Rapid-Setting Polymer-Modified Mortar Formulation

A professional-grade mortar mix enhanced with acrylic polymers for improved flexibility and adhesion. Ideal for fast-track construction projects and repairs, this formulation is suitable for both wet and dry environments, ensuring durability and performance.

Technical Specifications

  • pH Level: 12-13
  • Shelf Life: 12 months in a sealed container
  • Batch Size: 1000 kg batch
  • Processing Time: 45-60 minutes
  • Temperature: 15-25°C
  • Storage: Store in a cool, dry place away from direct sunlight and moisture.
  • Viscosity: Medium to high viscosity suitable for trowel applications
  • Certification: ISO 9001:2015, ASTM C270

Ingredients

IngredientPercentageFunction
Portland Cement50.0%Primary binding agent
Silica Sand30.0%Provides structural integrity and texture
Acrylic Polymer10.0%Enhances adhesion and elasticity
Calcium Aluminate5.0%Accelerates setting time
Hydrated Lime3.0%Improves workability and water retention
Water Reducing Agent1.5%Reduces water demand and improves flow
Defoamers0.5%Minimizes air entrainment for smoother application

Manufacturing Process

Dry Blend Phase

  1. Mix Portland Cement and Silica Sand thoroughly in a large mixer.
  2. Add Calcium Aluminate and Hydrated Lime to the mixture.
  3. Ensure even distribution of dry ingredients through consistent mixing.

Wet Blend Phase

  1. In a separate container, mix Acrylic Polymer with the Water Reducing Agent.
  2. Add the wet mixture to the dry blend slowly, while continuously mixing.
  3. Introduce Defoamers into the mixture, ensuring no air bubbles form.

Usage Instructions

Mix the formulated mortar with clean water at a ratio of 4:1 (mortar to water) before application. Apply to the desired surface within 20 minutes of mixing to ensure optimal performance.

View full formulation details on AIFormulator