How to reduce the mortar production cost has always been the thinking of various manufacturers. Only by producing more mortar with less cost can manufacturers earn more profits. This article lists 8 ways to reduce the mortar production cost.
Table of Contents
Determine the total production volume
If mortar enterprises want to be profitable, the production process must be reasonable and smooth. First of all, the annual production capacity of mortar main equipment should be determined according to the company’s own financial strength and local construction volume.
There is a difference between the designed output and the actual production. If the designed annual output is 300,000 tons, the actual production capacity is only 150,000 to 200,000 tons; if the design capacity is 600,000 tons, the actual production capacity is 300,000 to 400,000 tons. This is a comparison close to the actual algorithm.
After determining the mortar production equipment, determine the sand-making capacity of the sand-making machine. Generally speaking, it should be set to 1.5 times or 2 times the sand production required by the main machine.
Arrange working hours reasonably
According to the experience of mortar companies in the past, the production equipment will not be able to continue production due to waiting for the vehicle to load the material, which will cause severe wear and tear on the equipment and greatly increase the production cost.
It is cheaper to use valley electricity to produce electricity at night, so the sand-making machine should be produced at night and shut down during the day, which can reduce energy consumption. Sometimes, when the sales volume of mortar enterprises is not large, it is best to produce at night and rest during the day, so that the cost can be greatly reduced.
Control sand gradation
The coarser the screen of the sand-making machine, the lower the energy consumption; the finer the screen, the greater the power consumption. When making sand in mortar enterprises, generally the coarser the sand, the better, which can effectively increase the output of the sand-making table and reduce the unit power consumption. Of course, exquisite sand gradation adjustment technology is needed here.
If the technology is not good enough, the plastering workers will not be willing to accept mortar with a lot of coarse sand, the surface of the mortar is difficult to calendar and smooth, there are many pits and large sand particles on the surface, and the workability of the mortar is not good.
Laboratory technicians should strengthen their studies and improve the technical level of adjusting sand gradation, to make more use of coarse sand. The proportion of coarse sand is high, the overall specific surface area of sand is small, less powder is needed, less water is added, strong cohesive force, and high compressive strength, and not easy to hollow and crack. During the use of mortar, the probability of quality problems is small, and it can also reduce production costs.
Reduce the amount of fly ash
Using a reasonable screen to control the content of stone powder in the sand can eliminate the use of fly ash in the production of mortar and reduce production costs. Fly ash plays a lubricating role in the mortar, which can improve the fluidity of the mortar. If fly ash is not used, the fluidity of the mortar must be adjusted. Otherwise, the mortar is prone to quality problems. Many units do not use fly ash. As a result, the quality of the mortar is reduced and quality problems occur.
Sand binning technology is an important link in controlling production costs. If there is only a silo and only mixed sand is used, the power consumption is the lowest, but the requirements for laboratory technicians are relatively high. If the division of warehouses is too detailed, it seems reasonable, but if the energy consumption is too large, it is easy for one warehouse to be empty and the other warehouse is still full, resulting in unsmooth production and high costs.
The most scientific way is to have three sand bins, one silo (mixed sand bin), one coarse sand bin, and one fine sand bin. Such a division of bins can not only reduce energy consumption but also make production smoother.
Formulate relevant standards
There are national standards, industry standards, and local standards for ready-mixed mortar, which specify various performance indicators in detail, and are the guideline for mortar production. In addition to the standard indicators, the individual indicators of the mortar should be specially formulated according to the construction habits of the workers on the construction site and the construction environment, so that the quality of the mortar can be guaranteed. Otherwise, the plastering workers often report that the mortar is not easy to use. Quality issues arise behind the wall.
Reasonable selection of raw materials
In the 21st century, building materials are developing in the direction of green and environmental protection, and ready-mixed mortar has received unprecedented attention. Market promotion and policy intervention have made the ready-mixed mortar industry gradually transition from the market introduction stage to the rapid growth stage.
Ready-mixed mortar has high technical content, and the products are constantly developing in the direction of multi-variety and multi-function. It does not require on-site mixing, reduces floor space and raw material loss, and is conducive to environmental protection and civilized construction.
However, there are few studies on ready-mixed mortar at present, and most engineers know little about it and even have misunderstandings. Different raw materials (cement, coal ash, stone powder, sand) have different effects on the performance of premixed mortar.
- The sand fineness modulus is about 2.5-28, the dosage is less, the loss rate of consistency and bulk density is low, the water retention rate is good, and the strength growth is good. Therefore, it is recommended that the mortar fineness modulus be controlled between 25 and 28.
- In the case of the same consistency, there are certain differences in the water demand and bulk density of different brands of cement. In addition, the increase in the actual amount of water used will affect the water retention of the mortar but has little effect on its strength.
- Strength is greatly affected by bulk density. When consistency is reached, different brands of coal ash have a greater impact on the mortar, and their water demand, bulk density, and loss rate vary greatly.
- When the quality of coal ash fluctuates, the requirements can be met within a certain range by properly adjusting the amount and mix ratio of the water-retaining agent.
- The fineness of stone powder is different, which has little effect on water demand, bulk density, and loss rate, and its strength is relatively stable. Compared with coal ash, the quality of mortar formulated with stone powder is stable and easy to control, so the application of stone powder in mortar has gradually become a trend.
Perfect matching design
In general, medium sand is mainly used for the pre-mixing of mortar, which can not only meet the construction requirements but also ensure the consistency of wet mixing and ready-mixed mortar. The particle size of medium sand during screening should not be greater than 5mm, and meet the current standards.
When wet mixing mortar, it is necessary to ensure the consistency of the mortar and the ratio of water. When the standard consistency is 50mm, 70mm, or 90mm, the allowable error range is 10mm, and when the standard consistency is 110mm, the allowable error range is 5mm. Control the lime-sand ratio to improve the overall construction level.
Adding an appropriate amount of admixture can improve the overall performance of the mortar. With the continuous improvement of the level of science and technology, the choice of admixtures is becoming more and more extensive. Therefore, when improving performance, admixtures with different characteristics can be selected, which play an important role in improving the overall quality of mortar.
In addition, when the mortar is stored, the temperature is best controlled between 5 and 35°C. When determining the mix ratio of wet-mixed mortar, the amount of cementitious material must be determined first, and the construction party is required to provide relevant design strength data. The amount of cementitious material has a certain range, and proper use can play a good role in controlling the construction quality.
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