Mechanized plastering. It”s fast, but not always expensive!

Prioritizing efficiency and speed is common when plastering walls. Because mechanized plastering can cover large areas quickly and save time and labor, it has become a popular choice for many. Compared to conventional methods, this technique applies plaster more quickly and evenly because it makes use of specialized equipment.

Even though mechanized plastering works incredibly quickly, it’s vital to weigh the associated expenses. Although some people might believe that utilizing sophisticated equipment will always cost more, this isn’t always the case. Depending on the size and details of the project, mechanized plastering may or may not be cost-effective.

This post will explain the advantages of mechanized plastering and explain why it might be a better option for your upcoming project. We’ll also discuss circumstances in which it might not be the most economical choice, assisting you in making an informed choice regarding your plastering requirements.

Pros and cons of machine application

Mechanized plastering is a technique for leveling walls and ceilings in which an automatic or semi-automatic plastering machine applies the solution instead of a worker applying it by hand.

Plastering walls using this contemporary technique takes a lot less time and effort.

A lot of builders who do finishing work professionally and employ both manual and mechanized methods point out advantages and disadvantages of mechanizing the plastering of walls.

The following are a few benefits:

1. Performance. The mortar supply rate from the plastering station is from 1.2 m 3 /hour, which is 20-40 m 2 of walls plastered per hour. Mechanization of work saves time up to 4 times.
2. Economical. The use of special mechanisms for plastering eliminates waste of material. Also, when finishing manually, two layers are often applied, but with a mechanized method, one will be enough.
3. Labor force. For mechanical plastering using stations, two workers are enough: one applies the solution to the wall, the second levels it.
4. High-quality adhesion to the base. Thanks to the application of the solution under pressure, good adhesion to the wall is ensured.

Features of mechanized plastering that restrict its application to sporadic home repairs:

• Dirt. When applying plaster with a gunite station, part of the solution bounces off the wall under pressure, splashes fall on the floor.
• Cost of equipment. Plastering stations are expensive, therefore, it is advisable to purchase equipment for professional work. For one-time and independent repairs, it is more profitable to work manually or rent such equipment.
• Equipment of the work site reliable electrical wiring and centralized water supply.
• High noise level. Pneumatic equipment, runs on a powerful compressor, which works quite loudly. This also applies to the machine for mechanical plastering.
• Timely maintenance of equipment: washing after completion of work, checking the oil in the compressor, etc. Also, the solution should not remain motionless for more than 15 minutes, since during this time it will have time to set.

Large wall areas can be covered quickly and effectively with mechanized plastering, and when compared to traditional methods, the cost can be surprisingly low. Modern equipment allows you to complete projects smoothly and quickly, so it’s a sensible option for both small and large jobs. Despite having a high-tech appearance, it’s frequently more affordable than you might think, offering great value for your money.

Types of equipment

The following mechanisms are used to apply plaster to walls:

• semi-automatic (pneumatic), which use a ready-mixed solution.with They can be moved during the work.
• automatic (auger), in which everything is automated, including mixing the solution. Workers load the dry plaster mix into the machine, then the ready-made solution is applied to the wall under pressure, while the second worker follows and smooths the applied plaster.

It is noteworthy to mention that plaster can be sprayed using hand-operated devices known as "hurdy-gurdies." They are not appropriate for speedy plastering during the rough work stage; instead, they are used for decorative coatings like "fur coat."

After taking a closer look at the equipment on the list, we’ll go over the plastering machine work in more detail.

Pneumatic shovel (hopper bucket)

This device’s simplicity and ability to work with all plaster types currently on the market are major advantages.

The way it works is as follows: the handle-conductor is attached to the compressor, the ladle is filled with a pre-mixed solution, and then the lever is used to supply a stream of air that shoots out of the holes in the ladle along with the plaster. Maximum productivity of 60 m 2 per hour.

Such a device ranges in price from 3,000 to 15,000 rubles.

An extensive article explaining the self-production and usage of the hopper bucket.

Pneumatic gun (cartridge sprayer)

The working principle is comparable to that of a hopper bucket: the solution is sprayed onto the wall under pressure when a stream of air is supplied through a compressor hose that is attached to the gun. Air is supplied by the trigger, and the plaster is regulated by an internal needle that functions similarly to a spray gun.

About 60 m 2 are produced per hour. A cartridge gun frequently comes with extra attachments that allow you to alter the size of the plaster droplets.

A pneumatic gun can be made independently and costs no more than five thousand rubles.

The primary purpose of the Carter pistol is to apply ornamental textured plasters. Read our article to learn more about how to collaborate with him.

Plastering station (torque-installation)

These stationary devices, which start at 200 thousand rubles, are made for professional use.

Plastering stations typically completely automate the process; that is, they knead the solution and then apply it to the prepared surface.

These machines are designed with a supply mechanism, a mixer, a control unit, and a reception hopper. These stations need a specific amount of room in the room.

Plastering stations offer the advantage of automatically preparing the solution and ensuring that it remains consistent throughout the work process.

The working principle consists of multiple phases:

• equipment preparation: connection to the power supply panel and to the central water supply, pouring dry mixture into the hopper;
• mixing the solution: the mixture is fed from the hopper into the mixer and when water is supplied, the solution of the required consistency is mixed, which will also be maintained;
• application to the surface: the finished plaster solution is fed by a screw and sprayed onto the wall through a hose under pressure. This will be discussed in more detail below.

Choosing the mixture and preparing it yourself

Plasters applied mechanically are applied on a base of cement or gypsum. For instance, any compositions with a fraction size of no more than 10 mm can be sprayed through a hopper bucket. These can be factory-dry mixes or self-mixed solutions.

The composition chosen for plastering machines (stations) has a maximum grain size of 8.5 mm.

Typically, they purchase plasters whose composition is intended for application by a machine:

• Gypsum: KNAUF MP-75 and MN-Start, Volma Gips-Active, Starateli MN, Dauer Gipsart-M, Gipsopolimer Rotgips MS100, Osnovit PG26 M and others.
• Cement-sand: KNAUF Unterputz (Unterputz), Dauer Fasad-M, Quick-mix MK3 (lime-cement) and MZ1, Osnovit PC21 M, Volma Aquasloy MN, Weber Vetonit TT40, Ceresit CT 29 and others.

The following supplies are needed to make cement-sand mortar yourself:

1. Portland cement grade not lower than M400 (better M500) or VBC (waterproof shrinkage-free cement).
2. Quartz sand purified with a moisture content of 5-10%. Dry sand does not mix well with water in the fall, resulting in a non-uniform solution.
3. Additives and plasticizers. They are diluted in water before mixing or added to dry cement-sand mortar.

Examples of special parts for mechanized plastering are displayed in the table below.

Substance class	Brand
Hydration regulator. Increases or decreases setting time.	"Asilin", "Proston – D18"
Moisture delamination blockers. No liquid is released during plastering, which allows applying a thick layer of the mixture without it slipping.	«Conwisol SM-11», «SikaLatex»
Air-entraining. Reduce the density of the composition, which reduces its thermal conductivity.	«Mapeplast LA»
Plasticizers. Increase the elasticity and mobility of the solution, the strength of the coating for bending and stretching.	«Hardplast», «SikaPlast-520»
Waterproofing penetrates. Increase the water resistance of machine plaster. Can reduce adhesion, therefore they are added in a strictly limited manner.	«Kalmatron-D», «Sika-1»
Structure modifiers. Reduce shrinkage of the mixture, provide stress and water resistance.	«Parade», RSAM, Cement NC

Plastering with a machine station

There are several steps in the mechanized plastering process, but first the walls need to be manually prepped. This includes priming, cleaning, and installing beacons.

Crucial elements influencing the plaster application quality by machine:

Cutting and leveling. The second worker completes this step until the plaster hardens. He levels the plaster by working from bottom to top using a rule. Excess is cleaned up or reapplied to the wall in the depressions that remain, if needed.

The trimming process, which uses a trapezoidal rule, can begin after the mixture has set, which takes about fifteen to twenty minutes. Eliminate any small irregularities.

Swearing. To achieve a perfectly even surface on the wall, this step is required. The earliest grouting should be done an hour following leveling. Make use of a wide spatula and a float with a sponge surface. This process is repeated multiple times if required.

If the plaster contains Portland cement, the completed layer needs to be kept out of the cold and dry for a week after application.

Aspect	Description
Speed	Mechanized plastering is much faster than manual methods. It can cover large areas quickly, which is great for big projects.
Cost	While the initial setup might seem expensive, mechanized plastering can save money in the long run due to its efficiency and reduced labor costs.
Quality	It generally provides a more even and consistent finish compared to manual plastering.
Maintenance	Mechanized systems can require regular maintenance to ensure they operate smoothly and efficiently.

Because of its exceptional speed and efficiency, mechanized plastering is a preferred option for a lot of remodeling projects. Plaster application is automated, which saves a great deal of labor time and guarantees a uniform, smooth surface across large areas.

Mechanized plastering is not always the least expensive option, even though it can be a financially advantageous solution. The complexity of the work and the kind of materials used are two examples of factors that can affect total costs. It is crucial to compare these aspects to the amount of time saved and the level of quality attained.

Mechanized plastering is ultimately a decision based on your budget and unique requirements. Mechanized plastering is a good option if you can afford the associated costs and need a high-quality finish quickly. It’s important to consider all of your options when working on projects where budget is a top priority in order to strike the best balance between cost and speed.

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Mechanized plastering of walls. PLASTERING STATION.

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