Last week, a contractor called us frustrated because he’d just bought a mortar sprayer that couldn’t handle his stucco mix. The pump kept clogging, the gun didn’t have enough power for his fiber-reinforced material, and he was already two days behind schedule. He’d spent good money on equipment that couldn’t do his actual work.
This happens more often than you’d think. Contractors see “mortar sprayer” in a product description and assume all systems work the same way. They don’t. The equipment that works great for smooth plaster finishes will choke on heavy shotcrete with aggregates. A pump sized for small repair jobs won’t keep up with commercial stucco crews.
After building mortar spraying equipment for over 50 years, we’ve learned that matching equipment to your specific work makes the difference between a tool that pays for itself in months and an expensive mistake gathering dust in your shop.
Start with Your Material, Not the Equipment
Here’s where most people get it backwards – they pick equipment first, then try to make their materials work with it. Do it the other way around.
What Are You Actually Spraying?
Pull out your material spec sheets. What’s the aggregate size? Does it contain fiber reinforcement? What’s the consistency – pourable, trowelable, or something in between?
Smooth Materials (No Aggregates or Fine Aggregates):
- Finish plasters
- Waterproofing membranes
- Fine cement coatings
- Most fireproofing materials
These work with smaller pump sizes (1″ to 1.25″) and single jet spray guns. The material flows easily, so you don’t need massive pumping capacity or aggressive atomization.
Standard Stucco and Mortar Mixes:
- Traditional three-coat stucco
- Standard repair mortars
- EIFS base coats
- Most veneer plasters
You’re looking at 1.25″ to 1.5″ pumps paired with multi-jet guns. The aggregates and thicker consistency need more pumping power and better atomization than fine materials.
Heavy-Duty Applications:
- Shotcrete with 3/8″ or larger aggregate
- Fiber-reinforced structural repairs
- High-build stucco systems
- Thick fireproofing applications
This calls for 1.5″ to 2″ pumps with 8-jet guns. You need serious pumping capacity and aggressive atomization to move this stuff effectively.
The Fiber Factor
Fiber reinforcement changes everything. Glass fiber, polypropylene fiber, steel fiber – they all want to clump and clog in pumps and guns designed for plain mortar. If your mix contains fiber, make sure you’re looking at equipment specifically designed to handle it.
We’ve tested thousands of fiber-reinforced mixes over the years, and the difference between equipment that works and equipment that fails usually comes down to hose diameter and gun design. Undersized equipment with fiber-reinforced materials is asking for trouble.
Consider Your Actual Job Volume
Occasional Use vs. Daily Production
Be honest about how often you’ll use this equipment. There’s a big difference between a contractor who sprays mortar once or twice a month and a crew that’s spraying stucco five days a week.
Light Use (A Few Jobs Per Month): You can probably get by with a standard electric pump and basic gun setup. The equipment won’t see enough hours to wear out quickly, and portability matters more than maximum capacity.
Regular Use (Multiple Days Per Week): Now you need equipment built for continuous operation. Look at heavy-duty pumps with pneumatic or hydraulic power options. The upfront cost is higher, but you’ll make it back through reliability and reduced downtime.
Daily Production (Full-Time Spraying): This is where industrial-grade equipment becomes necessary. You need pumps that can run all day without overheating, spare parts on hand, and probably backup equipment so breakdowns don’t shut down your whole crew.
Batch Size Matters Too
How much material are you mixing at once? If you’re doing small repair work with 5-gallon batches, you don’t need a pump that handles 30 gallons. Conversely, if you’re spraying entire buildings, a small pump will slow you down.
Match your pump capacity to your mixing capacity. There’s no point in having a high-volume pump if you’re constantly waiting for the next batch to mix.
Power Source Considerations (This Actually Matters)
Electric Pumps (110V)
Pros:
- Most convenient – power is usually available
- Lower initial cost than pneumatic or hydraulic
- Quieter operation than air-powered units
- Good for indoor work and residential jobs
Cons:
- Limited to lighter-duty applications
- Can trip breakers on job sites with marginal power
- Extension cord length becomes an issue
- Not ideal for continuous heavy use
Best For: Residential work, repair jobs, indoor applications, contractors just getting into spraying
Electric Pumps (220V)
Pros:
- More power for continuous operation
- Better for commercial applications
- Still relatively convenient when 220V is available
- Can handle heavier materials than 110V
Cons:
- Requires 220V service (not always available)
- More expensive than 110V units
- Still limited compared to pneumatic/hydraulic
Best For: Commercial stucco contractors, daily production work, anyone doing serious volume
Pneumatic (Air-Powered)
Pros:
- Excellent power-to-weight ratio
- Can run continuously without overheating
- No electrical concerns in wet conditions
- Variable speed control through air pressure
Cons:
- Requires adequate air compressor (80+ CFM typical)
- Noisy operation
- Air hose management on job sites
- Initial cost of compressor if you don’t already have one
Best For: High-volume commercial work, exterior applications, contractors with existing air systems
Hydraulic
Pros:
- Maximum power for heavy materials
- Excellent for continuous operation
- Very reliable in demanding applications
- Smooth, consistent pumping action
Cons:
- Requires hydraulic power source
- Higher complexity and cost
- Less common (harder to find rental units)
Best For: Large commercial projects, specialized applications, contractors with hydraulic equipment already
Pump Design: Why Peristaltic Matters
You’ll see three main pump types for mortar: progressive cavity, piston, and peristaltic. We build peristaltic pumps, so yeah, we’re biased. But there are good reasons why.
Progressive Cavity Pumps: These use a metal rotor spinning inside a rubber stator. They work okay for smooth materials, but abrasive mortars wear out the stator fast. When it wears, you lose pressure and efficiency. Plus, they can’t run dry without damage.
Piston Pumps: Powerful but pulsating flow creates inconsistent spray patterns. The stop-start action is tough on hoses and fittings. Good for some applications, but not ideal for most mortar work.
Peristaltic Pumps: Rollers squeeze a rubber tube to push material through. Only the tube touches your material – everything else stays clean. The tube is cheap to replace when it eventually wears. Can run dry indefinitely. Smooth, consistent flow.
The trade-off? Peristaltic pumps are generally more expensive upfront. But factor in maintenance costs and longevity, and they usually come out ahead for contractors doing regular mortar work.
Spray Gun Selection (It’s Not One-Size-Fits-All)
Single Jet Guns
Think of these like a precision tool. One air stream atomizes the material into a fine,controlled pattern. Great for finish work, detail areas, and materials that don’t need aggressive application.
When to use: Waterproofing, fine plasters, decorative finishes, fireproofing, any application where overspray control matters
Multi-Jet Guns
Multiple air streams create better atomization and material projection. More aggressive than single jet, less aggressive than full shotcrete guns. This is the middle ground that works for most standard mortar applications.
When to use: Standard stucco, repair mortars, EIFS, most commercial coating work
8-Jet Shotcrete Guns
Maximum atomization and velocity for materials that need to be driven into the substrate. These move material fast and build thickness quickly.
When to use: Shotcrete, heavy stucco base coats, structural repairs, any application requiring high velocity and quick builds
Nozzle Options Matter
Rubber Cap with Metal Orifice: Good for fireproofing and materials prone to clogging
Metal Cap with Rubber Orifice: Works well for waterproofing and finer finishes
Stainless Steel: Maximum durability for abrasive materials like mortar and concrete
Rubber Orifice Only: Softer spray pattern for delicate materials
Real-World Selection Examples
Scenario 1: Residential Stucco Contractor
Typical Work: Three-coat stucco on homes, occasional repairs, mostly weekday work
Recommended Setup:
- 1.25″ or 1.5″ Carrousel pump with 220V electric power
- Multi-jet spray gun with rubber orifice
- Standard material hoses and couplings
Why: Enough capacity for daily production without overkill. 220V gives you power for continuous operation but still works at most job sites. Multi-jet handles standard stucco mixes well.
Scenario 2: Commercial Fireproofing Specialist
Typical Work: Large commercial buildings, continuous production, various fireproofing materials
Recommended Setup:
- Fireproofing pump package with integrated compressor
- Single jet gun with rubber cap/metal orifice configuration
- Clear reinforced hoses for visibility
Why: The integrated compressor means you’re not dependent on site air. Single jet gives you the atomization needed for fireproofing materials. Package deal simplifies equipment management.
Scenario 3: Pool Builder Doing Shotcrete
Typical Work: Pool shells, water features, some hardscape
Recommended Setup:
- 1.5″ or 2″ heavy-duty Carrousel pump, pneumatic power
- 8-jet shotcrete gun
- Heavy-duty hoses rated for shotcrete pressures
Why: Pneumatic power for continuous operation and power. 8-jet gun provides the velocity needed for proper shotcrete placement. Heavy-duty hoses handle the pressure and abrasion.
Scenario 4: Repair and Restoration Contractor
Typical Work: Varied projects, different materials, small to medium volumes
Recommended Setup:
- 1.25″ standard Carrousel pump with 110V electric
- Both single jet and multi-jet guns
- Various nozzle options
Why: Versatility matters more than maximum capacity. 110V works at most sites. Multiple gun options let you adapt to different materials and applications.
Questions to Ask Before You Buy
- “Can I test my actual materials with this equipment?”
If a manufacturer won’t test your materials, that’s a red flag. We do free material testing specifically because we know every mix behaves differently. You should see video of your actual mortar going through the proposed equipment.
- “What’s the actual maintenance schedule?”
“Low maintenance” means different things to different manufacturers. Get specifics: How often do wear parts need replacement? What does it cost? How long does it take?
- “Can you run this dry, or will that damage it?”
Pumps that can’t run dry create problems on job sites where material flow isn’t perfectly consistent. This matters more than most contractors realize until they’ve damaged a pump.
- “What’s the parts availability situation?”
Ask what happens if you need parts in five years. Ten years. We stock parts for pumps we built in the 1970s because we know contractors need long-term support.
- “What air requirements does the spray gun need?”
CFM requirements vary significantly between guns. Make sure your compressor (or the site compressor you’re counting on) can actually supply enough air.
Common Mistakes to Avoid
Undersizing for “Savings” A pump that’s too small for your materials won’t save money – it’ll frustrate you and slow down your crew. Size equipment for your actual work, not your budget.
Ignoring Cleanup Requirements Equipment that takes an hour to clean after each use costs you money every single day. Factor cleanup time into your decision.
Forgetting About Material Testing “The salesman said it would work” isn’t a plan. Test your materials or you’re gambling with thousands of dollars.
Buying Based on Initial Cost Alone A cheaper pump that needs parts every six months isn’t actually cheaper. Look at total cost of ownership, not just purchase price.
Not Considering Portability Moving equipment around job sites matters. A pump that’s too heavy or awkward to move ends up limiting where you can work.
Getting It Right
Choosing mortar spraying equipment isn’t complicated, but it does require honest assessment of your actual work. What are you spraying? How often? What volumes? What power sources are available?
Answer those questions first, then look at equipment that matches your real-world requirements. And for anything you’re uncertain about, test the materials. A few days of testing beats months of frustration with equipment that doesn’t work for your applications.
We’ve been helping contractors figure this out since 1968. If you’re not sure which direction to go, give us a call at (419) 732-2611. We’ll ask about your typical work and recommend equipment that makes sense for what you actually do – not what looks good in a catalog.
Because at the end of the day, the right equipment is the stuff that helps you finish jobs faster, with better quality, and without beating up your crew. Everything else is just features and specifications.