Replacement of job site mixing and Establishment of modern Drymix Mortars. Dmm Technology Components of plant engineering Components of site equipment Cutting-edge Technology

1. Near and Middle East Region
Kutlu Guvenc
Business Development Manager
m-tec mathis technik gmbh
17.11.2014
From the Consultant’s Perspective:
Specifying Drymix Mortars for High
Quality Applications

2. 1Replacement of job site mixing
and
Establishment of modern
Drymix Mortars

3. Traditional Job Site Mixing

4. 4
… the results
Traditional Job-Site Mix: - Quality Problems

5. 5
… the results
Traditional Job-Site Mix: - Quality Problems

6. 6
… the results
Traditional Job-Site Mix: - Quality Problems

7. 7
Traditional Job-Site Mix: - Quality Problems
… the results

8. 8
Advantages of Dry Mortar
• Materials of
consistently high
quality
• automatically fed to
the
point of application
• Minimum waste
• Maximum productivity
• Ultimate convenience

9. 2
Dmm Technology
The components of
success for mortar
performance

10. 10
Dry Mortar Producer’s responsibilities
• Product quality and properties
• Training, technical support for
certification and
documentation
• Marketing and sales support
• Preparation of Working
methods (Checklist,
Application, Quality control,
Machines and site equipment,
Trouble shooting)
• Liability and Extended
Warranties
• On Site Service and Support
• Transport & Application
Systems

11. From quarry into the bag
Plant engineering
Quarry management
raw material preparation
analysis
planning of plant processes of weighing, dosing, mixing process control
bagging, storage and transport

12. Site equipment
From bag onto the wall
Transport on job site
bulk handling
mixing
pneumatic
transportation
bricklaying application pumping
spraying
gluing
tiling
complete facade rendering

13. 13
Quality assurance in every step
Control of raw
materials
Product
certificate
Control of product
Production control/
ISO 9001/14001
Contractor
Delivery control
Preparation and
application
controlFinal inspection of applied
system

14. 2
Components of plant
engineering

15. 15
Control of production
… a factory made and quality controlled, homogeneous
dry blend of
Mixing
+ =
PowderAggregates
Binders
Additives
Pigments
Fibres
.
.
.
.
.

16. Possible plant designs
Small scale
Large scale

17. Aggregate preparation, sand and filler
production
Quelle: www.mogensen.de
Quelle: www.bhs-sonthofen.de

18. Process technology in plant engineering
- Crushing - Screening
- Dosing - Weighing
- Mixing - Conveying
- Bagging - Palletising - Maintanance and Repair in general

19. Automation & Control

20. Quality Control System for Dmm plant

21. Quality Control System for Dmm plant
That means:
Defining a testing program with all necassary tests and the testing frequency
Defining the Out-of –Specification Limits
Defining the Warning-Limits for most important material properties
Consistently carrying out tests according to the defined test procedures
Collecting of reference samples of raw materials and counter samples of selected
finished products
That implies:
Traceable recording of all relevant Quality data (test results and batch reports)
Consistently rejecting of raw material (education to suppliers) or sort out of
finished products (importance of recycling way) with out-of-specification results.
Further development and constant improvement of QC System

22. 22
Transportation to Site
Product Delivery Control to Construction Side

23. 3
Components of site
equipment

24. 24
On site, simply mix the pre-blend dry mortar with water!
Powder Water
+ +
Mixing on Site
Preparation and application control on Site

25. 25
Mechanization – Why?
Rationalisation of building site labour
 lower cost of wages
Ergonomical working process
 application of material by spraying
 utilisation of conveying systems
Premium quality of mortar and application
 continuous mixing processes
 mortar blending with consistency in quality
 material remains resistant to weather
conditions (Silo)
Ecological working process
 dust-free (CS, Silo)
 residue free (Silo)

26. 26
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

27. 27
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

28. 28
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

29. 29
4 main Stages of Development
4. Stage:
• Logh tec 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

30. 30
Job-site Mix versus Dry Premix Mortar
600%
200%
100%
400%

31. 31
Application Job-Site Mix

32. Floor System & Concept
Self leveling compounds – Reasons for mechanization
• floor screed and leveling compounds are applied over large
areas
• thicker layers must often be spread for leveling out uneven
surfaces or height differences, thus high thickness
• material transport to the place of application as well as
mixing, placing and spreading the compound are very time-
consuming, physically exhausting and hardly economical
activities.
– labor intensive
– low productivity
– less quality
32

33. Machine application of SLC
• mixing
• pumping
• casting

34. Self-sufficient machinery for use with flooring products
Can be fed on the building site via big-bags or road
tanker
Container contains
- silos, weighing and dosing system
- mixer, pump
- compressor, generator
Logistic concept: pumptruck

35. Reasons for mechanical application of ETICS
• The construction of external thermal insulation system consist in
many different phases, each of which requires careful operation
and practices
– Preparation of underground
– Scaffold / base rail
– Cutting of the plates
– Preparation of adhesive
– Application of adhesive
– Structural fastening (disc dowels)
– Preparation of the reinforcement mortar
– Application of the reinforcement mortar including
reinforcement mesh
– Application of the finishing coat
35

36. Reasons for mechanical application of ETICS
• The construction of external thermal insulation system
consist in many different phases, each of which requires
careful operation and practices
– Preparation of adhesive - mixer
– Application of adhesive – mixer + pump + glue gun
– Preparation of the reinforcement mortar - mixer
– Application of the reinforcement mortar including reinforcement
mesh - spraying machine
– Application of the finishing coat – spraying machine
36

37. 37
Application of the adhesive: manual way

38. Application of the adhesive: mechanical
38

39. 39
Spraying of reinforcement mortar

40. Product and application quality are
granted
• Guaranteed mix proportions so you don't have to
worry about accuracy
• Water to cement ratio is kept constant by the
machine application
• No consistency changes,
• Products compliant to national and international
norms
• Faster blocklaying all year round as no retarders
are needed

41. Organized jobsite means better quality
• Constant supply on site so you can avoid weather related
holdups and delivery delays
• No waste and a cleaner site
• Reduced dust emissions
• Optimized storage area
• Most efficient use of labor
• Dry mortar producers supply quick response site support
• Choice of different size silos and bags to suit your needs
• Silos protect products from weather conditions
• With silos no sand piles, pallets and bags on-site
• No theft
• Non-used material can be refund

42. BETTER QUALITY OF MORTAR…
HIGHER OUTPUT AND FASTER CONSTRUCTION
at the end

43. 4
Cutting-edge Technology

44. Leading in dry mortar technology
3 Sectors of business activities
Technology and consulting
Services related to product development, QM and training
Mixing technology and plant engineering
Solution provider for industrial premix manufacturing
Site equipment and logistics
Producer of on-site equipment to transport, process and apply
industrial dry mortars
Unique combination of services to our customers
Sales in 60 countries worldwide
Until now technology delivered for
300 plants
and sold
800 industrial mixers, 150.000 job site machines and 50.000 silos
4
4

45. 32 years of technology for better
building
1965 Maxit - first mixing pumps and plastering machines
1970 Mobile silo for transporting industrial dry mortar
1978 Foundation Mathis Systemtechnik GmbH
1984 Renaming into m-tec mathis technik GmbH
1985 Branch office Italy (Treviso)
1992 Foundation m-tec Iberica s.a. Madrid
1993 Foundation m-tec CZ (former SILOSYSTEM) Zlin and Ostrov
2002 Foundation m-tec UK Ltd. Warrington (today sales office)
2005 Foundation m-tec Shanghai Ltd (China)
2008 Acquisition by Saint Gobain
2014 Acquisition by Zoomlion

46. m-tec commitment

47. > 150.000
300
> 50,000
> 1,350
> 800
References
(worldwide)

48. Placing units
Application
machines
Service Know-how Transfer
Application trainings
in Training &
Technology Centre
Silos
Mechanisation along product transport and application

49. 49
From the production plant to the construction site

50. Key PERFORMANCE Factor No 1:
Interaction of all Components and Persons involved!
PERFORMANCE
SE
PE QC
Recipe
Material

51. 51
Many thanks for your attention
Please visit us in Hole 8 A 364