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. In this way, different types of dry-mix mortar products with well-defined properties and performance to meet specific requirements and applications can be produced. The use of premixed dry mortars not only increases significantly product performance but also guarantees a high degree of application reliability and consistency. Factory premixed dry mortars ensure binders, fillers and chemical additives of known quality are blended exactly in the same ratio thus ensuring high degree of product performance and consistency. Nowdadys, dry mortar mix plant is becoming more and more popular.
Raw Materials for Dry-Mix Mortar
Most of the dry-mix mortar products require only the addition of potable water and mixed with a simple mixer to produce high quality fresh mortars. Although the dry mortars are relatively easy to prepare and use, the ingredients and their proportions of each products are sometimes very complicated. You can have a look at our small dry mortar plant.
The raw materials used for dry-mix can generally be grouped into four main categories (binders, fillers, chemical additives, pigments) and some of the basic generic types are listed below:
(1)Binders
– Ordinary Portland cement (OPC)
– High alumina cement (HAC)
– Ground granulated blast furnace slag (GGBFS)
– Pulverized fuel ash (PFA)
– Micro silica
– Hydrated lime
– Gypsum
– Anhydrite
– Polymer
(2) Fillers
– Silica sand
– Quartz sand
– Limestone powder
– Silica powder
– Bentonite
– Perlite
– Polystyrene
– Vermiculite
– Expansion clay
– Cellulose fibre
– Polypropylene fibre
(3)Chemical Additives
– Cellulose esters
– Superplasticizers
– Thickening agents
– Air entraining agents
– Accelerating agents
– Retarding agents
– Defoaming agents
– Hydrophobic agents
– Plasticizing agents
– Shrinkage compensation agents
(4) Pigments
– Inorganic pigments
– Organic pigments
Most of the dry-mix mortar products contain both mineral cementitious binder (e.g. OPC) and polymer binder (e.g. re-dispersible powder) and they are normally packed in bags after mixing in the factory. Hence, the dry-mix mortar products are also known as Pre-mixed or Pre-bagged Polymer Modified Cementitious Mortar.
Production of Dry-Mix 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 handling the production of graded sands to be stored in silo containers. We can provide you with dry mortar production line. Depending on the setting up and associated facilities of the plant, the annual output production capacity can range from 20,000 Ton to 200,000 Ton. Modern Dry-Mix Production Plant For advanced dry mortar manufacturing plants with modern facilities, the production sequences are almost fully automatic with all the devices controlled 6 and monitored by electronic sensors. The automatic dosing system is usually very precise with extremely high accuracy (e.g. 30kg ± 3g, 0.01%) 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. Since the production is automatic and closely monitored by electronic devices, the product consistency is expected to be high provided that a tight quality control on the raw materials and products is performed. Therefore, for a top or world class dry mortar plant, a comprehensive and stringent quality control systems on both raw materials and finished products are implemented. Besides, a team of research specialist and technical staff is required to be stationed at the plant to provide continuous development and monitoring on products and production controls to guarantee the product performance. Visit this site: http://drymortarproductionline.net/small-mortar-mixer/.