What is machine plastering of walls – secrets and technology

The finishing of walls has been completely transformed by machine plastering, which provides consistency, speed, and accuracy that are difficult to achieve with manual techniques. This method is becoming more and more popular for both residential and commercial projects since it uses specialized equipment to apply plaster quickly and evenly.

However, what is machine plastering exactly, and how is it different from conventional techniques? Gaining an understanding of the underlying technology and a few essential insider tips will help you save time and effort while producing results that are professional.

This article will cover the fundamentals of machine plastering, including the kinds of machines used and the detailed procedure. These tips can help you learn the fundamentals of contemporary wall plastering, regardless of your level of experience or interest in do-it-yourself projects.

Mechanized plastering of walls what is it

In a nutshell, mechanized plastering is a plastering technique where the plaster mixture is applied to the base using mechanical devices.

Plastering involves varying amounts of mechanical and human participation:

1. When applying using cartridge guns or hoppers, compressors are also involved in the work, providing a supply of compressed air. Before plastering, the worker prepares the mixture separately, using a mixer or mortar mixer.
2. When applying with plastering stations, the worker is relieved of most of the concerns about preparing the solution (the components are dosed and mixed by machines).

In the second option, the machine is entrusted with the preparation of the solution and the application of the plaster mass to the wall. The mortar "liquid" is fed through the nozzle of the gun under pressure, sprayed with force onto the base, tightly laid, nailed down from above by subsequent splashes. The plasterer is required to hold the hose through which the plastering materials are supplied, at the required distance from the wall, moving the head of the gun as the layer is formed along the surface being treated. As a result, the machine replaces a person in routine, tedious physical labor, accelerating, facilitating the two most labor-intensive stages of plastering.

The master just needs to use a spatula to smooth the top of the mass along the beacons after it has been applied by the machine for a predetermined amount of time. There is also the trouble of maintaining the machinery after it has been used and getting it ready for work. Compared to puttying, which is eliminated with the machine method, it is simpler and requires less time.

Plastering stations were the name given to these amazing devices, and modifications were created that varied in:

• power;
• productivity;
• method of loading the components of the composition;
• number of operations performed;
• mobility;
• power source, etc.

Both the operator of such machinery and the plasterers who use mechanized methods to complete their work must be trained.

Large areas must be plastered, and since machine plastering reduces labor time by five to six times, this method is employed. Plastering stations are used for filling floor screeds as well as plastering.

For use in machine applications:

• gypsum;
• lime;
• sand;
• cement;
• mixtures based on these materials with modifying polymer additives.

Advantages of the method

Plastering walls by machine not only boosts productivity but also achieves the following advantages:

• no need for additional leveling by puttying;
• reduction of cracking and chipping of the coating due to the absence of shrinkage factors;
• preparation of the working mixture by machine eliminates the appearance of cement or gypsum dust in the air (or rather reduces its amount);
• increased strength of the coating, resistance to external influences (the layer does not crumble when screwing in screws, hammering in nails);
• a porous "fur coat" is formed, regulating the microclimate of the room, allowing the wall material to "breathe";
• higher adhesive properties of the mixture thrown under pressure;
• several times less plaster consumption;
• the cost of materials for machine plastering is lower, saving money on the purchase of raw materials;
• In the memory of the station, data on the preparation parameters are stored, the solution gripped between the screws at the output is more uniform than the quality of the machine “test” above;
• the plaster shell is warmer than the usual material from the same components;
• below the cost of work;
• The service life of machine "vestments" is higher, for example, gypsum decoration can serve more than 25 years.

The disadvantages of the method

But this approach was not without its drawbacks:

• It takes time to maintain the machine in front and at the end of plastering;
• For internal corners, the use of specialsugols is required;
• The method is unsuitable for plastering of curved surfaces;
• The wall plastered with gypsum is not suitable for cladding with tiles (over time, the tile will lag behind and split);
• the features of the coating properties require long drying (the wall can be processed only after a week);
• the need for a three-phase connection for most units, which not all houses are equipped with;
• increased energy consumption;
• high cost of equipment, as well as hiring a team (min 3 people);
• high level of pollution;
• impossibility of performing work in the evening or at night due to increased noise levels.

With less manual labor and faster plaster application, machine plastering is a contemporary technique that produces smooth, even walls. Plaster is mixed and sprayed onto the walls using specialized equipment, which ensures uniform coverage and lowers the possibility of human error. Large-scale projects benefit greatly from this approach, which can reduce labor and time requirements without sacrificing output quality. Achieving professional finishes quickly and efficiently can be facilitated by knowing the technology and secrets behind machine plastering.

Selection of the necessary equipment and tools

Let’s discuss plastering stations (PS), which are the means by which walls can be fully machine plastered. Both stationary and mobile (portable) units are available. Although the latter are used more frequently, the former are utilized on larger sites.

Pumps form the basis of the units:

• diaphragm;
• screw (have continuous mixers);
• piston.

The SS’s productivity is determined by the mortar pump’s productivity. The mortar mixture is made using software, which, after a few small adjustments, keeps the components in their ideal proportions. A few minutes after startup, the working mixture is fed to the injectors, nozzles, or nozzles.

Using a gun, the plasterer controls how much of the solution is applied to the wall. Apart from the pumps, the unit kit consists of:

• controller;
• compressor (there are units that do not include a compressor);
• receiving hopper;
• mixing chamber, where the dry mixture is fed by a gear drum or auger;
• solution supply hose;
• air supply hose;
• spraying device.

The plastering station is connected to both the power grid and the water supply in order to function. The machine model dictates whether power grid parameters are required:

1. At large-scale industrial or civil construction sites, for example, parking lots, hospitals, schools, they use stations with power supply parameters of a three-phase network of 50 Hz, 380 V with a pump with a capacity of 5.5-7.5 kW. A station with an average capacity of 22 liters per minute, working together with a team of four people, processes 150-200 m2 per shift. Work with heavy cement mortars (> 1300 kg / m3)
2. In private houses, cottages, apartments, where there is only alternating voltage of 220 V, 50 Hz, small mobile single-phase units with a pump with a capacity of 2.2-3.5 kW, with a capacity (depending on the type of screw pair) of 13-18 liters per minute are used. Work with solutions up to 1300 kg / m3 (inclusive).
3. There are also multi-voltage plastering stations that can be switched to 220-volt or 380-volt mode. Productivity (respectively) 18-22 liters per minute. The most expensive models.

One-time or double-mixing SHs are both possible; the latter is required to expose the prepared mixtures.

Machine wall plastering technology

Next, we learn about mechanized plastering—what it is and how it is done in real life.

Surface preparation

Both machine and manual plastering require this step. The wall is slightly nuanced in preparation for the latter.

1. We clean the surfaces to be treated completely, remove dirt, traces of wallpaper, paint residue, old plaster layer and drips. We clean weak, crumbling areas of the base, reinforce with nylon mesh for facades, cover them and the depressions with plaster mortar.
2. We remove or cut off protruding metal parts, clean the remaining ones with a metal brush, cover with an anti-corrosion compound.
3. We de-dust the surface, prime with a product appropriate for the wall material in two passes (do not forget to dry each layer).
4. We check the evenness of the base instrumentally. We mark serious deviations.
5. We install profiles on the corners and slopes.
6. We check the base material for its ability to absorb moisture. If water absorption is high, we wet and apply a thin layer of mortar. Let it dry.
7. Install beacons, fixing them on the working solution.

Installation of beacons

Beacon installations are carried out in the same manner as manual plastering. Determine the location of the beacon profiles by taking measurements and building an auxiliary plane with a plumb line or laser level. Metal or mortar can serve as beacons. The spacing between the strips is designated to be 20–30 cm less than the rule’s length.

In the event that the plaster coating layer exceeds the permitted amount, a reinforcing mesh is fixed to the wall prior to the installation of beacons.

Preparation of equipment

Prior to starting work, the working equipment is set up for machine plastering of walls. The plastering room is where the unit is installed. Plastering stations are positioned in the center of the room if its dimensions permit you to reach every surface that needs to be processed from that point.

Put the unit together:

1. First, install the chamber-tank in which the composition is mixed.
2. Connect the feed pipe to the inlet.
3. Screw the nozzle selected for the job onto the pipe (the nozzle width depends on the grain size and thickness of the solution).
4. Connect the complex to water, and the last connection is to the power grid.
5. Check the machine for compliance with safety regulations.
6. Pour the dry mixture into the receiving hopper, set the desired operating mode using the remote control.

Applying plaster

Plaster mortar application technology is straightforward.

1. After turning on the MS, wait for the time required for the solution to mix and saturate the mass with oxygen (the duration is indicated by the SS manufacturer on the packaging).
2. The feed hose or gun is directed at the wall (at a right angle), holding it at a distance of ~ 30 cm from the surface.
3. Press the trigger or open the air supply valve. The solution begins to flow through the nozzle.
4. The working composition is applied by moving the nozzle along the surface in rows with a step of 3-4 cm. The movement of the nozzle between two beacons is carried out continuously (alternating forward and backward directions), applying the plaster mass with an overlap (overlap – 40-50%).

The first step in mechanized plastering is to fill the joints and corners with the working mass, and then plaster the flat areas. The nozzle’s speed along the base’s surface determines how thick the layer is applied with a consistent mortar supply. The layer forms thicker the slower the nozzle is moved. The layer thickness in gypsum compositions can be adjusted up to one centimeter. Layers of cement mortar up to 5 mm are applied, with several hours elapsed between applications (packaging information).

Make sure the solution’s top rises uniformly above the beacons when applying it. The speed of application is one benefit of applying solutions in a different way. Gypsum is applied roughly twice as slowly as cement.

Final leveling of the solution

If the mixture is made of gypsum, it is leveled right away; if it is made of cement, it takes an hour (refer to the package for details). In other words, leveling is done prior to setting. Using a rule, the plaster layer is leveled by advancing the instrument from bottom to top along the beacons. Using a spatula, excess mortar is moved from the rule to areas where there is insufficient mass.

Once the mass has set, the husks and whiskers are aligned. If a specific structure needs to be exposed, floats, smoothers, or figured trowels are used to process the wall. There is one more ironing of the cement coating.

Trimming is done with a trapezoidal or H-shaped rule 20 minutes after the initial leveling, just like you would cut a thin layer of plaster with a knife. This gets rid of any last bits of lumps, rollers, and drips.

After trimming, grouting is done 20 to 30 minutes later. If grouting is done two to three hours later, the surface has been moistened. Use floats, trowels, or grouting machines to grind. Glossing refers to the process of smoothing surfaces with a wet tool before painting.

Beacons are removed once the plaster has solidified; the plaster layer needs to stick to the base. The solution is applied to the channels that have formed. Using a wide spatula, level the area; the wall next to the groove provides a leveling reference.

Types of work and their features

To what extent is the machine method of plastering universal? Plastering stations and machines can be used outside as well as indoors because the mixtures are made for both exterior and interior use. There are some limitations on the street. For instance, plaster cannot be mechanically applied outside during the winter. Plastering with machines requires, among other things, that the surface being treated be at least 20 degrees Celsius in temperature. The characteristics of the solution, not the mechanism, impose this requirement.

Interior work

The most common materials used in interior design are gypsum or lime-gypsum compositions. Cement mixtures in high humidity rooms. When handling gypsum mass, efficiency is needed. As soon as the layer is applied, the equipment is cleaned. Cleaning the gypsum mass that has adhered to the mechanism’s components is impractical.

Facade work

Only in positive temperatures can walls be machine plastered outdoors. Creating an environment that plasterers will find comfortable to work in is also essential. Using cement compositions, which are mechanically stronger, resistant to hail damage, heavy rain, and frost, is the hallmark of facade work. Furthermore, a significant portion of facade compositions may contain components, such as mixtures of bark beetles. As a result, the manufacturer’s data CC is used to set the machine’s settings.

Mechanized plastering of the ceiling, subtleties of the process

The uniqueness of the surface being treated’s location affects how plaster is applied to ceiling surfaces. It is necessary to use protective measures, especially for the eyes. They try to position cables and hoses so that they are not stepped on because the plasterer is looking up at his feet less and less.

A specialized nozzle is used to plaster ceilings, removing the need for the plasterer to be in direct contact with the working mass. Plastering is done in two passes, or in two sections of one centimeter. The rule is followed in your direction when cutting or leveling. It makes perfect sense to install reinforced mesh on the ceiling.

Errors in machine wall plastering

Errors in plaster application are automated:

• Instructions for equipment do not follow the management, as a result, the appearance of non -mixtures (lumps), electricity defeat, breakdown of equipment in the working mass.
• Use mixtures of "self -packing" production or for manual plastering. The first is unacceptable, since the correctness of the unit is not guaranteed, the second, even less seriously, can also give a negative result, since the mixer is programmed for special mixtures.
• Do not take measures to increase adhesion – applying notes to concrete, failure to fulfill priming, non -use of reinforcement with a net when setting joints, cracks.
• Non -compliance with the requirements for the maximum thickness of the layer. The layer becomes fragile, easily disappears.
• Non -compliance with the hardening and drying mode. The use of heating devices.
• Violation of the consistency of the composition. Different compositions may differ in consistency (be harder to lay or stick and hold on the wall less well).
• A serious mistake is adding SS to the prepared solution. The consequence is the formation of lumps.

A video showing how to set up and run a plastering station.

Aspect	Description
What is Machine Plastering?	A method that uses specialized equipment to apply plaster to walls quickly and evenly, ideal for large areas.
Advantages	Faster application, consistent finish, and less manual labor compared to traditional plastering.
Technology Used	Plastering machines mix and pump plaster through a hose, spraying it onto the walls.
Common Secrets	Proper machine calibration, using the right plaster mix, and maintaining consistent spraying technique ensure a quality finish.

The method we use to finish walls has been completely transformed by machine plastering. Compared to traditional methods, the process is faster, more efficient, and produces a smoother, more even surface when using sophisticated machinery.

For large-scale projects where efficiency and reliability are critical, this method is perfect. Even the most complex details can be handled precisely with the correct planning and technological knowledge.

Using machine plastering in your building or remodeling projects guarantees a high-quality finish that satisfies contemporary standards while also saving time. Those looking for a polished, long-lasting outcome should give this approach serious thought.

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