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On-Site & Ready-Mix Plaster Comparison Essay

Ready-Mix Spray Plasters are a rapid, cost-effective alternative to traditional (manually mixed & manually applied) plaster for finishing external & internals walls and ceilings. They are formulated for machine application on fast-track & quality building projects. They are supplied as “dry pre-mixed” to the correct consistency for spray application by Plaster Machines.

Ready-Mix Spray plastering has been used in Europe, UK, Far-East for many years and is quickly becoming a widespread alternative to traditional plastering due to both it’s economic benefits and rapid speed of application. What are the Major Differences between:

Traditional On-Site Plaster Vs Ready-Mix Plaster Vs Ready-Mix Spray Plaster? Traditional On-Site Plaster
Highly labour intensive
Ingredients / raw materials
are measured and mixed
in small quantities on site

Ready-Mix Plaster
Labour intensive task

Ready-Mix Spray Plaster
Not at all labour intensive
Dry complete Ready-Mix in bags –
Absolutely no mixing of ingredients
required at site

Mixing time with water
approx. 6-10 minutes
before applying
Mixture not workable

Dry Ready-Mix in bags –
normally no additional
mixing of ingredients at
Mixing time with water
approx. 6-10 minutes
before applying
Mixture less workable

Normally no admixtures

Only some admixtures

Application by hand – Mix
is picked up by the
tradesman and laid onto the
wall prior to floating and

Application by hand –
Mix is picked up by the
tradesman and laid onto
the wall prior to floating
and trowelling

Mixing time with water approx. 3-6
seconds before applying
Retarders slow down the setting time
and generally make the mixture more
workable Modern plasters come already mixed
with perlite, vermiculite and several
other additives.

These additives
provide a greater degree of insulation
and fire resistance
Application by UELZENER ReadyMix Spray Plastering Machine
(Mixing-Pumping-ConveyingSpraying) – It has a mixing pump
(rotor-stator). Dry pre-mixed material
is fed into the hopper and is
transported into the mixing chamber.

A constant supply of water, adjustable
according to the mixture required, is
fed into the chamber to produce a
continuous consistent mix.

The mixing
shaft transforms the dry powder into
smooth wet plaster, render, mortar,
grout or floor screed in seconds, also
drives a pump which conveys the
always fresh mixture to the work area.

The plaster mixture is very
sensitive to variations in
water content.

The skill of
the plasterer is not just in
the finishing but in the
gauging the wetness of the
mixture to be applied.

Plasterer adds more water
for ease of application
Setting Time approx. 10 to
20 minutes

Very Low Productivity
Inconsistent Quality
Not at all flexible – Results
in high cracking, flaking,
Traditional On-Site Plaster

The plaster mixture is
sensitive to variations
in water content.

skill of the plasterer is
not just in the finishing
but in the gauging the
wetness of the mixture
to be applied
Setting Time approx. 10
to 15 minutes
Low Productivity
Inconsistent Quality
Not flexible – Results in
cracking, flaking,
Ready-Mix Plaster

The mix is sprayed with remote
controlled spray gun
Fixed and accurate quantity of water
is dosed in the dry ready-mix. Hence
the wetness of plaster is
independent on the plasterer

Setting Time approx. 8- 15 minutes
Very High Productivity & Efficiency
Consistent High Quality
Inherent flexibility – Much less prone
to cracking, chipping and flaking
Ready-Mix Spray Plaster

How many Types of Ready-Mix Spray Plasters are available?
There are quite a few plasters but two main types: Gypsum-based: They are used indoors only, damp will attack a gypsum based plaster and cause it to crumble. Cement-based: They are used mainly for outdoors, generally for rendering. Cement based plasters can be used indoors for areas that are susceptible to damp and areas that require a greater thickness of cover.

What Finishes are available in Ready-Mix Spray Plaster?
Normally Ready-Mix Plasters are available in three finishes: Standard smooth Finish – After spray plastering Base & Finish costs, the plaster is then manually smoothed over with large spatulas or butterfly trowels to give a smooth hard wearing finish

Fine Textured – After spray plastering Base & Finish costs, the spray may be left to give a “textured” finish. Course Textured – After spray plastering Base & Finish costs, the spray may be troweled to give a “textured” finish. For the texture finishes a hard wearing, water resistant material is used which does not need final decoration; ideal for high traffic areas such as stairwells and corridors.

What are the Ready-Mix Spray Plaster range?
Normally 2 product ranges: Base Plaster: Filler and levelling compound for use over thin joint brick / block systems, uneven in-situ concrete and on refurbishment projects to fill cracks, holes and undulations

to prepare surface for final decoration. Normally applied upto 5-10 mm (max. 20 mm) thick in one application. 1 to 2 coats are recommended with 12-24 hrs drying between applications. This is applied using Uelzener Ready-Mix Plaster Machines. Finish Plaster: Normally applied upto 1-2 mm thick as a single top coat on “Base Plaster” or as a 2 coat finish directly onto smooth backgrounds including pre-cast panels, Aircrete panels, composite boards, and/or refurbishment over previously decorated surfaces. This is applied using Uelzener Ready-Mix Plaster Machines.

What is the Coverage of Ready-Mix Spray Plaster?
Base Plaster: Normally 1.5–2.0 Kg per m2 at 1 mm thickness Finish Plaster: Normally 1.35-1.5 Kg per m2

Where can Ready-Mix Spray Plaster be used?
Ready mix plaster can be applied to almost any substrate including brick work, block work, concrete panels, dry lining, plaster boards, ceramic tiling, artex, wood, glass, steel, old / damaged plaster, and even painted wall coverings (e.g. woodchip).

Why should you use Ready-Mix Spray rather than “traditional on-site” plastering? What are the benefits of “Ready-Mix Spray Plaster” using UELZENER German Spray Plastering Machines?
* The plaster is supplied “pre-mixed to the correct consistency” for spray application. * Flexible products: Less likely to crack than plaster skim coats. Final surface is less prone to cracking than traditional plaster. It accommodates normal thermal movement without flaking or chipping.

* Non-reactive with all substrates including lime plasters and sand and cement renders. * Offers moisture resistance so suitable for kitchens, bathrooms and changing areas. * Hard Wearing: The material can be specified to be high density and water resistant so is ideal for use in high wear areas such as school and hospital corridors and stair wells. * Specifications: Confirming to DIN, EN, British Standards for Fire Integrity, Acoustic & Thermal performance & Mechanical strength.

* It absorbs and subsequently releases moisture (5-10% of its own weight in water) greatly reducing the incidence of condensation and mould growth.
* Insulation properties.

* Can be applied by the same teams applying paint finishes
Speed & Cost…
* The use of ready mix plastering over traditional plastering techniques offers significant savings during the project by significantly reducing construction time by optimizing internal fit-out. It’s fast! A two man team can cover between 200 and 500 m2 per day (typically 2-4 times faster than traditional plastering techniques) depending on the substrate. Upto 1,000 m2 per week can be finished by a three man gang.

* Surfaces can be emulsion painted 24-48 hrs after final coat (saving project time and cost).
* White surface finish reducing paint coats required (saving project time and cost). * Material can be tinted the same colour as the decoration reducing maintenance requirements over a long period (saving project time and cost). * Ease of Access: Heights of upto 3.0-3.5 meters can be plastered without the need for scaffolding or platforms, although brick/block work & surface preparation may require scaffolding (Health and Safety).

* Material is premixed so no need for water and messy mixing on site. * The material is accurately sprayed at the wall or ceiling and any material removed during the smoothing process is fed back into the spray machine.

* No need for surplus material to be disposed of at the end it simply gets stored in the machine and re-used the next day.
Environment Friendly…
* VOC free as there are no plasticisers or solvents used in the production process. * Water consumption vastly reduced.
* No waste: Approx. 1% waste produced – all material that is taken from the wall or ceiling during the smoothing over (trowelled from surface) can be re-applied, thus reducing site waste.
* Water-based product, non-damaging to health or the environment.

What is the normal Performance of Ready-Mix Spray Plaster?
Hardness = range of 10 N/ mm²
Tensile Strength = range of 1.8 N/ mm²
Compressive Strength = 2.2 to 5.5 N/ mm²
Flexural Strength = 1.8 N/mm²
Bond Strength = 0.33 N/mm²
Pull-off adhesion Strength = 0.35 N/mm²
Impact Strength = 4.5 mm

What are the Advantages to the Architect?
The key benefit of mixing and pumping plastering machines to architects is that of consistent quality, helping to ensure that colour and finish are as envisaged at the design stage. Architects and specifiers also have the facility to select modern materials such as fast flowing, fast drying, self levelling floor screeds and other liquid mortars with the benefit of greater performance, physical properties relevant to their location and reduced drying times.

What are the Advantages to the Contractor?
For the contractor the key benefit is also that of higher consistent quality, resulting in lesser correction, no hacking off and so reducing the likelihood of rectification costs. Costs are further reduced as construction can proceed more quickly and importantly there is less risk of damage to materials on site. Other advantages to the contractor include early removal of scaffolding, less waste on site and low maintenance cost. But the key benefit is that using a machine enables an accurate account of the material used.

11th Cross Lane, Prabhat Road, Sanjeevani Apartments, E-6,
Pune – 411 004. INDIA
Tel: (020) 2567-9001, (020) 2567-2824
Fax: (020) 2567-9000; M: 098220-23439 E-mail: [email protected], [email protected] ; Website: www.uelzener-ums.de

Advantages & Disadvantages of
On-Site Traditional Vs Ready-Mix Spray Plastering Approaches (A) Traditional On-Site Plaster
Uelzener Models suitable: S82 EMV and S82 DMV

Existing on-site cement-sand is used as
Can be pumped up to 80m conveying
distance depending upon mix




Requires admixtures suitable for
pumping & conveying
Requires on-site control of Sand “Sieve
Requires on-site control of correct
plaster mix suitable for pumpingconveying-spraying i.e. exact proportion of sand, cement, water, admixtures
No guarantee of actual “Plaster Quality”
in terms of strength, cracking, setting
time, etc…
Plaster mixing time approx. 8-12
minutes per batch
Plastering Machine cost in the range of
Rs. 18 to Rs. 21 Lacs depending upon
accessories, conveying distance, etc…

(B) Ready-Mix Spray Plaster
Uelzener Models suitable: S44, S48, S48Easy




Pre-Mix dry plaster readily available in
bags – depending upon site-sand.
It is inclusive of necessary admixtures,
and is suitable for pumping, conveying &
Hence does not require on-site control of
Sand “Sieve Curve”, and on-site control
of “exact proportions” of mix

Guarantee of actual “Plaster Quality” in
terms of strength, cracking, setting time,
etc… can be offered Plaster mixing time approx. few seconds
per batch Plastering Machines are light weight and
can be easily shifted from floor-to-floor
Plastering Machine cost in the range of
Rs. 5 to 6 Lacs depending upon
accessories, conveying distance, etc…

Actual cost of Ready-Mix Dry Spray
Plaster are higher than on-site plasters;
But the overall costing considering
quality, speed, efficiency, wastages
would result into SAME cost
Can be pumped up to 20 to 30m
conveying distance depending upon mix

Please feel free to contact: Mr. Pradeep Ghumare for all your end-to-end Plastering Solutions

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