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The process of plastering has long been a cornerstone of construction, yet traditional methods often come with significant challenges. Conventional plaster applications using sand as aggregates and cement as binders typically involve ratios ranging from 1:5 to 1:8. These inefficient ratios, combined with unmeasured water mixing, result in defects and wastage. In fact, reported wastage in conventional plaster applications can be as high as 35%. Achieving optimal ratios requires constant supervision, and inefficiencies often compromise the durability and aesthetics of the final output.

Evolution of Plastering: From Traditional to Ready-Mix Solutions

The introduction of ready-mix plaster represented a leap forward, significantly reducing application wastage to around 15-20%. However, the responsibility for application quality still rests heavily on the mason. This reliance on manual expertise means many traditional challenges persist, such as:

1. Excess Water Ratios: Both traditional and ready-mix plaster applications often involve excessive water in the mix. During application, this excess water gets trapped, weakening the plaster as it vaporizes, leaving voids and leading to hairline cracks on the surface.
2. Cold Climate Challenges: In colder climates, water-to-powder ratios are sometimes reduced below the level required for proper cement hydration. This results in plaster cracking and loose bonding of particles.
3. Weak Substrate for Subsequent Layers: Low binder content in plasters creates a weak substrate, which affects the performance and adhesion of subsequent applications. This significantly impacts the durability of multi-layer plaster systems.

The Game Changer: Spray Plaster Machines

Spray plaster machines have revolutionized the way plaster is applied, addressing these challenges with remarkable efficiency. These machines utilize advanced materials composed of graded sand, cement, and polymers, ensuring consistent and high-quality results. Key benefits of spray plaster machines include:

1. Consistent Mixing and Application: Spray plaster machines mix, convey, and apply plaster uniformly. They respond dynamically to changes in material formulation, maintaining consistency throughout the process.
2. Eliminating Water Trapping: The machine mixes the S-RMP with water in precise percentages, forming the plaster mixture in an isolated chamber. With a rigorous mixing speed of 400 RPM, the plaster is then pumped under a pressure of 30 bars over a distance of 10-15 meters and sprayed onto the wall with constant air pressure of 1 bar. This process ensures consistent mixing and application using mechanization.
3. Air Pressure Precision: Controlled application with air pressure eliminates any remaining voids, resulting in a dense, flawless finish.
4. Speed and Superior Quality: Spray plastering delivers high-speed application with unmatched quality. The finished surfaces are free from shrinkage cracks and debonding, ensuring long-lasting durability.

Aakhani Solutions: Pioneering Excellence in Spray Plaster Applications

Aakhani Solutions leads the industry in adopting and implementing spray plaster technology. Combining expertise in spray plaster materials and machine operation, Aakhani has set a benchmark for quality and efficiency.

Our expertise has earned us the trust of leading names in the construction industry, including:

• Shapoorji Pallonji Real Estate (SPRE)
• Lodha Group
• Birla Institute of Technology’s School of Management (BITSOM)
• Shrem Airport Hotel Pvt Ltd
• National Buildings Construction Corporation (NBCC)

By mastering the fine-tuning between materials and machinery, Aakhani consistently delivers outstanding results, solidifying its reputation as a leader in the field.

Join the Revolution

Aakhani Solutions invites you to explore the benefits of spray plaster technology. We welcome your queries, suggestions, and feedback as we continue to innovate and improve. Your insights are invaluable to us.

Spray plaster technology is setting new standards in construction by combining efficiency, durability, and quality. Aakhani Solutions is proud to be at the forefront of this transformation, delivering reliable solutions tailored to modern construction needs.

In the world of construction, plastering plays a crucial role in ensuring the durability and aesthetics of buildings. The methods of plaster application have evolved significantly over time, each with its unique advantages and challenges. In this blog, we will explore three primary plastering methods: Site Mix Plasters, Manually Applied Ready Mix Plasters, and Machine Applied Sprayable Ready Mix Plasters. We will delve into their application processes and highlight the innovative techniques Aakhani Solutions employs to ensure superior results.

Site Mix Plasters

Application Process :
Site Mix Plasters involve mixing raw materials like cement, sand, and water directly on-site. This traditional method requires skilled labor to achieve the right consistency and application. The plaster is manually mixed and applied using trowels, ensuring a smooth and even surface.

Challenges :

• Inconsistent quality due to variations in material proportions and mixing techniques.
• Labor-intensive and time-consuming process.
• Higher material wastage and inefficiency.

Manually Applied Ready Mix Plasters

Application Process :

Manually Applied Ready Mix Plasters are pre-mixed formulations that only require the addition of water. These plasters are prepared in controlled environments, ensuring consistent quality. They are applied manually using trowels, similar to site mix plasters, but with reduced preparation time.

Advantages :

• Consistent quality and performance due to pre-mixed formulations.
• Reduced preparation time and labor effort.
• Improved workability and ease of application.

Challenges :

• Still labor-intensive, requiring skilled applicators.
• Potential for human error in mixing and application.

Machine Applied Sprayable Ready Mix Plasters

Application Process:
Machine Applied Sprayable Ready Mix Plasters represent the pinnacle of plastering technology. These pre-mixed plasters are specifically formulated for use with plaster pumps, which handle mixing, pumping, and spraying. The process involves:

1. Mixing : The plaster pump mixes the ready mix plaster with water to achieve the perfect consistency.
2. Pumping : The mixed plaster is pumped through hoses to the application area.
3. Spraying : The plaster is sprayed onto the surface using a spray nozzle, ensuring even and efficient coverage.

Advantages :

• Superior consistency and quality due to controlled mixing and application.
• Significant reduction in labor and application time.
• Enhanced workability and finish, with reduced risk of cracks and defects.

Aakhani Solutions : Pioneers in Plaster Application

At Aakhani Solutions, we are dedicated to advancing plastering technology and setting new standards in the industry. Our team of highly trained supervisors and engineers excels in both machine handling and material knowledge, ensuring top-tier results for every project.

Choose Aakhani’s Spray Applied Plaster Systems :

• Advanced Techniques : We utilize the best plaster application techniques, including hacking or bond coats on concrete surfaces, and GI mesh application on differential surfaces such as block and concrete columns and beams.
• Expert Team : Our professionals are skilled in the latest plastering methods, ensuring high-quality and durable finishes.
• Comprehensive Solutions : From material formulation to the functioning of plaster pumps, we cover all aspects to deliver superior performance and efficiency.

Our commitment is to provide you with peace of mind through our next-gen plastering excellence. With Aakhani Solutions, you can trust that your project will benefit from the best practices and innovative techniques in the industry.

Conclusion

The evolution of plastering methods has significantly improved the quality, efficiency, and durability of construction projects. Aakhani Solutions is at the forefront of this revolution, offering cutting-edge plaster application services that set new benchmarks for the industry. Join us in embracing the future of plastering, and experience the unmatched benefits of machine-applied sprayable ready mix plasters.