AAC Blocks Manufacturing Plant
Autoclaved Aerated Concrete (AAC) is an intricate composite material comprising siliceous substances such as sand, fly ash, and silicon tailings (which can consist of waste porcelain clay, stone processing waste materials, blast furnace slag, and other similar substances) along with calcareous materials like lime and cement as its main raw materials. The preparation of AAC involves the incorporation of a gas agent with a high-fat content, such as aluminum powder, and subsequently mixing, casting, pre-raising, cutting, autoclaving, and curing to manufacture a lightweight, porous silicate product.
AAC block, also known as AAC brick, is a brick made of ACC technology. The ACC blocks need to be produced in the ACC blocks manufacturing plant.
Manufacturing of AAC Blocks
- Preparing material
In the initial phase of the AAC block manufacturing process, a sand ball mill or fly ash ball mill is employed to grind sand, fly ash, silicon tailings, and other raw materials to the desired size. These raw materials are then matched, combined, and loaded into a mixer, where they are meticulously blended with water to create a uniform mixture.
- Moulding
The following step in the AAC blocks manufacturing process entails pouring the meticulously blended mixture into a mould and subjecting it to a pre-curing treatment at a specific temperature until it attains a predetermined level of hardness.
- Forming blank
Following the pre-curing stage of AAC block manufacturing process, the solidified mixture is rotated along with the mould. Next, the mould is unloaded while the mould bottom remains intact. The solidified mixture is then expertly sliced into blank blocks of the required size and shape.
- Hardening blank to end product
In the ensuing phase of AAC production process, the blank blocks and bottom are deftly hung onto a hardening car with the assistance of a semi-production hanger. Subsequently, the hardening car, bearing the blank blocks, is pulled into an autoclave, where they are exposed to high temperature and pressure, thus effectively solidifying them into durable bricks.
- Packing
Once the Autoclaved Aerated Concrete (AAC) bricks have been subjected to the rigorous autoclaving process, they are hung to allow for stacking and packing. The mould bottom is then returned to its rightful place, ready for reuse in the next production cycle. This meticulous process guarantees the consistent and efficient production of top-quality AAC bricks.
Main AAC Blocks Manufacturing Machinery
The AAC blocks manufacturing plant is composed of a series of AAC blocks manufacturing machinery. Each production section has its own key equipment. See the following table for the major equipment in AAC blocks manufacturing plant.
| Raw Material Preparation Section: | Ball Mill, Jaw Crusher, Bucket Elevator, Powder Storage Silo |
| Baching and Pouring Section: | Slurry Storage Tank, Aluminum Powder Mixer, Pouring mixer |
| Pre-curing Section: | Mould, Side Plate, Traction Mechanism |
| Cutting Seation: | Cutting machine, Tongue, and Groove Milling Device, Tilting table |
| Autoclaving Section: | Ferry Push Car before/after autoclave, Autoclave, Hardening Car |
| Packaging Section: | Separator, Clamping machine, Packing line |
Ball mill
In the AAC blocks manufacturing process, the ball mill is used to make the fly ash, silica sand, slag, lime, and other raw materials into the required size in production, which is divided into wet grinding and dry grinding.
Slurry Storage Tank
Slurry storage tank is a vital component of our autoclaved aerated concrete equipment, consisting of a silo, gear reducer, mixing spindle, movable frame, and central fulcrum. It’s used to store fly ash or sand slurry.
Side Plate
Side plate is an essential component in AAC production line that works together with mould. After demoulding, it carries green cake to cutting, grouping, autoclaving, packing. It is made of welded U-channel steel, H-channel steel, and steel plate.
Cutting machine
The concrete cutting machine is designed to accurately cut all six sides of concrete blocks into various required sizes. It is primarily composed of transfer cars, vertical cutters, cross-cutters, and car exchange devices.
Autoclave
The autoclave is a sizeable steam-based device suitable for steaming a range of materials, including sand AAC blocks, fly ash AAC blocks, and AAC bricks or panels. Autoclave uses high pressure and temperature to cure materials.
Separator
The concrete panels stacked together after autoclaving require separation along the cuts to prevent sticking. This separation ensures that each AAC panel remains independent from the adjacent ones.
AGICO AAC Blocks Manufacturing Plant Capacity Type
| ITEM | AAC-5 | AAC-10 | AAC-15 | AAC-20 | AAC-30 |
|---|---|---|---|---|---|
| Capacity(m3/year) | 50,000 | 100,000 | 150,000 | 200,000 | 300,000 |
| Cake Size(m3) | 4.2*1.2*0.6 | 4.2*1.2*0.6 | 4.2*1.2*0.6 | 4.8*1.2*0.6 | 6.0*1.2*0.6 |
| Installation Power(kw) | 600 | 800 | 900 | 1300 | 1400 |
| ProductionCycle(mould/min) | 5 | 6 | 6 | 6 | 6 |
| Workshop Area(m2) | 3,000 | 3,000 | 3,500 | 4,000 | 5,000 |
| Plant Area(m2) | 20,000 | 20,000 | 25,000 | 30,000 | 35,000 |
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Why Choose Us
In collaboration with China National Building Material Group Co., Ltd. (CNBM), AGICO has established a team of experts specializing in the research of aerated concrete technology, process design, development of AAC blocks manufacturing plants, and research and manufacturing of a series of AAC blocks manufacturing machinery. The unique aerated concrete production process system developed and applied in the AAC block production line is one of the representative technologies of the world’s aerated concrete production process. The AAC block equipment produced by this process not only has the characteristics of low failure rate, low maintenance costs, and easy operation but also has the advantage of low operating costs and good economic benefits.
AAC Block Factory Success Cases
- 300.000 m3/year AAC blocks manufacturing plant in Indonesia
| Annual output(m3/year) | Construction site | Equipment and Supply Information |
|---|---|---|
| 300.000 | Indonesia | AAC blocks manufacturing plant EPC whole process equipment |
- 300.000 m3/year AAC block factory in Malaysia
| Annual output(m3/year) | Construction site | Equipment and Supply Information |
|---|---|---|
| 300.000 | Malaysia | AAC block factory EPC whole process equipment |