UltraTech Building Products Division

Project 15
Leveraging Cement Integrated
Plants for manufacturing of
Seal & Dry ILW+
Introduction to Building Products Division

UltraTech Building Products Division is into specialised engineered construction products & solutions like Dry Mix Mortars, Liquid Water-Proofing Products
and AAC Blocks, which give a 360o solutions to our customers & influencers and also help our cement dealer network to cater & achieve a significant Building
Products Share of Wallet and help differentiate from competitors.

DRY MIX LIQUID

Plasters & Mortars

Industrial
Waterproofing Systems
Grouting
Thickness: 12-15 mm Thickness: 3-5 mm

Thickness: 25 mm Thickness: 6 mm

Tile Adhesive

Waterproofing Coating Systems

Thickness: 6-9 mm

Repair & Rehabilitation Products Flooring Screeds

Thickness: 40 mm
2
Introduction to Liquid Water-Proofing systems and Seal & Dry ILW+

Integral liquid waterproofing is the system of introducing a liquid system/ polymer into the mixed concrete or mortar to reduce the
water ratio and improve the cohesion and workability. With reduction of water the strength increases with increased compaction of the
mix reducing porosity, the integral water-proofing liquid reduces the water permeability in concrete and mortar.

Ultra Tech Seal & Dry ILW+ is specially formulated Integral waterproofing liquid system which will improve the performance properties of plaster,
mortar and concrete. It makes plaster, mortar and Concrete cohesive and enhances the yield, compressive strength and water tightness. It
Improves work ability in reduced water cement ratio, Compatible due to liquid form hence easy to mix no shrinkage, Produces dense homogenous
concrete.

Features and Benefits Areas of Application

 Reduces water-cement ratio UltraTech Seal & Dry ILW+ is recommended for increasing the workability, density of
 Improves workability concrete and mortars. It can be used for all types of site-mixed concreting, for external
 Easy to Mix and internal plastering, for brickwork jointing works and also in the repair concrete and
 Reduces permeability mortar work applications
 Produces dense homogeneous mixtures
 Enhances the comprehensive strength

Available SKUs:
200 ml, 1 Lit, 5L, 10 L, 20 L, 50 L and 100L
Introduction to Project 15

• In line with business expansion plan, UltraTech Building Products Division plans to increase manufacturing facilities
of Seal & Dry ILW+ product across India.

• At present we manufacture this product from our plants at Wada & U-Mix and now we plan to manufacture these
products at our integrated cement plants leveraging the facilities at plant such as availability of Land, DM Water
plant etc.

• With Total 15 plants proposed, 15000KL monthly production capacity (1,80,000KL Annual capacity) is targeted
and production capacity of each Manufacturing plant is 1000KL per month (1,20,00KL Annual capacity).

• The project is planned in 2 Phases

Phase 1: Annual capacity of 8000KL
Phase2: Annual Capacity of 7000KL
Manufacturing Process Flow

• This is a simple blending / mixing process at room temperature with an r.p.m of

blender at 80 to 100
• Raw Materials required are as follows
• DM Water
• Additives
• Polymers.

• Process Flow:
• At first DM water is charged in the Reactor through pump by using a flow meter for good
accuracy, after that additives / polymers are charged into the vessel.
• All the Raw Materials are charged and allowed to mix properly for 3 hours, after that
sampling is carried out for PH, Solids, Density, Slump /flow in mm.
• Once all the parameters are ok, Produced batch quantity transferred to Storage vessel for
packing /filling in different SKUs and new Batch material is charged in Reactor.

Current Raw Material Procurement:

DM Water is currently purchased from outside, we can also set up DM plant as a

perennial source inside the plant, Additives and polymers are procured from local as
well as from imported sources.
Area Required for manufacturing

Parameter Liquid Plant

1000 KL per
Manufacturing Capacity
Month

Area for Operating Shed 5000 Sqft

Storage Space- Raw Material 10000 Sqft

Storage Space- Finished Good 5000 Sqft

Lay Out
Total Area required 20000 Sqft
Plan

Total Area including Land for weigh bridge Office,

Building for Invoicing, Staff, Restrooms, Land for
0.75 Acres
Parking, Land for vehicle movement, Land as per
factory design for freespace etc
Additional Requirements

Environmental compliance and production Licenses:

• Manufacturing of Seal & Dry involves blending of polymer additives with De-Mineralisation water. Necessary Licenses must be taken as we are setting-up
inside the cement plant

Safety Compliance:
• The raw materials, packaging materials and the finished goods used are of inflammable nature, required safety precautions has to be considered in the
planned design protocol.

Packaging:
• Seal & Dry ILW+- Liquid Water-proofing product is majorly positioned through Trade. For which smaller SKUs like 200 ml, 1 Lit, 5L, 10 L and 20 L are
catered. For projects and larger volume usages 50 L & 100 L SKUs are packed.

Logistics Operations Infra:

Seal & Dry ILW+ has to be transported through liquid despatch methodology, which is having carton boxes filled with smaller SKUs and pails which are
loaded in clustered lot. In view of this, the logistic operations and its planning is completely different from our cement operations. This has to be looked
into while devising the Logistics operations
Seal & Dry ILW+ Technical Data Sheet
Annexures
Photos of Manufacturing facilities at Wada

Chemical Storage Reactor 5KL

Chemical Storage Filling Station

Photos of Manufacturing facilities at Wada

Bottle Printing Area QC LabArea

Packaging & Finished Goods Area Packaging & Finished Goods Area