ACTIVITY-10

STUDY AND PRESENT ADVANCED PLASTERING ACTIVITY AND SURFACE

FINISHING TECHNIQUES AND ITS SUITABILITY
What is Cement Plaster and Plastering:-
Cement Plaster is a layer of cement mortar of a desired proportion (mixture of sand and cement) as per
specification. It is a thin layer applied over the rough masonry surface to make it smooth. For good plaster, it is
essential that the plaster should have proper bond with the surface of masonry to be plastered.

Plastering is the process of applying plaster cover of cement mortar over the exposed surface in order to safeguard
against penetration of rain water and other atmospheric agencies.

Advantages of Plastering:-

1. Plastering also provides a finished surface over the masonry that is firm and smooth.
2. It enhances the appearance of the building.
3. Plaster safeguard against penetration of rain water and other atmospheric agencies.
4. It acts as a damp-proof coat over the brick masonry work.
5. Plastering helps to cover the defective workmanship in masonry, to conceal porous materials,
and to provide a suitable surface for painting/whitewashing.

Disadvantages of Plastering:-
1. The appearance of brick masonry such as Ashlar bond, English bond is not visible if plastering
is done over such type of brick masonry.

Plastering Work Procedure:-

1. Preparation of Surface for Plastering:-

1. All the mortar joints of wall should be rough, so as to give a good bonding to hold plaster.
2. Clean all the joints and surfaces of the wall by brushing or scrapping with a wire brush. There
should be not be any oil, grease and efflorescence spots on the surface to be plastered.
3. If there are any cavities or holes on the surface, or any loose inferior materials, then fill it in
advance with appropriate specified material.
4. If the surface is smooth or the wall to be plastered is old, then rake out the mortar joint to a
depth of 12 mm – 20 mm for proper bonding of mortar with the surface.
5. Wash the mortar joints and entire wall to be plastered, and keep it wet for at least 6 hours
before applying cement plaster.
6. If the projection on the wall surface is more than 12 mm, then knock it off, so as to obtain a
uniform surface of wall. This will reduce the consumption of plaster.

2. Applying Under Coat or Base Coat

Preliminary Groundwork :-

1.For uniform thickness of plastering throughout the wall surface, dots on the wall should be
fixed first at a distance of 2m horizontally and Vertically. A dot means patch of plaster of size
15 mm x 15 mm and having thickness of about 10 mm.
2. With the help of Plumb bob verticality is checked and screeds are formed as per the required
thickness in the 2mx2m patches formed.
(Sometimes a cement slury coat is applied on the wall surface for proper bonding between the surface).

Procedure for applying First coat or Base coat:-

1. The ratio of cement and sand for first coat plaster varies from 1:3 to 1:6.
2. In case of Brick masonry the thickness of first coat plaster is 12 mm and for concrete masonry
this thickness varies from
9 to 15 mm.
3. First coat of plaster should be applied between the patches formed on wall surface. This is
done by means of trowel. Level the surface by means of flat wooden floats and wooden
straight edges.
4. First coat should set but it should not to dry. Roughen it with a scratching tool to form a key to
the second coat of plaster.

3. Applying Finishing Coat :-

1. Before applying the second coat the first coat applied should be kept wet/damp.
2. Finishing coat is a final coat of plaster to be applied for finishing the plaster. The thickness of
second coat or finishing coat may vary between 2 to 3 mm of cement mortar ratio 1:4 to 1:6.
3. The finishing coat should be applied starting from top to bottom and completed in one
operation to eliminate joining marks.

4. Curing of Plastering :-

1. After both coats of plastering, it is kept wet by sprinkling water for at least 7 days in order to
develop strength and hardness.
2. Improper curing may lead to cracks formation or efflorescence in plaster work. Gunny bags
can be used for keping the surface damp, to achieve proper curing.

Points to remember after Completion of Plaster Work

• Cleaning of door and window frame and floor area after completion of work.
• Curing should be started as soon as the plaster has hardened. Plaster should be cured for at
least 7 days.
 • Curing shall commence, 24 hours after the plaster is laid.

Objectives of Using a machine for Plastering:-

As compared to old plastering technique / Traditional plastering technique, following objectives can be achieved
using machine for plastering.

1. This Machine will reduce the human work reducing the labor cost. (Since labor
employment is necessary for any country, this factor can be only considered in
some exceptional cases.) Although skilled labor is required for operation of
machines.
2. It will avoid wastage’s of the mortar, thus saves the overall cost of construction.
3. Higher accuracy of the plaster can be acquired along with fast plaster coverage.
4. Machine is portable i.e. can be moved from one place to another.
5. Cost of Plastering per Sq.m can be reduced for large construction work.
Types of plastering machines:-
1. Spray plastering Machines
2. Automatic Rendering machines.
Types of Spray Plastering Machines based on Pump used:-
Plaster sprayers are of three types:

1. Worm-drive pump :- Most commonly, sprayers have a worm-drive pump that pumps the
plaster up to a spray gun that has a large nozzle, usually 4 to 8 mm, that extrudes the plaster
into a chamber on the end of the gun.
2. Peristaltic pump: – There are a few plaster sprayers that have a peristaltic pump (a tube
squeezed by rollers) which also requires compressed air to produce a spray. These types of
plaster sprayer can also spray textured coatings with particle sizes up to about 3mm diameter,
providing that they are not solvent based
3. Piston pump: – Newer types of plaster sprayer have a piston pump, which has sufficient
pressure to spray smooth (untextured) plaster without compressed air.
Advantages of Spray Plastering:-
1. It is powerful and suitable for any type of surface.
2. Can be sprayed to a long delivery distance and height.
3. High output and less time consuming as compared to traditional method.
4. These machines have long service life, if maintained properly.
5. Less labor cost as compared to traditional method.
6. Suitable for site mix with raw materials, alike traditional method.
7. It can be used for a broad range of materials and application. (Ex- Putty spray, epoxy spray etc.)

Automatic Rendering Machine:-

With increasing technology, plastering machines are also developed further, now automatic plastering machines
are patented. These machines are capable of plastering a wall with absolutely “No Mason”. Finishing and
trowelling is done simultaneously with precise degree of accuracy and thickness of plaster needed. This is indeed
a useful and new advance technology in construction sector. This types of machines are also known as “Plastering
Robots”

Advantages of this type of Machines:-

• Save 70% labor cost.

• Increase productivity 10-15times.
• Capability of rendering below or above window openings.
• Stable function & easy operate.
• Easy to Maintain.

Features of Automatic rendering Machines:-

• Wall Plastering Machine can reach the very top of the roof.
• Large hopper can load about 120kg cement.
• Intelligent Wall Plastering Machine can make the wall smooth one time within 1 min.
• Two mini vibrators on the Machine can avoid hollowness of walls, ensured rendering quality
and fully adhesive.
• Machine equipped with omni-directional wheels. You can move it anywhere easily.
 SURFACE FINISHING TECHNIQUES

Electropolishing

Electropolishing is similar to electroplating in that both processes include the use of electricity and chemical reactions;
however, in electropolishing, ions are removed from the surface being treated, while in electroplating, ions are added to
the surface. Electropolishing is a typical procedure for deburring and lowering average surface roughness to obtain a
smooth, level, and flaw-free surface. Metals such as stainless steel, aluminum, copper, titanium, nickel, and copper
alloys are often electropolished. This method is particularly beneficial for metals in the food, medicinal, and
pharmaceutical sectors.

Painting

Engineers often demand painting as a surface treatment to improve a product’s aesthetic and corrosion
resistance. Spray painting, electrostatic painting, dipping, brushing, and powder coat paint are the most popular
techniques for applying paint to the surface of a component. An alternative is to paint using a powder coat.

Metal components may be protected against a wide variety of environmental conditions by using any of a number of
different paint formulas. The automobile industry has completely mechanized and mechanized the process of painting
cars and trucks, using hundreds of robot arms to achieve remarkably consistent results.

Sanding Or Sand Blasting

These surface finishing procedures need relatively basic tools and equipment, but the personnel engaged must have a
high degree of skill since they are primarily done manually. Automation developments have lowered the amount of
required human labour, boosting the output’s dependability and consistency.

A surface layer is removed or changed in this kind of operation utilizing a variety of machining processes known
collectively as abrasive machining. This procedure eliminates dry or wet surface imperfections from metal depending
on the circumstances (using oils, water, or other liquids).Abrasive machining processes are often required for metals
such as aluminum, brass, cast iron, carbon steel, and stainless steel. Lapping is often used to manufacture optical lenses,
bearings, and other components that need fine finishes and great accuracy.

Electroplating

All kinds of electroplating include using electricity to drive an electric current through a bath of liquid to plate metals.
The substrate is then treated substance, while the bath is a solution containing ions of the metal being added.The
substrate serves as a cathode when an electric current is delivered through it. It enables it to attract ions from the bath,
which are then deposited on the treated surface. Higher durability, increased corrosion resistance, less surface friction,
and improved aesthetics are a few benefits of this method. This method treats zinc, nickel, copper, gold, silver, and
other metals. However, we may use this process to cure almost any other metal.