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Jörg Schreck
Business Development Director Americas
Gonzalo Montoya Stehr
Business Development Americas
Dry Premix Mortars –
Added value by smart investment
www.m-tec.com
ANFACAL , Queretaro, October 24th , 2012
Why dry premix mortar?
Working the traditional way…
Why dry premix mortar?
… and the results!
Why dry premix mortar?
… and the results! … 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 Sanierputzsystem zu Mauermörtel, Dünn- Putzgrundvorbereitung
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Maschinenputz für maxit san weiß maxit mur 960 Maschinenputze
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Kraftputz, Dämmputz maxit Silikatfarbe maxit ton SM 40 maxit ip 250
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Handputze, Glätten ergänzende Produkte Zementestich, Zement- maxit ip Stuckgips
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Dünnschichtputz, Klebe- Mauermörtel, Dünnbett- estrich Kalk-Zement-Putze/
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Kalkputze Vormauermörtel
maxit ip 370 maxit mur 980
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Sanier- und Renovations- Dünnbettmörtel
putze maxit mur 900 hell
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maxit san Grund maxit mur 983
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Oberputze maxit plan 425
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Dickschichtige Oberputze WDV-Systeme
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maxit silco maxit mur 950
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maxit kip Kalk-Edelputz maxit therm 815
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Farben und Anstriche
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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
• full range of colours and mixes
• reduction of material „loss“ on job site
• and… no more “loss“ if delivered to site in silos
• less dependent on weather conditions
What are the benefits?
… resulting in
• more chance of completing jobs on time
• more profit per m²
• dramatically reduced man hours per m²
• more jobs per week with the amount of people
Benefits for your customers at a glance
What are the benefits?
Why invest in dry premix mortar?
Price comparison (typically)
• OPC 100 %
•Masonry mortar 100-150%
•Plasters 200-300%
•Dry concrete 100-150%
•Tile adhesive 200-800 %
•Tile grout 1000-1500 %
•Floor screed 150-300%
•Decorative render 400-800%
•Insulation mortars 250-600%
•Renovation renders 300-800%
Why invest in dry premix mortar?
Business development and growth of a dry mortar producer
in Latinamerica
2002 2003 2004 2005 2006 2007 2008Sales
Sales costs
$0,00
$5.000.000,00
$10.000.000,00
$15.000.000,00
$20.000.000,00
$25.000.000,00
$30.000.000,00
Relation Sales vs. Sales costs
Sales
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
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
Why invest in dry premix mortar?
1 – 1,5% new housing units 1 Mio inhabitants today
Mexico aprox. 110 Mio inhabitants
1.100.000 – 1.650.000 units / year
Considering:
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
Organic
Anorganic
What does dry premix mortar consist of?
Dry (15-35 %)
OPC
HAC
Hydrated Lime
Hydraulic Lime
Gypsum
Anhydrite
Polymers
Binder
Water Retainer
Air Entrainer
Defoamer
Retarder
Thickener
Accelerator
Plasticizer
Shrinkage Compensator
Pigment(s) Additive(s)
Silica Sand
Quartz Sand
Limestone
Silica Powder
Bentonite
Perlite
Polystyrene
Vermiculite
Aggregate
Dry (65-85%) Dry (0,02-2%) Dry < 1%
Focus on Lime industry
Aggregate
Limestone available in different gradations
Sand processing equipment available
Know how available
Binder
Hydrated lime, Fine Lime, Hydraulic Lime
Developement of recipes with lime content between 5 to 20%
Added value
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
Why choosing m-tec technology
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
16 plants South America
30 plants in CIS
24 plants in Southeast Asia
16 plants in China
104 plants in
West. Europe 4 plant
North America
1 plant in Australia
17 plants
in Middle East
3 plants in South Africa
13 plants
Central America
14 plants in
East. Europe
No. 1 1983 maxit Singen Germany
Why choosing m-tec technology
Plant equipment (PE)
Raw mat analysis
Product formulation
Design and construction Technology
Automation & Control
Packing and
transportation
Innovation
Experience
Project realization
Why choosing m-tec technology
Plant equipment (PE)
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
Innovation
Powerdos compact
uses the same
dosing units but
is connected to a
fixed scale.
Innovation
2. Fiberdos
What is Fiberdos?
What can Fiberdos?
Fibre dosing system with which
glass, synthetic and cellulose-
Fibres are full automatically
introduce into the production
process.
- 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
PE (plastic)
PP (plastic)
Glass fiber
Cellulose / Methyl cellulose
Basaltfibers
Not suitable for steel fibers.
Safety data sheet is very important.
Fibers which can be dosed
Innovation
3. New plant concepts
Automatic cleaning system mixing plant
additivescale
main component
scale
PowerDos mobile
inletnozzle
mixing tools
mixing druml
mixer underhopper
rotary valve
belt conveyor
prehopper
packingmachine
Innovation
mixer inside
mixing tools
Raw
Material
Analysis
Recipe
Devlopment
Design &
Construction
Site
Equipment
Logistic
Systems
Filling &
Packing
Conveying
Mixing
Dosing
& Weighing
Control
Sand
Preparation
How to produce dry premix mortars?
Experience
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
4 Main components 4 Main components
8 Additives
6 Main components
8 Additives
8 Main components
16 Additives
11 Main components
16 Additives
10 Main components
16 Additives
14 Main components
16 Additives
Tower mixing plant MTA, silo concept
Number of consumed additives of a
dry mortar plant with a complete assortment
22
25
45
52
5756
0
10
20
30
40
50
60
Nov 8
8
Jan 9
2
Jan 9
4
Jan 9
5
Jan 9
6
Nov 9
7
Mixing Tower Plant
Mixing Tower Plant (concept and structure)
Serial Mixing Plant
Small Mixing Plant
Site equipment (SE)
Transportation
Mixing,
conveying,
pumping For all applications
at the job site
Why choosing m-tec technology
Innovation
Experience
Project realization
Site equipment (SE)
Why choosing m-tec technology
61
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
Innovation: Silo Logistics
Innovation: Application Machines
Experience: Product overview
Experience: Product overview
Placing units
Different lifting system
machines
Service Rent & Service centre
mixer
Silos
training
pumps
Conveying system
Special systems
Different size
Different filling system
3,4 axle trucks
semi trailer
hanger
PTC (pump truck container)
66
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
67
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
68
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
69
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
70
Tile fixing
Internal wall plastering
Flooring
D20/D30
Façade
mortars Technical mortars
Silos
D50
modul-
twin
M300
M100
Masonry mortars
job site mix
Project realization
In dry mortar business, experience is not the most
important thing when it comes to quality…
… it is everything !
Thank you for your attention
