.2 Discussions ................................................................................................................... 22

CHAPTER 6: CONCLUSION AND RECOMMENDATIONS ..................................... 24

6.1 Conclusion .................................................................................................................... 24

6.2 Recommendation .......................................................................................................... 24

REFERENCES .................................................................................................................... 25

APPENDIX .......................................................................................................................... 27

xi
 CHAPTER 1: INTRODUCTION

1.1 Background

Plasterwork is construction or ornamentation done with plaster, such as a layer of plaster on

an interior or exterior wall structure, or plaster decorative moldings on ceilings or wall. The
process of creating plasterwork, called plastering.

The existing technique for plastering the walls is manual i.e. the labors are used to plaster the
walls with their hand by using some instruments like flat board or other flat surface object
which are made by metal, wood or plastic. In this process the mortar which is the mixture of
cement and sand has been spread on the wall which is to be plaster with the help of these
objects. After dispersal the mortar the labors need to concentrate to make a skinny film of
mortar on the wall, which has been smooth and having good surface finish. Due to which labor
need to work repeatedly until they get the required surface finish [1].

This process takes long time and consumes additional human power. So due to this slow
process the labor cost has also been increase as the labors are working on daily basis. If the
labor is not a skilled person then there have been a low-quality work and there has been wastage
of material. Ultimately the manual plastering technique have some downsides like high cost,
more time, material wastage and low-quality work due to unskilled labors.

1.1.1 Types of plastering method

• Automatic
Plastering is done with help of robots and mobile machines.

• Manual
Plastering is done manually with hands.
1.1.2 Trowel
A trowel is a small hand tool used for digging, applying, smoothing, or moving small amounts
of viscous or particulate material. Common varieties include the masonry trowel, garden
trowel, and float trowel.
1.1.2.1 Types of trowel
• Smooth Trowel

1
 They are used to apply the plaster on the walls, in circular movements always in the
same direction.
Another practical use is the sealing of the plaster when it is necessary to perform some
drilling or repair; Finally, when it is necessary to repair cracks in a wall or apply a
coating (stucco to the tail), the trowel allows a neat and uniform application of the
material.

Figure 1. 1. Felt trowel Figure 1. 2. Smooth trowel

• Felt Trowel
These trowels, on the other hand, are used to soften and eliminate the small imperfections left
by the use of the smooth trowel; generally, lines generated by the edges of the tool. They are
also often used to achieve details of relief in plastering works such as modern stucco and
splashing.

1.1.3 Types of Plastering

There are different types of plasters are available such as:
a) Lime plaster: -
• When lime is used as a binding material it is called lime plaster.
• Lime plaster is a type of plaster composed of hydrated lime, sand and water.
• Lime plaster is similar to lime mortar, the main difference is based on use rather
than composition.
• Mortar for lime plaster is usually prepared by mixing sand and lime in equal
proportions, to improve the strength small quantity of cement is added to it.

b) Cement plaster: -

2
 • When cement is used as a binding material it is called cement plaster.
• It is especially suited for damp condition.
• Cement plaster is usually applied in one coat.
• Thickness of coat can be 12 – 15mm or 20mm depending upon site conditions
and type of building.
• 6mm thickness of plastering of 1:3 or 1:4 Ratio is recommended for cement
plastering of RCC surfaces.

c) Mud plaster: -
• The surface to be prepared exactly in the same manner as that of for lime plaster
or cement plaster.
• Mud plaster is generally applied in two coats, the first coat being 18mm thick
while the thickness of second coat kept 6mm.

d) Stucco plaster: -
• Stucco is the name given to decorative type of plaster which gives an excellent
finish.
• Stucco plaster can be used for interior as well as exterior surfaces.
It is usually laid in three coats making the total thickness of plaster about 25mm. The
first coat is called scratch coat, the second coatis called fine coat, it is also known as
brown coat and the third coat is called white coat or finishing coat.

1.2 Problem statement

In the manual plastering technique, the crucial factor is skilled labor because of which
plastering has been done on the walls, but presently there is lack of skilled labors due to which
it is very inconvenient to complete this process. The labor requires more time to finish the
process which increases their wages and hence the total plastering or labor cost increases [1].

1.3 Objectives

➢ General Objectives:
• To Model and fabricate Automatic Wall Plastering Machine.
➢ Specific Objectives
• To test the performance automatic wall plastering machine.

3
 • To understand the chain and sprocket mechanism.

1.4 Organization of project

In this project it consists of 6 chapters in which chapter one includes the introduction of the
project, which contains background, statement of problem and objectives regarding the project.
Chapter two contains literature review, which includes the history and evolution of AWPM in
different eras. Chapter three contains the methodology used in the project. It includes the
different mechanism employed in the project. Chapter four contains the CAD modelling from
SOLIDWORKS software and also the fabrication of the different components of the project and
its testing. Chapter five shows the obtained results. Chapter six consists of the conclusion and
recommendation for the project

4
 CHAPTER 2: LITERATURE REVIEW

2.1 History of AWPM

In general, the growth of a country is mainly dependent on the infrastructure, agriculture, and
industry. Hence the constructional sector is of prime economic significance to many countries.
In most countries, 10–20% of the GNP is for the construction industries, thereby making it one
of the largest economic employment sectors. Plastering is construction or ornamentation work
done with plasters or cement mortar over the walls. Failing to allow the plastering to fully cure
can lead to excess shrinkage and cracking after the walls have been plastered. The distinct
types of surface finish are as follows:

a) Smooth finish, which can be obtained by using a wooden float, rather than a steel trowel;

b) Roughcast finish is for rural or coastal areas, and is splashed on to the surface as a wet mix
and left rough. The maximum size of sand and crushed stone or gravel may vary from 12.5
mm to 6.3 mm;

c) Pebbledash finish is the most durable of all finishes and is generally free from effects. It
gives a rough texture to the wall and is obtained by means of small pebbles or crushed stone,
graded from 12.5 mm to 6.3 mm being splashed on to a fresh coat of and left exposed; and

d) Textured finishes of assorted designs are now becoming very popular and can be obtained
in a variety of ways. Special effects can be obtained by scraping the surface of the rendering
with a straight edge hacksaw blade or with the edge of a steel trowel. Apart from this,
commercial wall plastering machines are also available [6].

But these machines do not have self-alignment capability, which is essential for flat and smooth
plastering of the wall. Also, these types of wall plastering machines are used to plaster the
entire wall and cannot be used to re-plaster patches and damaged plastered walls.

Although plastering is one of the most physically strenuous jobs in building construction it was
not before the early fifties that machines were developed which supported this strenuous task.
The first machines to be developed were automated mixers which made the task of manual
[2, 3]
plaster mixing obsolete . The introduction of plastering machines such as RUMA 1,
Putzmeister KS 1 [4] and Putzmeister Gipsomat [5, 6] in the sixties was considered revolutionary

5
and marked the beginning of a new era in plastering technology. The development of the
AMPA machine was the first attempt to significantly increase the level of automation but this
kind of equipment has never been accepted in practice. Automated spraying of mortar and paint
has recently been demonstrated by means of the mobile articulated prototype robot TAMIR
[7]
which had been developed in Israel and a prototype of a cartesian robot which had been
constructed in a Swedish joint venture between Swedish construction companies and
universities [8]. Unfortunately, these developments have been unable to provide a breakthrough
in the plastering industry. Thus, even today, the plastering machines developed in the sixties
such as are still considered to be State-of-the Art.

The construction industry is labor-intensive and conducted in dangerous situations; therefore,

the importance of construction robotics has been realized and is grown rapidly. Applications
and activities of robotics and automation in this construction industry started in the early 90’s
aiming to optimize equipment operations, improve safety, enhance perception of workspace
and furthermore, ensure quality environment for building occupant. After this, the advances in
the robotics and automation in the construction industry has grown rapidly.

1. Design and Fabrication of Automatic Wall Plastering Machine.

The project of Mahesha P.K. and Sree Rajendra includes applying mortar into the wall and
additionally pressuring mortar with creating a surface level. The model was developed and
tested successfully. With this development, two major downsides to the construction
industries were reduced, namely, labor shortage and quality within construction method
with less wastage. During the trials, it was noted that the machine was more productive
compared with labor in relation to rendering the work, and additionally, the standard
achieved was admirable [9].

2. Automatic Plastering Machine.

The project done by Arivazhagan B. shows the Machine-driven rendering machine is

exclusive and maybe one reasonably machine-driven rendering machinery is ideally
appropriate for the construction/building business. Machine-driven rendering machine
works with typical cement mortar that brings it to a swish, flat end with variable and
adjustable thickness to suit every application. It makes rendering easier, faster, and easy
compared with manual application. This concept also can additional increased by
interfacing liquid crystal display & computer keyboard for creating the method while not

6
 external supply. This point and cash saving machine, keeps up with the ever-dynamic world
of building automation [10].

3. Automation and Robotics in Construction: Opportunities and Challenges

The project done by S.M.S. Elattar by Robots square measure progressively concerned in
construction operations to take care of extremely correct actions and to scale back venturous
risks achieving improved management and safety. Machine-driven constructions are often
developed to include: design, engineering, and maintenance of existing and planned
structures. Several analysis works counsel extremely autonomous robotic system for the
development performance. The “Sense-and-Act” could become a reality with the
development of a lot of advanced robotic systems for construction applications. Efforts
should be made to persuade professionals in building management to integrate AI and
building automation enhance the standard of services of contemporary intelligent buildings.
All new concepts for automation or robotizing on the vacant lot need to be generated by a
mix of recent designs, new forms, and new materials that meet the requirements for building
in a very metropolis. However, many of the problems in construction engineering cannot be
absolutely addressed through improvement and computation. With intelligence activities
reminiscent of generalization, analysis and decision-making for multi-objectives, there are
often a higher understanding of the development engineering downside [11].

4. Automation in Construction.

This paper prepared by Pentti Vähä provides a survey for potential sensor technologies for
building construction automation, highlighting their potential Also with contributions from
robotics. The paper carries out the survey from the viewpoints of building construction
phases[12].

5. Concept to Position and Enhance Automation Technologies in Emerging Construction

Market.

According to Mohan Ramanathan, Automation has been an indicator of technological and

developmental progress of construction industry. The objectives of any automation have to
improve the quality of work, productivity, higher safety for both workers and public through
developing machines for dangerous job, uniform quality of work with higher accuracy.
Improving work environment as conventional manual work is reduced to minimum so

7
 workers are relieved from dangerous work, but disadvantage of automation is high cost, less
knowledge torun the worker, high maintenance cost etc[13].

6. Automatic Wall Plastering Machine.

As per Arunkumar Birder works, the building construction is time consuming sector because
lot of work is labor based there is too much shortage of skilled labor, increase in labor cost
and technological advances are forcing rapid change in the building construction. Building
construction mainly consists of commercial infrastructure and residential building, but in
every sector plastering work is must. We are introducing new machine to automate the
plastering work which is very much demand for construction field. The machine consists of
AC/DC motor, Gear box, wire rope, pulley, tray mechanism, guide ways, etc. The present
work developed model of wall plastering machine [14].

8
 CHAPTER 3: METHODOLOGY

3.1 Construction of Prototype of Wall Plastering Machine

The prototype consists of three main parts that is Base, Top& sliding box. The sliding box
consist of two sliders which are mounted in the box, which slides vertically on hollow square
bar. It consists of a DC motor which drives the shaft through chain sprocket mechanism. The
shaft consists of two grooved nylon bar that supports the rope for lifting mechanism through
pulleys, mounted on the top. And also help for driving conveyor belt. A trowel is mounted at
the front of the machine that plasters the walls.

Figure 3. 1. Fabricated prototpe of machine

9
3.2 Working of the Prototype
Initially, the machine should be brought close to the wall to be plastered and positioned as per
need. Then, the mortar of cement and sand roughly in the proportion of 1:4 is poured into the
hopper-tray, which is lifted by means of a rope coupled to the motor through pulley. The mortar
flows downwards due to gravitational force. The trowel applies pressure on to the cement
mixture so that the cement adheres to the wall. The clearance between the wall and machine
can be adjusted as per the thickness of the plaster. When the sliding box moves upward, the
mortar gets applied, and the downward movement sees that the finishing of the plaster is done.

3.3 Mechanisms involved in Automated Wall Plastering Prototype

3.3.1 Chain and sprocket mechanism

Chain and Sprocket A sprocket is a toothed wheel that is used to transmit motion and torque
from one shaft to another. Chains that are used to transmit motion and force from one sprocket
to another are called power transmission chains. Unlike gears that have to mesh to transmit
motion and torque from one gear to another, sprockets may be positioned far apart. Sprockets
are connected by a chain. A sprocket with a hole that matches the diameter of the shaft is chosen
and slid onto the shaft. The sprocket is then rotated until the keyways in the sprocket and shaft
line up. A rectangular piece of steel bar called a key is slid into the keyways to prevent the
sprocket from spinning on the shaft.

Figure 3. 2. Chain & sprocket

10
Chain and sprocket mechanisms perform the same task as a belt and pulley system, i.e. they
transfer motion and force from one shaft to another. A belt can slip on a pulley but the teeth on
the sprocket prevent the chain from slipping.

3.3.2 Conveyor mechanism

A conveyor mechanism is of common piece of mechanical handling equipment that moves
materials from one location to another. Conveyers are especially useful in application involving
transportation of heavy or bulk materials. Conveyors system allows efficient transportation for
a wide variety of materials, which make them very popular in the material handling and
packaging industries many kinds of conveying system are available and are used according to
the various needs of different industries.

In this project, the conveyor belt basically performs feeding of mortar to the trowel.
It is also driven by a motor of 80 rpm.

Figure 3. 3. Conveyor belt

11
3.3.3 Lifting mechanism
Lifting mechanism in mechanical process in which the weight raised or lowered to certain
height application of force. Lifting is especially useful in application involving transportation
of heavy or bulk materials to certain height.
In this project, pulley is used to lift the sliding box driven by motor for plastering on the wall.

Figure 3. 4. Pulley

12
3.4 Selection of materials and costing of AWPM

For fabrication of system prototype, the below listed materials were used based on the system
requirement, ease of availability and economic feasibility

Table 3.1 Selection of materials and cost

S.N. Items Specification Quantity Cost (Rs.)

1. Hollow square bar 40x40 13.6 kg 1250
2. Hollow square bar 20x20 5.5 kg 550
3. Wiper motor 12V D.C 1pc 2500
4. Switch DPDT 1 200
5. Nylon rope 2mm 6m 100
6. chain 2 pcs 300
7. Sprocket 4 pcs 1200
8. Pulley 50mm dia 2 pcs 800
9. Bearing 12mm dia 25pcs 3000
10. Nut-bolt 35pcs 600
11. Spring 4 pcs 200
12. Wheel 12cm dia 4 pcs 800
13. Thread Rod 14mm dia 1m 100
14. Iron rod 12mm dia 3 kg 180
15. Clamp 25mm 6 pcs 150
16. Miscellaneous 3000
Total 14000

13
 CHAPTER 4: CAD MODELLING AND FABRICATION OF AWPM

4.1 CAD Model

This AWPM has been designed with the help of Solid Works Software.

Figure 4. 1 Isometric view of prototype

14
4.2 Modelling Numerical Calculation

4.2.1. Loads on Hopper:

Plastering Width = 0.305m

Plastering height = 1.15m
Plastering thickness = 1m = 0.01m
Mortar mixing proportions:
1:4 (normally)
Density of wet mortar, ρ= 2400 kg/m3
Plastering Volume, V=0.305x1.15x0.01
V=3.5075x10-3 m3
Mass, m= ρxV
m= 2400x3.507x10-3=8.42 kg
mass of hopper excluding mortar, M= 13 kg
Total weight on hopper including cement mixture, (M+m) =21.42Kg
Maximum force acting on rope is

F=(M+m)xg
F = 21.42x9.81=210 N
4.2.2 Rope Design

Approximate weight on hopper =21.42kg

Axial load acting on rope=21.42Kg

Select rope material as polypropylene wire.

Take F.O.S. for polypropylene wire is (lifting) =10

Nominal breaking strength of rope

σbreak =850 N/mm2

Allowable Stress,

σallowable = σbreak / F.O.S. =850/10=85

15
 We know that,

F=210 N

F Π ⅆ2
σallowable=A, where, A= 4

𝐹
σallowable > Π ⅆ2
( )
4

𝛱 ⅆ2 210
>
4 85

210×4
d2 > 85𝜋

d2 > 3.1456
d > 1.773 mm
Hence, for safe design, take d= 2mm.

4.2.3. Gear Design

Motor used =12V, 50W DC

For motor,
Motor speed (N1) =75 rpm
Teeth on sprocket 1 (T1) = 20
For shaft,
Teeth on sprocket 2 (T2) = 36
Speed of shaft (N2) =?
As we know that,
𝑁2 𝑇1
=
𝑁1 𝑇2
N2 = (20x75)/36
N2 = 42 rpm

16
4.3 Fabrication

While carrying out the process of fabrication and assembly of wall plastering model, different
type of machining operation such as welding, drilling, hack sawing, filling, grinding etc. were
encountered. Most of the operation where performed in the machining section, fabrication
section, carpentry section of Purwanchal Campus, IOE while some of them performed outside
and some of the parts where purchased in the market.
Nearly all the parts were made by hollow iron pipes. Shaft of DC Motor was manufactured in
Koshi Workshop, Dharan. Pulley was made up of nylon fabrics in machining section through
lathe operation. Shaft of slider were made up of solid cast iron through lathe operation. Shaft
of conveyor was made up of hollow circular pipes.

The fabrication of different components is explained as follows:

4.3.1 Base and Top

The base and top of the machine is made up of hollow square pipe (cross-section area of 4x4
cm and thickness of 2cm) of iron. Long pipe is cut in pieces with power hacksaw and made a
rectangular base of 40x30cm through welding process.

Figure 4. 2 Base and Top

4.3.2 Vertical Column
Long square pipe is cut in two pieces of 120 cm by hack sawing. Both the stands were attached
in the top and base frame through nut-bolt.

17
 Figure 4. 3 Vertical Column

4.3.3 Slider
Slider consists of eight shafts and eight bearing. The shaft diameter is decreased to 13mm in
machining section through lathe operation and the bearing is fitted in that shaft. The shafts
consisting bearing are welded on a square pipe of cross section of 2 cm.

Figure 4. 4 Slider

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4.3.4 Pulley
Pulley was made up cast iron with lathe operation. It has a diameter of 5cm and groove depth
of 2cm

.
Figure 4. 5 Pulley

4.3.5 Conveyor
The conveyer is connected with the help of two shaft mounted on the sliding box. The conveyor
belt is made up of jeans of dimension 24x18 cm.

Figure 4. 6 Conveyor

19
4.3.6 Trowel
The trowel is made up of iron metal sheet of dimension 32x15x0.2 cm. It is attached to the
slider box with the pin joint and spring.

Figure 4. 7 Trowel

4.3.7 Sliding box

All the above made slider, trowel and conveyor are fitted in this box.

Figure 4. 8.Sliding box

20
4.4 Assembly

After the fabrication of the mechanical components and the purchase of components from the
market, the assembly work was started which was done with precise dimension. The following
steps were carried out during the assembly of the wall plastering machine.

a) Firstly, we cut the hollow square pipes according to the designed data and then base of
40x30 cm is constructed by welding process.
b) For the lift system, two vertical iron columns were made and adjusted to the horizontally
placed base with the help of nuts and bolts.
c) Then sliding box frame of dimension 70x30x15 was made with the hollow iron pipes of
dimension 2x2cm by welding process in which sliders are mounted for proper vertical
motion.
d) The motor is attached to the box and power is supplied for lifting through chain and
sprocket mechanism.
e) The sliding box is lifted with rope through pulley mechanism.
f) The trowel is attached to the sliding box with the help of nut-bolt and pin joint.
g) Finally, the top where pulley is assembled is placed on the top of the machine through
welding process.

4.5 Preliminary Testing

Initially all the fabrication and assembly work were completed. All the electric connections
were checked to configure the motor coupling with via chain and sprocket. DPDT switches
were checked to test the polarity. The individual mechanism testing was done to test configure
each mechanism operation. Then, testing was done on prototype, without putting the load in
order to check working of the system. Everything was configured accordingly and the
preliminary testing was done.

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 CHAPTER 5: RESULT AND DISCUSSIONS

5.1 Results

After performing all the test i.e. weight lifting capacity of rope, driving capacity, slipping
capacity and conveyor belt was found out respectively by different observations and following
results were obtained.

Table 5.1 Results Obtained

S.N. Time(min) Plastering area (m2)

By machine By manually
1. 3 1.05 0.25
2. 5 1.75 0.42
3. 8 2.8 0.67
4. 10 3.5 0.85

Hence, plastering done by machine is nearly 4 times faster than manual plastering. Time
taken for lifting up of the box is 1min.10sec and for lifting down is nearly 1min 05sec.

5.2 Discussions

The automatic wall plastering machine prototype based in three different mechanism i.e. chain
and sprocket, pulley drive, conveyor drive. The selection of these mechanism were based on
the availability, benefits and economic feasibility.

Different difficulties were encountered in making the machine prototype from beginning to the
completion of the project. These difficulties were occurred due to lack of proper technical
knowledge in selecting components, lack of machine accuracy. Some other encountered
problems are listed below here:

• The first proposed model was fully based on rack and pinion for lifting. During lifting, the
motor could not deliver the required torque and also the rack and pinion was not perfectly
meshed with each other. The motor with high torque was used with pulley drive for lifting.

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• For vertical motion, two columns for lifting were used. As a result, the C.G. was not
balanced during lifting. We used two sliders in the column having eight bearing in each to
overcome this problem.
• Plywood box was used as a sliding box. There were problem in load bearing capacity of
components used inside it and also getting difficulty in fixing the position of motor shaft
etc. To overcome these problems, we used hollow square pipes for better functioning as
sliding box.

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 CHAPTER 6: CONCLUSION AND RECOMMENDATIONS

6.1 Conclusion

The present work includes applying the mortar into the wall and also pressuring mortar with a
making surface level. The model has been developed and tested successfully. With this
development the two major problem construction industries currently facing can be reduced,
they are skilled labor shortage and Quality in the construction process with less wastage.
Through the trials it is noted that the machine is more productive compare to the labor with
respect to the plastering work and also the quality achieved is almost equivalent to the labor.

6.2 Recommendation

The prototype is capable of plastering the vertical wall with good surface finish. There are
certain recommendations that can be made for this project.

• A hydraulic lift can be employed for rigidly fixing the machine with ceiling.
• Lasers can be used for adjusting the gap between the trowel and vertical wall.
• Different types of tools and techniques can be employed for plastering in curved areas
and ceiling.
• Sensors can be used for mortar control.

If all these steps in fabricating and recommendations are to be followed, the commercialization
of wall plastering is no hard job. In future, this system can be used as one of the best alternatives
to reduce the problems regarding plastering.

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 APPENDIX

Different CAD Views of AWPM

Figure A. 1.Front view of AWPM prototype

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Figure A. 2.Back view of AWPM prototype

28
Figure A. 3.Right side of AWPM prototype

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Figure A. 4.Left side view of AWPM prototype

30
Figure A. 5. Top side view of AWPM prototype

31
Different Experimental Images

Figure: Testing lifting mechanism

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Figure: Plastering on the wall

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34