Detailed Project Report (DPR) on DRY MIX MORTAR (DMM) (DRY MIX PLANT WILL CONSTITUTE OF FOLLOWING ITEMS: READY MIX PLASTER, THIN BED MORTAR, TILE ADHESIVES (FLOOR AND WALL TILES) AND TILE GROUTS)

DRY MIX MORTAR (DMM)
(DRY MIX PLANT WILL CONSTITUTE OF FOLLOWING ITEMS: READY MIX PLASTER,
THIN BED MORTAR, TILE ADHESIVES (FLOOR AND WALL TILES) AND TILE GROUTS)
[CODE NO.3308] J.C.: 1386


Dry Mortar Mix is gaining eminence in modern times owing to its versatile superiority in regard to characteristics over the conventional in-situ mortars viz. better performance easy to uses easy to set and the quality of leaving no crakes and voiles. Besides it has preferably better and wider field of application as patching & repairing materials for plasting purposes and other construction works viz. internal/external plastering masonry work etc.  It is a very good substitute for conventional in-situ mortars.

Various  types  of  Ready mix  dry  mortar  comprise internal plaster  mortar,  external plaster mortar masonry  mortar,  quick setting  mortar high strength mortar repair mortar  self  leaving flooring mortar pre-mix RCC mortar etc.
 
One specific advantage regarding manufacture of these ready mix dry mortar is that they can be manufactured in a single unit by variation in composition proportions as per different formulations.

Ready mix dry mortar is particularly useful on congested siles or in road construction where little space for the  mixing plant and for extensive aggregate stockpile is available but  the greatest single advantage of ready mix dry mortar is that it may be made under better conditions of control than are  normally possible on any large construction sites.

MORTARS

These consist of finely ground refractory grain and plasticizers that can be  thinly spread on brick during construction.

For air - setting mortars sodium silicates or phosphates provide strength at  room temperature. Heat setting mortars contain no additives and develop strength only when a ceramic bond is formed at high temperatures.

AIR - SETTING MORTAR

A refractory composition containing chemical agents that sure hardening at temperatures below that of ceramic bonding but above room temperature sometimes called "air hardening".

HOT-SETTING BONDING MORTAR

A refractory mortar material which requires relatively high temperature fro the development of a bond.

MASONRY CEMENTS

Masonry cements are cements fro use in mortars for masonry construction.  They are formulated to yield easily workable mortars and contain special additives that reduce the  loss  of water from the mortar to the prours masonry units.

COST ESTIMATION

Plant  Capacity                                             :       25.00 MT./day
land & Building (2000 Sq.Mtrs)                 :        Rs. 1.14  Cr
Plant & Machinery                                        :       Rs. 54.75 Lacs
Working Capital for 2 Months                    :       Rs. 1,32  Cr
Total Capital Investment                             :       Rs. 3.12  Cr
Rate of Return                                               :       50%
Break Even Point                                          :       45%

INTRODUCTION    
MORTARS    
AIR - SETTING MORTAR    
HOT-SETTING BONDING MORTAR    
MASONRY CEMENTS    
USES AND APPLICATION    
DRY MORTAR PRODUCTS:    
PROPERTIES AND CHARACTERISTICS    
B.I.S. SPECIFICATION    
PROCESS AND EQUIPMENT MAINLY USED IN DRY MORTAR PLANT    
RAW SAND RECEIVING & STORAGE:    
CEMENT, FLY ASH AND ADDITIVE RECEIVING AND STORAGE:    
ALL INGREDIENT EXTRACTION, WEIGHING AND DISCHARGE IN MIXER:    
MIXING:    
MIXER DISCHARGE AND PACKING:    
PROCESS FLOW DIAGRAM    
RAW MATERIALS FOR DRY MIX MORTAR    
(1) BINDERS    
(2) FILLERS    
(3) CHEMICAL ADDITIVES    
(4) PIGMENTS    
PRODUCTION AND TYPES OF DRY MIX MORTAR    
TYPE OF DRY MORTAR PRODUCTS    
OVERVIEW OF CONSTRUCTION CHEMICAL IN INDIA    
MARKET SIZE AND PAST GROWTH    
FIGURE: INDIAN CONSTRUCTION CHEMICAL INDUSTRY (INR CRORES)    
CONSTRUCTION CHEMICALS SEGMENTS    
FIGURE: INDIAN CONSTRUCTION CHEMICAL PRODUCT SHARE (%AGE)    
ADMIXTURES    
FLOORING AGENTS    
WATERPROOFING AGENTS    
REPAIR & REHABILITATION    
MISCELLANEOUS    
SEALANTS    
GROUTS    
TILE ADHESIVES    
MAJOR PLAYERS    
KEY CHALLENGES    
GROWTH DRIVERS AND FUTURE OUTLOOK    
GROWTH IN URBAN HOUSING SECTOR:    
GROWTH IN END-USE MARKET:    
FIGURE: CONSTRUCTION INDUSTRY IN INDIA    
INCREASING PENETRATION OF CONSTRUCTION CHEMICAL PRODUCTS:    
FIGURE: SPENDING ON CONCRETE ADMIXTURES IN INDIA    
INCREASING COMPLIANCE WITH INTERNATIONAL MANUFACTURING STANDARDS:    
FIGURE: INDIAN CONSTRUCTION CHEMICAL INDUSTRY (INR CR)    
POTENTIAL OF DRY MIX MORTAR IN INDIA    
SOME OF THE DRY MIX MORTAR PRODUCTS INCLUDE    
THE ADVANTAGES    
FUTURE:    
MARKET SURVEY (INDIAN)    
RISE IN POPULARITY    
APPLICATION AREAS    
DEMAND DRIVERS    
BUOYANT FUTURE    
INCREASING PREFERENCE FOR DRY MIX MORTAR OVER TRADITIONAL
MATERIALS BODES WELL FOR THE DRY MIX MORTAR MARKET    
DRY MIX MORTAR TECHNOLOGY    
STANDARDS    
DEFINITIONS    
MARKET OUTLOOK AND ESTIMATING OF DEMAND    
THE GLOBAL PRODUCTION VOLUMES    
FIG. WORLD MARKET DEMAND AND DEVELOPMENT IN 2006-2011    
CEMENT IN MORTARS    
CAPACITIES VS. MARKET DEVELOPMENT    
MAJOR MORTAR PRODUCERS    
THE DRY MIX MORTAR INDUSTRY CURRENTLY SHOWS THREE REMARKABLE TENDENCIES    
THE WORLD BY REGIONS    
AN ATTEMPT AT MARKET CLASSIFICATION    
THE MAIN DRIVERS FOR DRY MIX MORTARS IN EMERGING AND GROWING
MARKETS ECOLOGY AND PROLONGED LIFETIME    
CONSISTENCY OF QUALITY    
EFFICIENCY AND LOGISTICS    
EASE OF APPLICATION    
REGIONAL ADAPTABILITY    
THE FIELDS OF GROWTH    
NEW CONSTRUCTION    
MAINTENANCE AND RENOVATION, WATERPROOFING    
RETROFITTING FIFS    
INFRASTRUCTURE    
CHALLENGES TO THE DRY MIX MORTAR INDUSTRY    
CEMENT AS MAIN BINDER    
CHANGING STYLES AND HABITS IN ARCHITECTURE    
DETERIORATION OF QUALITY    
LACK OF WARRANTIES AND LEGAL REQUIREMENTS    
SUMMARY AND CONCLUSIONS    
PRODUCTION OF DRY MIX MORTAR    
INSTALLED CAPACITY & UTILIZATION OF DRY MIX MORTAR    
APPARENT CONSUMPTION OF DRY MIX MORTAR    
ESTIMATED DEMAND    
DEMAND SUPPLY GAP    
PRESENT STATUS AND FUTURE GROWTH PROSPECT OF READY MIX CONCRETE    
POTENTIAL OF FUTURE GROWTH OF RMC IN INDIA    
TABLE – PROBABLE PATTERN OF CEMENT AND CONCRETE CONSUMPTION
IN NEXT THREE FIVE YEARS PLANS.    
TABLE: EXPECTED GROWTH OF COMMERCIAL RMC IN INDIA    
PRESENT MANUFACTURERS/SUPPLIERS OF DRY MIX MORTAR    
RAW MATERIALS AND COMPOSITION OF DRY MIX MORTAR    
DRY MORTAR FORMULATIONS COMPRISING    
MOST PREFERRED ARE COMPOSITIONS COMPRISING    
TECHNICAL DETAILS OF MORTAR MIX    
COLORS    
SIZES    
YIELD    
TECHNICAL DATA    
APPLICABLE STANDARDS    
PHYSICAL/CHEMICAL PROPERTIES    
INSTALLATION    
SURFACE PREPARATION    
MIXING    
INSTALLATION    
CURING    
PRECAUTIONS    
WARRANTY    
FORMULATIONS    
COMPOSITIONS WITH INGREDIENTS OF DIFFERENT    
READY MIX DRY MORTARS    
1.INTERNAL PLASTER MORTAR    
2.EXTERNAL PLASTER MORTAR    
3.MASONRY MORTAR    
4.QUICK SETTING MORTAR (RCC)    
5.HIGH STRENGTH MORTAR    
6. REPAIR MORTAR (MORTAR FOR REPAIR & PATCM WORK)    
7. SELF LEVELING FLOORING MORTAR    
8. PREMIX RCC MORTAR    
FORMULATION OF DRY MIX MORTAR (TILE ADHESIVE)    
FORMULATION OF BRICK LAYING MORTAR AND AERATED LIGHT WEIGHT
CONCRETE ADHESIVE    
FORMULATION OF VOID PATCH MIX    
FORMULATION OF WATER PROOF MORTAR (RCC)    
FORMULATION OF HIGH STRENGTH R.C.C MORTAR    
FORMULATION OF ACEATED LIGHT WEIGHT    
CONCRETE ADHESIVE    
FORMULATION OF CERAMIC TILE ADHESIVE    
FORMULATION OF TILE GROUT    
CEMENT BASED TILE ADHESIVE WITH LEVELING PROPERTIES    
CEMENT BASED TILE GROUT WITH FAST SETTING PROPERTIES    
FORMULATION OF CEMENTITIONS TILE ADHESIVE    
FORMULATION OF THIN BED MORTAR    
FORMULATION OF THIN BED AAC BLOCKS JOINTING ADHESIVE    
FORMULATION OF TILE GROUT    
FORMULATION -1    
FORMULATION -2    
PROCESS OF MANUFACTURE OF READY DRY MIX MORTAR    
WORKING PROCESS OF ROTARY DRYER    126
PROCESS IN DETAILS AND EXPERIMENTAL WORK FOR PROPERTY SPECIFICATION    
DRY MIX MANUFACTURING PROCESS:    
MANUFACTURING PROCESS FLOW DIAGRAM OF THE PLANT    
EXPERIMENTAL WORK FOR PROPERTY SPECIFICATIONS OF DRY MIX MORTAR:    
COMPRESSIVE STRENGTH TEST:    
TABLE  AVERAGE COMPRESSIVE STRENGTH AFTER 28 DAYS IN N/MM2    
CONSISTENCY -CONE PENETROMETER TEST:    
WATER RETENTION-FLOW TABLE TEST:    
COMPARISON WITH THE DRY MIX MORTAR SAMPLES COLLECTED FROM
THE THREE PLANTS FOR PROPERTY SPECIFICATIONS:    
COMPARISON FOR COMPRESSIVE STRENGTH:    
TABLE COMPARISON WITH ASTM STANDARD VALUES    
COMPARISON FOR CONSISTENCY:    
TABLE COMPARISON WITH ASTM STANDARD VALUES    
COMPARISON FOR WATER RETENTION:    
TABLE COMPARISON WITH ASTM STANDARD VALUES    
TABLE ASTM C270 PROPERTY SPECIFICATION REQUIREMENTS (REF. 7)    
TABLE ASTM C780 CONE PENETRATION PROPERTY SPECIFICATION
REQUIREMENTS (REF. 11)    
COST COMPARISON OF DRY MIX MORTAR AND CONVENTIONAL MORTAR:    
TABLE COST OF DRY MIX MORTAR    
TABLE COST OF CONVENTIONAL MORTAR    
PROCESS FLOW DIAGRAM    
DRY MIX MORTOR TECHNOLOGY AND ITS ADVANTAGES    
CEMENT (ORDINARY PORTLAND CEMENT):    
RIVER SAND:    
ADMIXTURES:    
MIX PROPORTION:    
ADVANTAGES OF DRY MIX MORTAR:    
MANUFACTURING OF VARIOUS TYPES OF READY MIX DRY MORTARS IN
THE SAME PLANT    
INGREDIENT USED FOR THE MANUFACTURE OF READY MIX DRY MORTARS    
COST ANALYSIS OF VARIOUS TYPES OF MORTORS AND    
COMPARISON WITH CONVENTIONAL IN-SITU MORTARS    
ADVANTAGES OF READY MIX DRY MORTARS    
OVER THE CONVENTIONAL IN-SITU MORTAR    
BUSINESS PRACTICE OF READY MIX MORTAR IN INDIA THEIR PERFORMANCE
IN INDIA NCR READINESS FOR A PRODUCT LIKE THIS LOOKING AT THE
SUCCESS OF THIS PRODUCT IN UK AND USA    
CONCEPT OF READY MIX MORTAR AS A SUBSTITUTE FOR THE CONVENTIONAL
IN-SITU (MADE AT SITE) MORTAR    
MARKETING/ADVERTISING REQUIRED FOR THIS KIND OF BUSINESS    
POSSIBILITY/VIABILITY TO SET UP THE PLANT AT A DISTANCE OF 500 TO
1000 KMS FROM THE MARKET BEING TARGETED    
MARKETING OF THIS PRODUCT READY MIX DRY MORTAR VIS A VIS RETAIL
& BULK (MASS CONSTRUCTION)    
GENERAL PUBLIC PERCEPTION OF PRODUCT IN INDIA    
RAW MATERIALS CALCULATIONS BASIS: 1MT    
1. FOR INTERNAL PLASTER MORTAR    
2. FOR EXTERNAL PLASTER MORTAR    
3. FOR MASONRY MORTAR    
4. QUICK SETTING MORTAR    
5. FOR HIGH STRENGTH MORTAR    
6. FOR REPAIR MORTAR    
7. FOR SELF LEVELLING FLOORING MORTAR    
8. FOR PREMIX RCC MORTAR    
PLANT LAYOUT    
SUPPLIERS OF PLANT & MACHINERIES (INDIAN)    
BATCHING UNIT    
SAND DRYER    
MIXER    
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS    
MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)    
SUPPLIERS OF RAW MATERIALS    
SULPHUR    
SODIUM SILICATE    
PORTLAND CEMENT    
CLAY    
BATCHING UNIT    
SAND DRYER    
MIXER    
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)    
SUPPLIERS OF RAW MATERIALS    
SULPHUR    
SODIUM SILICATE    
PORTLAND CEMENT    
CLAY    

        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET