AAC Block production line

AAC is Autoclaved Aerated Concrete. The AAC blocks are made to aerate by creating a reaction between silica in base material such as fly ash or sand, active lime, and aluminum power. The block hardness is being achieved by cement strength, and instant curing mechanism by autoclaving. Gypsum acts as a long term strength gainer.

The finished product is a 2.5 times lighter Block compared to conventional Bricks, while providing the similar strengths. The specific gravity stays around 0.6 to 0.65. This is one single most USP of the AAC blocks, because by using these blocks in structural buildings, the builder saves around 30 to 35 % of structural steel, and concrete, as these blocks reduce the dead load on the building significantly.

The major raw materials are Fly-Ash and sand , an indispensable by-product of Thermal Power Plants, is an environmental threat across the globe. Power plants are facing an ever increasing challenge disposal of this polluting agent. This unit is proposed to manufacture AAC Bricks & Blocks by consuming the Fly-Ash as one of the prime raw material. Secondly, it also helps environment by saving the invaluable top soil by not using them in brick making like conventional brick making. Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand. The steam curing requires far less fuel, compared to the backing for each cubic meter of Bricks. This is the reason these bricks are also referred as Eco Bricks or popularly Green Bricks, (though the color is gray).  AAC  block production line

AAC Blocks are largely used in various constructions, such as load bearing and pillar structure Buildings, Boundary walls, Roads, Culverts, Pavements, and wherever conventional bricks can be used. The general AAC blocks fall in the strength zone of 30- 60 Kg/Cm2, thus is having comparable strength as conventional Bricks, and hollow concrete blocks. These Blocks gain strength over a period of time up to 2 years, whereas the conventional bricks tend to lose strength over a period of time.

These green bricks can attain very regular and uniform shapes. As no burning is involved, so the shape also remains unchanged. As a result, the final Brick work with these green bricks consumes less mortar to build, less mortar to plaster. Further, the AAC being a concrete itself, it forms a more uniform bond with cement mortar, giving almost a homogeneous structure. Not only this, even exposed brickwork (without plastering) is a good durable structure. So people prefer to leave the Green Bricks Brickworks in garages, boundary walls etc. un-plastered.

AAC block, AAC block production line features:

1. Sound proof

AAC wall has an excellent sound Transmission class (STC), rating of 44. Result: Virtually Soundproof Interiors

2. Thermal Insulation

It has highest thermal rating in the industry….R30! Thus provides well insulated interiors, keeping out warm air in summer and cold air in winter. AAC reduces Air conditioning cost by 30%.

3. Earthquake Resistant

Earthquake forces on structure are proportional to the weight of the building, hence AAC shows excellent resistant to earthquake forces. Regions of high seismic activity like Japan exclusively use AAC. It has been proven to withstand wind loads of category 5 tropical storms.

4. Floor Space

Area Use of thinner blocks (6" instead of 9" exterior walls) because of its excellent water barrier & insulation properties leads to an increase in floor space area between 3-5%.

5. Cost saving

Being lightweight AAC drastically reduces the dead weight of building, resulting into reduction in steel (up to 27%) and cement (up to 20%) structural cost saving.Being 8 times the size of a clay brick, AAC wall construction involves 1/3 the joints, thus an overall mortar saving up to 66%. Its automatic manufacturing process gives AAC an exceptional dimensional accuracy & smooth surfaces, eliminating need of three-coat plaster walls and allows for a final 6 mm skim coat (putty/POP).

6. Fire Resistant

Best in class fire rating of 4 hours. The melting point of AAC is over 1600 ºc, more than twice the typical temperature in a building fire of 650 ºc.

7. Pest Resistant Termites hate AAC!

Being made of inorganic minerals, it does not promote growth of molds.

8. Water Barrier

Its structure does not allow for capillary action making it impervious to water. Its water barrier properties are further enhanced by adding silicone based additives. Strength to weight ratio, higher than even M150 concrete and far exceeds the Indian Building code requirements.

9. Energy Efficient

AAC is 100% Green Building Material & is a walling material of choice in LEED certified buildings (ITC centre, the highest rated Green Building has been built using AAC). AAC is most energy & resource efficient in the sense that it uses least amount of energy & material per m³ of product.Unlike brick manufacturing process which uses previous toplayer agricultural soil, AAC uses FlyAsh (65% of its weight), thus provides the most constructive solution to the nation’s flyash utilization problem.  AAC  block production line

BRIEF PRODUCTION PROCESS of AAC  block production line: 

COAL FLY ASH:

The coal fly ash will be sent to the slurry preparing pond by wheel loader to be prepared required concentration coal fly ash slurry by add rated water, which will be pumped into slurry tank to be stored and ready to be used.

QUICK LIME:

The powder will sent into the lime powder silo for storage and read to be used by bucket elevator, after coming into the factory.

GYPSUM:

The gypsum in the storage shed will be added into slurry pond according to the required proportion, while preparing slurry.

CEMENT:

The cement will be transported into factory by tank truck and directly is pumped into cement silo to be used

ALUMINUM POWDER PASTE:

The purchased aluminum powder past in the bucket or bag will be stored in its storehouse, When being used, it will be lifted to second floor of the batching building, then measured and added into aluminum mixer to prepare 5% suspending liquid to be used.

SCRAPE AND WASTE SLURRY:

The cleaning waste water under the casting machine will be pumped to ball mill to be used as grinding water. The scrape from the cutting machine will be prepared to slurry and pumped into waste slurry tank to be used.

BATCHING, MIXING, CASTING:

Coal fly ash will be sent to electronic scale in the batching building by pump at the bottom slurry tank to be measured. When the slurry concentration arrives at batching requirement, the control system will turn of the pump to stop pump slurry. The measured the slurry will be directly discharged into casting mixer.

Lime and cement will be sent to electronic scale in the batching building by single screw conveyer at the bottom of their silos. When measuring arrives at the required quantity, they will be sent to casting mixer by screw conveyer.

Aluminum powder will be measured by manual, and added into aluminum mixer to be prepared suspending liquid one by one for each mould. The finished suspending liquid can be directly added into the casting mixer.

The slurry temperature should be arrived at required process temperature before coasting. And mould will be moved to the bottom of the casting mixer by ferry car.

CUTTING AND GROUPING:

After pre-curing, the green block arrive at the required strength, the crane will take it to the cutting machine section. After remove the mould, the green block will be cut according to the required size.

The green block after cutting will be move to the curing trolley with the bottom plate by crane in front of autoclave for grouping. The seven trolley for each autoclave with 14 pieces of green block.

AUTOCLAVED AND FINISHED PRODUCT:

The green block after grouping, will be move into the autoclave by windlass for curing. The whole curing period is approx. 12h, pressure approx.1.2Mpa, temperature approx. 185

After curing, the product will be pulling out of autoclave, and be sent to the store yard.

THE BOTTOM PLATE RETURNING, COMBINING WITH MOULD AND OILING:

After unloading, the side plate on the trolley will be lifted to returning rail by crane, and be returned to the side of the cutting machine, which will be combined with the mould and sent to mould returning line for cleaning and oiling to be reused

AAC block machine, AAC block production line Capacity:

Structure of AAC block production line

AAC block production line: 

The equipment will be divided into two parts: specialized equipment and universal equipment. 

Specialized equipment of AAC block procuction line includes:  

1. Cutting equipment: tilting crane, cutting machine.   

2.Automatic Proportioning equipment: electronic measuring scale, slurry beating machine, slurry storage tank, slurry mixer. 

3. Pouring and autoclave related equipment:  aluminum powder mixer,  pouring & mixing machine,  moulds, side plates,  steaming cart,  carrier car. 

4.Conveying equipment: semi-product sling, end product sling. ferry car

Universal equipment of AAC block production line includes: 

1.Pressure vessel equipment: boiler, autoclave. 

2. Crushing & milling equipment:  jaw crusher, ball mill 

3. Transportation equipment: bucket elevator, feeder machine, belt conveyor, slurry pump, screw conveyor, semi-product crane, grouping crane, finished product crane, rail, dragger. 

4. Environmental protection equipment: dust remover for jaw crusher, ball mill, storage bin 

5. Lab equipment

Our company has realized the computer informationization of management, production, and the CAD and CAPP of production research and process design. We have 29800 square meters of total factory area. We have established strict quality control system to make sure each manufacture step is perfect.

We have passed some international certifications such as ISO, SGS, GMP,CE etc. You can rest assured aboutour machinery.

With advanced CAD&CAPP technology we have built long coorperate relationships with world customers such as America, Cannada, Poland, India, Russia, Australia, Brazil, South Africa, Mongolia, etc. Our products have been exported to 98 countries.

You are welcome to visit our company, AAC block machine & AAC block production line at any time!

Any questions or requirement please call  Justin:0086-15378701348

WhatsApp : +86 15378701348

Skype: liuhuan0710