What is dry mortar?

Dry mortar is also called dry mix mortar, dry powder material, dry mixed mortar, dry powder building materials, dry mixed mortar or ready-mixed mortar, etc.

Dry mortar is polymer dry-mixed mortar or ready-mix mortar. It is a kind of cement or gypsum as the main base material. According to different functional requirements, aggregates, fillers, and additives are added proportionally. Raw materials, various varieties, and multi-purpose premixed powders made according to scientific ingredients, precise measurement, and industrial production, are supplied as commodities.

In China the "Guidance Catalog for the Development of New Building Materials and Products" promulgated by the former National Bureau of Building Materials Industry in 1998, polymer dry-mixed mortar was listed as a supporting material for new wall materials in the development category, thus playing a positive role in the development of dry mix mortar.

Development history of dry mortar

For thousands of years, the construction of houses has been inseparable from inorganic mortar materials.

The patent for dry mortar appeared in Europe as early as 1893, but it has not been developed. Construction still uses on-site mixing and mixing of mortar.

The production of dry mortar originated in Finland and Austria. As the quality of wall materials has improved, the flatness of the wall has gradually improved. Thick layers of mortar are no longer required for wall leveling. However, it is difficult to achieve thin plastering with mortar mixed on-site. Therefore, industrial production Dry mortar began to be applied.

Key characteristics of dry mortar:

Pre-mixed: Eliminates the need for on-site mixing, reducing labor costs and the risk of human error in measuring and mixing individual components.
Consistent quality: Ensures consistent material properties throughout the project, leading to better performance and reliability.
Convenience and ease of use: Requires only the addition of water at the job site, making it user-friendly and suitable for various applications.
Reduced waste: Minimizes the risk of material waste compared to traditional methods.
Improved storage: Dry mortar has a longer shelf life when stored properly in dry conditions compared to wet mortar, which can solidify over time.

Types of Dry Mortar:

  • Use dry mortar for wall plastering, such as polymer interior and exterior wall putty, stucco gypsum, etc.;
  • Dry mortar for thermal insulation, such as vitrified microbead insulation mortar, polystyrene particle insulation mortar, mortar for external wall insulation systems, etc.;
  • Dry mortar for the ground, such as self-leveling floor mortar, etc.;
  • Dry mortar is used for waterproofing systems, such as cement-based penetrating crystalline waterproof coatings, elastic waterproof coatings, etc.;
  • Dry mortar for colored joints and caulking, such as ceramic tile jointing agent, gypsum board caulking agent, etc.;
  • Dry mortar for adhesives, such as tile adhesive, etc.;
  • Dry mortar for masonry, such as aerated concrete masonry mortar, etc.;

Advantages of Using Dry Mortar:

Improved construction efficiency: Saves time and labor compared to traditional wet mortar mixing.
Enhanced quality control: Consistent pre-mixed formula ensures consistent performance throughout the project.
Reduced material waste: Minimizes waste through accurate pre-dosing of components.
Convenience and ease of use: Requires minimal training and equipment for application.
Improved site safety: Eliminates the dust and hazards associated with mixing individual components.

Disadvantages of Dry Mortar:

Higher initial cost: Compared to individual components, dry mortar might initially appear more expensive. (However, the saved labor costs and reduced site downtime can often offset the higher initial price.)
Limited flexibility: Formulations are designed for specific applications and may not be suitable for all situations.
Storage requirements: Requires proper storage in dry conditions to maintain its quality and prevent clumping.

Applications of Dry Mortar:

Dry mortar finds applications in various construction projects, including:

  • Residential and commercial building construction.
  • Renovations and restoration projects.
  • Tile installations.
  • Floor leveling and screening.
  • Wall and ceiling plastering.
  • Exterior wall finishes

How to produce dry mortar in mass?

Dry mortar production involves a series of steps to ensure consistent quality and meet the demands of large-scale construction projects. Here's an overview of the process:

1. Raw Material Handling and Storage:

Sourcing: Cement, sand, and other additives are sourced from reliable suppliers based on specific quality requirements.

Receiving and inspection: Incoming materials undergo a thorough inspection to ensure they meet desired specifications in terms of physical and chemical properties.

Storage: Separate storage facilities ensure proper segregation and protection of different materials from moisture and contamination. For example, cement silos.

2. Crushing and Screening:

Crushing: Large aggregates of sand and other materials are crushed to achieve a consistent and desired particle size distribution. Generally use jaw crusher, hammer crusher, impact crusher.

Screening: Crushed materials are passed through a series of screens to separate them into different size fractions, ensuring a homogenous blend for optimal mortar performance.For example, vibrating screens.

3. Drying:

Sand and other aggregates are typically dried in rotary dryers or fluidized bed dryers to remove any moisture that might affect the final product's quality and consistency.

4. Blending and Mixing:

Dosing: Pre-determined quantities of cement, sand, and additives are accurately measured and weighed using automated systems for precise control.

Mixing: The pre-dosed components are thoroughly mixed in large industrial mixers to achieve a uniform and homogenous blend.

5. Packaging and Storage:

Packaging: The finished dry mortar is packaged in various sizes (e.g., bags, sacks, bulk bags) depending on customer requirements and transport needs.

Storage: Packaged dry mortar is stored in dry and well-ventilated warehouses to maintain its quality and prevent clumping.

Your professional dry mortar plant manufacturer

FUREIN Machinery is a professional dry mortar plant manufacturer with many years of experience, committed to providing customers with high-quality equipment and solutions. We have an experienced team and advanced production technology to meet your various needs.

We look forward to cooperating with you and developing together!