Dry Premix Mortars

ANFACAL , Queretaro, October 24th , 2012
Dry Premix Mortars –
Added value by smart investment
Jörg Schreck
Business Development Director Americas
Gonzalo Montoya Stehr
Business Development Americas
www.m-tec.com
Why dry premix mortar?
Working the traditional way…
Why dry premix mortar?
… and the results!
Why dry premix mortar?
… and the results!
What is dry premix mortar?
How to make it ready for use?
Simply mix the pre-blended dry materials with water!
Powder
Water
+
Mixing
+
Maschinenputz für innen
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Maschinenputz für
aussen
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Putze, Spezialputze und
Zubehör
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Kraftputz, Dämmputz
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Handputze, Glätten
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Dünnschichtputz, Klebeund Armierungsmörtel
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Sanierputzsystem
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Farben
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ergänzende Produkte
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weiss
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Mauermörtel, Dünnbettmörtel
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zu Mauermörtel, Dünnbettmörtel
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Trassmörtel
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Universalprodukte, Binde
mittel
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Beton
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Spritzbeton/Strahlmittel
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Zementestich, ZementFliessestrich
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Calciumsulfat-Fliessestrich
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Handputze
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Dünnputze
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Spachtel
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Unterputze
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Wärmedämmputze
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Kalkputze
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Oberputze
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Dickschichtige Oberputze
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Pastöse Oberputze
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Farben und Anstriche
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Vormauermörtel
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Dünnbettmörtel
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Spezialmörtel
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Estriche
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Spachtel-, Ausgleichsmassen
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Klebe- und Armierungsmörtel
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WDV-Systeme
Diese Produkte finden Sie
in unserem Lieferprogramm:
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Mauermörtel
Hintermauermörtel
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Examples for dry premix mortars
(bricklaying mortar)
Examples for dry mortar applications
(grouts / pressure pointing)
Examples for dry premix mortars
(plasters / renders)
Examples for dry premix mortars
(spray rendering)
Examples for dry mortar applications
(external wall insulation)
Examples for dry premix mortars
(self-levelling floor screed)
Examples for dry premix mortars
(concrete works)
What are the benefits?
Benefits for your customers at a glance
• materials of consistently high quality
• eliminates the inaccuracy of site mixing
• constantly available supply
• clean, efficient production on site
• eliminates wastage
• improved labour efficiency on site
• reduced manual handling
• less dependent on weather conditions
• full range of colours and mixes
• reduction of material „loss“ on job site
• and… no more “loss“ if delivered to site in silos
What are the benefits?
Benefits for your customers at a glance
… resulting in
• dramatically
reduced man hours per m²
• more
chance of completing jobs on time
• more
jobs per week with the amount of people
• more
profit per m²
What are the benefits?
Why invest in dry premix mortar?
Price comparison (typically)
• OPC
100 %
•Masonry mortar
•Plasters
•Dry concrete
•Tile adhesive
•Tile grout
•Floor screed
•Decorative render
•Insulation mortars
•Renovation renders
100-150%
200-300%
100-150%
200-800 %
1000-1500 %
150-300%
400-800%
250-600%
300-800%
Why invest in dry premix mortar?
Business development and growth of a dry mortar producer
in Latinamerica
Relation Sales vs. Sales costs
$30.000.000,00
$25.000.000,00
$20.000.000,00
$15.000.000,00
Sales
$10.000.000,00
$5.000.000,00
$0,00
Sales costs
Sales
2002
2003
2004
2005
2006
2007
2008
Sales costs
Why invest in dry premix mortar?
According to m-tec, a 70 m2 house uses approx.
Brick Laying Mortar
8,3 Ton
Base Coat, Plasters, Stuccos,
5,6 Ton
Renders, Decorative, ...
Floor Leveling Mortars
6,3 Ton
Tile Adhesives
0,3 Ton
TOTAL
20,5 Ton
Why invest in dry premix mortar?
General market information
México necesita 10.8 millones de casas
El directivo del Instituto Mexicano de Ejecutivos de
Finanzas refiere que en el país existen 600,000
viviendas que son habitadas por dos o más
familias, 1.1 millón de casas deterioradas, 7.2
millones construidas con materiales no duraderos,
por lo que en suma daría un 8.9 millones de casas
con rezagos. Si a lo anterior se le adiciona la
necesidad de 1.9 millones de viviendas nuevas para
el periodo 2012-2014, existe un potencial para el
mercado de la construcción de viviendas de 10.8
millones.
Fuente: CNN Expansion
Why invest in dry premix mortar?
Estimation of Actual Total Potential Dry mortar Market
Considering:
1 – 1,5% new housing units 1 Mio inhabitants
today
Mexico aprox. 110 Mio inhabitants
1.100.000 – 1.650.000 units / year
Actual potential of Dry mortar 22 – 33 Mio t /
Year
Estimate: < 5 % market penetration
> 1,100.000 t/year market potential for job sites
mortars
What does dry premix mortar consist of?
Dry (15-35 %)
Dry (65-85%)
Dry (0,02-2%)
Dry < 1%
Binder
Aggregate
Additive(s)
Pigment(s)
OPC
Silica Sand
Water Retainer
Organic
HAC
Quartz Sand
Air Entrainer
Anorganic
Hydrated Lime
Limestone
Defoamer
Hydraulic Lime
Silica Powder
Retarder
Gypsum
Bentonite
Thickener
Anhydrite
Perlite
Accelerator
Polymers
Polystyrene
Plasticizer
Vermiculite
Shrinkage
Compensator
Focus on Lime industry
Aggregate
Binder
Limestone available in
different gradations
Hydrated lime, Fine Lime,
Hydraulic Lime
Sand processing equipment
available
Developement of recipes
with lime content between 5
to 20%
Know how available
Added value
Why choosing m-tec technology
Knowledge of dry mortar markets worldwide
Driven to make dry mortar products
succeed
Cutting edge production & application
technology
Offering systems and services from the
sand quarry all the way to the job site
m-tec dry mortar technology
3 Sectors of business activities
Technology center
services related to product development and QM inc training
Mixing technology and plant equipment
develops and provides entire production engineering
for industrial premix manufacture inc process control
Site equipment and logistics
transport and conveying solutions, on site machines for
processing and applying of all kind of dry mortars
Unique combination of business fields “All from one hand”
Sales in almost 60 countries worldwide
Until now m-tec delivered
240 plants in 56 countries and 750 mixers
150.000 job site machines and 50.000 silos
Plant Equipment (PE)
mixers MR type for industrial production
m-tec plant installations worldwide
30 plants in CIS
4 plant
North America
104 plants in
West. Europe
14 plants in
East. Europe
16 plants in China
17 plants
in Middle East
13 plants
Central America
24 plants in Southeast Asia
16 plants South America
3 plants in South Africa
1 plant in Australia
No. 1 1983 maxit Singen Germany
Why choosing m-tec technology
Plant equipment (PE)
Packing and
transportation
Raw mat analysis
Product formulation
Design and construction
Technology
Automation & Control
Why choosing m-tec technology
Plant equipment (PE)
Innovation
Experience
Project realization
Innovation
1. Powerdos
- Dosing: +/- 1g – 2-25.000g
- additives and powder pigments
- unique dosing- and discharge
system
- precise and quick
- variable construction possibility
- variable automisation level
Powerdos compact
uses the same
dosing units but
is connected to a
fixed scale.
Innovation
2. Fiberdos
What is Fiberdos?
Fibre dosing system with which
glass, synthetic and celluloseFibres are full automatically
introduce into the production
process.
What can Fiberdos?
- Dosing of
glass, synthetic, cellulose fibres
- aprox. 100µm – aprox. 6mm
- Batch size from 50g – 25kg
dosing accuracy up to +/- 20g
- Standard size of the storage silo
500l / 1500l
- Fiberdos is variable:
- integrated into Powerdos
- autarkical installation
Fibers which can be dosed
PE (plastic)
PP (plastic)
Glass fiber
Cellulose /
Methyl cellulose
Basaltfibers
Not suitable for
steel fibers.
Safety data sheet is
very important.
Innovation
3. New plant concepts
Innovation
Automatic cleaning system mixing plant
additivescale
main component
scale
PowerDos mobile
inletnozzle
mixing tools
mixing druml
mixer underhopper
rotary valve
belt conveyor
prehopper
packingmachine
mixer inside
mixing tools
Experience
How to produce dry premix mortars?
Sand
Preparation
Recipe
Devlopment
Design &
Construction
Raw
Material
Analysis
Dosing
& Weighing
Control
Mixing
Conveying
Filling &
Packing
Logistic
Systems
Site
Equipment
The required sand gradation for the different
production scenarios
•
•
•
•
•
•
•
Filler
< 0,09 mm
Tile grout
< 0,3 mm
Tile adhesive
< 0,6 mm
Plasters
< 1,2 mm
Masonry mortar
< 2,4 mm
Floor screed
< 4mm
Dry concrete
< 8mm
Production on an industrial scale
Mixing Tower Plant
Capacity
• up to 30 charges/h
• max. 19.5 m³/h to 138 m³/h
• max. 45,900 t/a to 649,000 t/a
(at 70% utilization, 16 h/day, 300 days/year)
Inside Mixing Tower Plant
Inside Mixing Tower Plant
Inside Mixing Tower Plant
Tower mixing plant MTA, silo concept
8 Main components
16 Additives
6 Main components
8 Additives
14 Main components
16 Additives
4 Main components
8 Additives
10 Main components
16 Additives
4 Main components
11 Main components
16 Additives
Number of consumed additives of a
dry mortar plant with a complete assortment
60
57
56
52
50
45
40
30
25
22
20
10
Nov 97
Jan 96
Jan 95
Jan 94
Jan 92
Nov 88
0
Mixing Tower Plant
Mixing Tower Plant
(concept and structure)
Serial Mixing Plant
Small Mixing Plant
Why choosing m-tec technology
Site equipment (SE)
Transportation
Mixing,
conveying,
pumping
For all applications
at the job site
Why choosing m-tec technology
Site equipment (SE)
Innovation
Experience
Project realization
Innovation: PumpTruck
Self-sufficient machinery for use with flooring
products
Can be fed on the building site via big-bags
Container contains
- silos, weighing and dosing system
- mixer, pump, compressor
- control panel
Different options available
61
Innovation: Silo Logistics
Innovation: Application Machines
Experience: Product overview
Experience: Product overview
Different lifting system
Silos
Different size
Different filling system
3,4 axle trucks
Placing units
semi trailer
hanger
PTC (pump truck container)
mixer
machines
pumps
Conveying system
Special systems
Service
Rent & Service centre
training
4 main Stages of Development
1. Stage:
•
•
•
•
•
No pre-mixed materials on the market
No machines or max. batch mixer is used
No continuous mixing process
No stable mixing quality
Labour costs very low
66
4 main Stages of Development
2. Stage:
•
•
•
•
•
First pre-mixed materials on
the market
Handmixers like „Collomix“ machines
are used
No continuous mixing process
No stabel mixing quality
Labour costs still on a low level
67
4 main Stages of Development
3. Stage:
•
•
•
•
•
Pre-mixed materials are common
on the market
continuous mixers like m-tec D20
are used
Continuous mixing process
Stable mixing quality
Labour costs grow up
68
4 main Stages of Development
4. Stage:
•
•
•
•
•
•
Low tech pre-mixed materials are on
the market
Also high-tech pre-mixed materials like ETICS
or
self-Levelling-materials are on the market
Mixing Pumps, mixers and pumps
are widely spread
Conveying systems with silo use are efficient
machinery combinations (systems)
Stable mixing quality
High labour costs
69
Project realization
Masonry mortars
modultwin
Silos
D50
Flooring
D20/D30
Tile fixing
job site mix
M300
Technical mortars
M100
Façade
mortars
Internal wall plastering
70
In dry mortar business, experience is not the most
important thing when it comes to quality…
… it is everything !
Thank you for your attention