dry premix mortars - anfacalanfacal.org/media/eventos/presentaciones_del_evento_conaca… · m-tec...

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

maxit ip 202 maxit fach bettmörtel maxit fix

maxit ip 22 maxit Feinzug maxit mur 950 KS maxit ip 12

maxit ip 22 E maxit Grobzug maxit mur 980 maxit multi 262

maxit ip 23 E maxit Gießstuck maxit mur 980 VS maxit isofon

maxit ip 23 F maxit san Vorspitz Trassmörtel maxit Haftgrund

maxit ip 23 maxit san Grund maxit mur 956 maxit Quarzgrund

maxit ip 380 maxit san Standard maxit mur 958 Gips-/Gips-Kalk-Putze

Maschinenputz für maxit san weiß maxit mur 960 Maschinenputze

aussen maxit san Stop Universalprodukte, Binde maxit ip 22

maxit ip 370 pastöse Edelputze mittel maxit ip 22 E

maxit ip 390 maxit kip maxit uni maxit ip 23 F

maxit ip 12 maxit sil maxit uni S maxit ip 23

maxit ip 12 HVS maxit silco maxit NO MIX Handputze

maxit ip 14 maxit spectra maxit ip Superbinder maxit ip 27

maxit ip 18 pulverförmige Edelputze maxit ip Weisskalkhydrat maxit ip 27 F

maxit ip 18 LL maxit sipu maxit ip Weissfeinkalk maxit ip 27 Rotfuchs

maxit ip 18 E maxit kapu maxit ip Stuckgips maxit ip 28

Putze, Spezialputze und maxit ip color Beton maxit ip 28 F

Zubehör maxit ip color plus maxit ton 904 maxit ip 28 Goldfuchs

maxit ip 18 S maxit ip ariba maxit ton 905 Dünnputze

maxit therm 78 maxit ip fino maxit ton 908 maxit ip 201

maxit uni Farben maxit ton 908 VZ maxit ip 202

maxit fix maxit color Egalisatiosfarbe maxit ton 908 FB maxit ip 200

maxit muro maxit Dispersionsfarbe Spritzbeton/Strahlmittel Spachtel

Kraftputz, Dämmputz maxit Silikatfarbe maxit ton SM 40 maxit ip 250

maxit ip 50 maxit Siliconharzfarbe maxit ton SB 80 maxit ip 252

maxit ip 52 maxit Innendispersionsfarbe maxit ton SB 80 B maxit ip 253

maxit therm 75 maxit Innensilikatfarbe maxit ST Baugipse

Handputze, Glätten ergänzende Produkte Zementestich, Zement- maxit ip Stuckgips

maxit ip 27 maxit Tiefgrund Fliessestrich maxit ip Putzgips

maxit ip 203 maxit Hydrogrund maxit plan 415 maxit ip Modellgips

maxit ip 210 maxit Haftsperrgrund maxit plan 420 maxit ip Bau- und Hobby-

maxit ip 200 maxit Sperrgrund maxit plan 425 gips

maxit ip 300 maxit isofon Aubrennsperre maxit plan 428 maxit ip Ansetzgips

maxit ip 100 maxit isofon Aubrennsperre maxit plan 435 Zement-/Sockelgips

maxit ip Ansetzgips weiss maxit plan 440 maxit ip 14

maxit ip 252 maxit Quarzgrund Calciumsulfat-Fliess- maxit ip 14 L

Dünnschichtputz, Klebe- Mauermörtel, Dünnbett- estrich Kalk-Zement-Putze/

und Armierungsmörtel mörtel maxit plan 450 Unterputze

maxit therm 75 A maxit therm 800 maxit plan 470 maxit ip 390

maxit multi 275 maxit 810 maxit plan 480 maxit ip 17

maxit multi 280 maxit therm 815 maxit plan 490 maxit ip 18

maxit multi 285 maxit therm 820 maxit plan 493 maxit ip 18 E

maxit multi 290 E maxit therm 820 VZ Fließspachtel, Haft- maxit ip 18 LL

maxit mur 900 grundierung Kalk-Zement-Dünnputze

maxit mur 900 hell maxit plan 405 maxit ip 210

maxit mur 920 maxit plan 495 maxit ip 220

maxit mur 930 maxit plan Haftgrundierung Wärmedämmputze

maxit mur 950 maxit therm 74

maxit therm 75

maxit therm 75 A

Kalkputze Vormauermörtel

maxit ip 370 maxit mur 980

maxit ip 380 maxit mur 980 VS

maxit ip 300 maxit mur 980

Sanier- und Renovations- Dünnbettmörtel

putze maxit mur 900 hell

maxit san Vorspitz Spezialmörtel

maxit san Grund maxit mur 983

maxit san weiß maxit muro

maxit sasta maxit ton 908 FB

maxit multi 280 maxit mur 960

maxit multi 262 Estriche

Oberputze maxit plan 425

Dünnschichtige Oberputze maxit plan 428

maxit ip 40 maxit plan 499

maxit ip ariba maxit plan 490

maxit ip 42 R maxit plan 480

maxit ip 44 k Spachtel-, Ausgleichs-

maxit ip 45 massen

maxit ip 45 S maxit plan 415

maxit ip 47 maxit plan 495

maxit ip 48 Klebe- und Armierungs-

maxit ip colibri R mörtel

maxit ip colibri K maxit multi 290 E

Dickschichtige Oberputze WDV-Systeme

maxit ip 50 Diese Produkte finden Sie

maxit ip 55 in unserem Lieferpro-

maxit ip 52 gramm:

maxit ip 59L maxit Wärmedämmver-

Pastöse Oberputze bundsysteme

maxit sil Mauermörtel

maxit isofon Aufbrennsperre Hintermauermörtel

maxit silco maxit mur 950

maxit Hydrogrund maxit mur 920

maxit kip maxit therm 820

maxit spectra Spritzputz maxit therm 820 VZ

maxit kip Kalk-Edelputz maxit therm 815

maxit spectra maxit mur 958

maxit spectra Modellierputz maxit uni

Farben und Anstriche

maxit color Egolisationsfarbe

maxit color Silikatfarbe

maxit Siliconharzfarbe

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