DESIGN, STRUCTURAL ANALYSIS, AND FABRICATION OF A PORTABLE CEMENT SPRAYING CHAMBER FOR CONSTRUCTION APPLICATIONS

Abstract

This study presents the design, structural analysis, fabrication, and performance evaluation of a portable cement spraying chamber intended for efficient, uniform application of mortar in construction and repair works. The proposed system aims to offer a lightweight, cost-effective alternative to bulky commercial sprayers and labor-intensive manual plastering methods. A CAD model of the chamber was developed and subjected to finite element analysis (FEA) using ANSYS to assess its structural integrity under nozzle reaction forces and pneumatic pressure loads. The analysis revealed a maximum von Mises stress of 51.06 MPa, a maximum deformation of 0.1432 mm, and a minimum factor of safety (FOS) of 1.62, validating the chamber’s mechanical robustness for operational conditions. The prototype was fabricated using aluminum alloy casting and fitted with brass nozzles for enhanced durability. Field trials confirmed uniform spray distribution, ease of handling, and resistance to clogging or leakage. The strong correlation between simulation results and experimental observations underscores the reliability of the design. This work delivers a validated, field-ready spraying unit suitable for on-site applications, contributing to improved quality and productivity in small-scale construction practices.