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What is AAC Blocks ?

  • Autoclaved Aerated Concrete is a Lightweight, Load-bearing, High-insulating, Durable building product, which is produced in a wide range of sizes and strengths. AAC Blocks is lightweight and compare to the red bricks AAC blocks are three times lighter. The Autoclaved Aerated Concrete (AAC) material was developed in 1924 in Sweden. It has become one of the most used building materials in Europe and is rapidly growing in many other countries around the world.
  • AAC is produced from the common materials lime, sand, cement and water, and a small amount of rising agent in Brickvision machinery. After mixing and molding, it is then autoclaved under heat and pressure to create its unique properties. AAC has excellent thermal insulation and acoustic absorption properties. AAC is fire and pest resistant, and is economically and environmentally superior to the more traditional structural building materials such as concrete, wood, brick and stone.
  • At the point when AAC is blended and cast in structures, a few compound responses occur that give AAC its light weight (20% of the heaviness of cement) and warm properties. Aluminum powder responds with calcium hydroxide and water to frame hydrogen. The hydrogen gas froths and copies the volume of the crude blend making gas rises to 3mm (? inch) in distance across. Toward the end of the frothing procedure, the hydrogen escapes into the air and is supplanted via air.
  • AAC Blocks is a unique and excellent type of building material due to its super heat, fire and sound resistance, AAC blocks are lightweight and offers ultimate workability, flexibility and durability. Its main ingredients include sand, water, quicklime, cement and gypsum. The chemical reaction due to the aluminum paste provides AAC its distinct porous structure, lightness, and insulation properties, completely different compared to other lightweight concrete materials.
  • When the forms are removed from the material, it is solid but still soft. It is then cut into either blocks or panels, and placed in an autoclave chamber for 12 hours. During this steam pressure hardening process, when the temperature reaches 190 degree Celsius (374 degree Fahrenheit) and the pressure reaches 8 to 12 bars, quartz sand reacts with calcium hydroxide to form calcium silicate hydrate, which gives AAC its high strength and other unique properties. Because of the relatively low temperature used AAC blocks are not considered fired brick but a lightweight concrete masonry unit. After the autoclaving process, the material is ready for immediate use on the construction site. Depending on its density, up to 80% of the volume of an AAC block is air. AACs low density also accounts for its low structural compression strength. It can carry loads of up to 8 MPa (1,160 PSI), approximately 50% of the compressive strength of regular concrete.
  • AAC offers incredible opportunities to increase building quality and at the same time reduce costs at the construction site. AAC is produced out of a mix of quartz sand and/or pulverized fly ash (PFA), lime, cement, gypsum, water and aluminum and is hardened by steam-curing in autoclaves. As a result of its excellent properties, AAC is used in many building constructions, for example in residential homes, commercial and industrial buildings, schools, hospitals, hotels and many other applications. AAC contains 60% to 85% air by volume.

How To make AAC Blocks ?

  • 1. RAW MATERIAL STORAGE SECTION : In This Stage All Raw material is Stored in Silos or in Big Hopper with the Help of Silo Feeding Systems And Pree Feeding Loader, Screw Conveyor which is help to save batching time as well as labour.
  • 2. RAW MATERIAL PREPARATION AND TRANSPORT SECTION : A ball mill wet-grinds the quartz sand with water to a sand slurry. The sand slurry is stored in slurry tanks and pumped into the slurry weighing hopper in the mixer tower. The binders are stored in silos. It is also possible to mill the anhydrite together with the sand in the ball mill. The aluminum powder or paste is prepared in a separate building where it is dispersed in water.
  • 3. CASTING, RISING/PRE-CURING AND MOULD CIRCULATION : The mould consists of four fixed sides and one detachable platform. The inner mould surfaces are covered with demoulding release oil before casting. This oil is applied either manually. The mix is then poured into the mould. A transfer platform transports the filled casting mould to the closed and heated pre-hardening area, also called the Pre-curing room. Due to the alkaline reaction of the aluminium in the slurry, many small bubbles develop in the compound. At the same time, the cake begins to harden. After a waiting time of approx. 2 - 3 hours, the preset "green strength" (cutting strength) is reached. The waiting time depends on the temperature in the Pre-curing room, but also on the quality of the raw materials used and the chosen recipe.
  • 4. TILTING : The tilting crane tilts the mould by 90 Degree. The Tilting crane unlocks the mould and removes the mould body, so that the cake remains on Side plate for cutting. This tilting system has proven to be the safest method for tilting the cake into the vertical cutting position, as the cake is remaining on Side plate for the cutting process
  • 5. CUTING : The cake in cut by high precision cutting machines. Cutting is done by pneumatically tensioned cutting wires. As the aerated concrete block stands upright, it is possible to use short cutting wires. The horizontal cutter and vertical cutter cut the block length and width. All waste material generated in the cutting process is collected in a basin underneath the cutting line, recycled, and returned to the production process.
  • 6. AUTOCLAVING : After cutting, the green cakes are grouped on steam car by crane. The aerated concrete is hardened under steam pressure in special, sealed pressure vessels, the autoclaves, thereby achieving its final strength. The steam pressure is approx. 12 bar, the temperature approx. 192 Degree C. Usually, the hardening time is between 10 and 12 hours. The used steam for the hardening process in the autoclaves is generated in a steam boiler plant. Usually, high-capacity steam boilers that are operated by coal or wood are used to generate the steam.
  • How many AAC blocks in 1 cubic meter?

    BLOCK SIZES OF STANDERD AAC BLOCK PLANT MODEL NO 1
    Sr NO Length Width Height AAC Block in One CBM
    1 600 200 100 83.33
    2 600 200 125 66.67
    3 600 200 150 55.56/td>
    4 600 200 200 41.67
    5 600 200 300 27.78
    BLOCK SIZES OF STANDERD AAC BLOCK PLANT MODEL NO 2
    Sr NO Length Width Height AAC Block in One CBM
    1 625 200 100 80.00
    2 625 200 125 64.00
    3 625 200 150 53.33
    4 625 200 200 40.00
    5 625/td> 200 300 26.67
    BLOCK SIZES OF STANDERD AAC BLOCK PLANT MODEL NO 3
    Sr NO Length Width Height AAC Block in One CBM
    1 650 200 100 76.92
    2 650 200 125 61.54
    3 650/td> 200 150 51.28
    4 650 200 200 38.46
    5 650/td> 200 300 25.64
    BLOCK SIZES OF STANDERD AAC BLOCK PLANT MODEL NO 4
    Sr NO Length Width Height AAC Block in One CBM
    1 600 240 100 69.44
    2 600 240 125 55.56
    3 600/td> 240 150 46.30
    4 600 240 200 34.72
    BLOCK SIZES OF STANDERD AAC BLOCK PLANT MODEL NO 5
    Sr NO Length Width Height AAC Block in One CBM
    1 625 240 100 66.67
    2 625 240 125 53.33
    3 625/td> 240 150 44.44
    4 625 240 200 33.33
    BLOCK SIZES OF STANDERD AAC BLOCK PLANT MODEL NO 6
    Sr NO Length Width Height AAC Block in One CBM
    1 650 240 100 64.10
    2 650 240 125 51.28
    3 650/td> 240 150 42.74
    4 650 240 200 32.05

    Comparison of AAC Block, Clay Brick, CLC Brick


    Comparison of Various Bricks And Blocks (AAC Blocks Vs. CLC Blocks Vs. Red Clay Bricks)   

    S.No

    Parameter

    AAC Blocks

    Red Clay Bricks

    CLC Blocks

    1

    Raw Materials

    Cement, fly ash, water and Air entraining agents

    Locally avaiable clay

    Cement, lime, specially grinded sand, foam

    2

    Size

    400-600mm X 200mm X 150mm – 300mm

    225mm X 75mm X 100/150mm

    400-600 x 200 x 100/150/200 mm

    3

    Variation Size

    1.5 mm (+/-)

    5 mm (+/-)

    5 mm (+/-)

    4

    Compressive Strength (As per IS codes)

    3-4 N/mm2

    3.5 N/mm2

    2 -2.5 kg/cm2

    5

    Dry Density (As per IS codes)

    550-650 kg/m3 Its one-third of the weight of clay brick which makes it easy to lift and transport

    1800 kg/m3

    800 kg/m3

    6

    Cost Benefit

    For high rise buildings there will be reduction of Dead weight which leads to saving in Concrete and steel quantities.

    As easily available in local market hence it is beneficiary for low rise structure.

    For high rise buildings there will be reduction of Dead weight which leads to saving in Concrete and steel quantities.

    7

    Fire Resistance (8″ Wall)

    Upto 4 Hours

    Around 2 Hours

    Around 4 Hours

    8

    Quality of End Product

    Factory made product. So the quality of end product is consistent and good

    Locally made product. Quality depends on various parameters like quality of raw materials used, process of manufacture etc.,

    The quality of the end product depends on the foam used and degree of quality control

    9

    Sound Insulation

    Better Sound absoprtion/insulation as compared to bricks

    Normal

    Better Sound absoprtion/insulation as compared to bricks

    10

    Energy Saving

    Low thermal conductivity (0.24 Kw-M/C) helps in saving electricity costs 30% for heating and cooling of house

    High thermal Conductivity (0.81 Kw-M/C). So no significant cost savings

    Low thermal conductivity (0.32 Kw-M/C) helps in saving electricity costs 30% for heating and cooling of house

    11

    Environmental Friendliness

    In AAC Block there is no topsoil consumption and it emits very low Carbon dioxide as compare to Red clay bricks while manufacturing

    One sq ft of carpet area with clay brick walling will consume 25.5 kg of topsoil (approx). It actually damages environment

    In CLC Block there is no topsoil consumption and it emits very low Carbon dioxide as compare to Red clay bricks while manufacturing.

    12

    Internal and External Plaster

    As these bricks have dimensional accuracy, the internal and extenal plaster thickness can be reduced

    Requires thick plaster surface as there are variations in the dimensions

    As these bricks have dimensional accuracy, the internal and external plaster thickness can be reduced

    13

    Finishing 

    excellent

    Very bad

    Not linear 

    14

    Joining Process

    Chemical mortars can be used for joining the brick. This reduces the material consumption for cement and also avoids curing process

    Traditional mortar needs to be used and the brick work should be cured for at least 7 days before plastering

    Chemical mortars can be used for joining the brick. This reduces the material consumption of cement and also avoids curing process.

    15

    Availability

    Factory setup cost is high.Not many factories, so availability is a concern.

    Available locally in all cities and villages.

    Factory setup cost is low as compared to AAC. Also takes a long time to produce if steam curing is not used.Timely availability is a concern.

    16

    Thermal Insulator

    AAC Blocks are very good thermal insulators if cooling is a major component of any building monthly expenses it will save cost for entire lifetime

    It has low thermal insulation as compared to AAC and CLC Block

    CLC Blocks are very good thermal insulators if cooling is a major component of any building monthly expenses it will save cost for entire lifetime

    17

    Tax Contribution

    GST REFUNDABLE

    No Tax Contribution

    GST REFUNDABLE 

    18

    Cylindrical Structures

    For Cylindrical structure these blocks are not much useful

    Cylindrical manholes or sewage chambers need small size of bricks so that the curvature can be formed hence Red clay bricks are useful

    For Cylindrical structure these blocks are not much useful

    19

    Water Absorption

    Absorb 12- 15% by total volume of AAC blocks

    Absorb 17 -20% by total volume of red clay brick

    Absorb 12-15% of water by total volume of Block

    20

    Range of Application

    They are suitable for Non load bearing or RCC structure in partition wall

    They are useful in both load bearing and non load bearing structure

    They are suitable for Non load bearing or RCC structure in partition wall

    Which Raw Material Used IN AAC Production?

    Fly-Ash: A lot has been said about this raw material in this Project Profile itself. But this Raw material is freely available in Thermal Power plants. There are no taxes on this item whatsoever. Transportation charges are only to be attended.

    Lime: Active powered lime is a requirement for giving the real aeration to the product. In phase 1 we can aim to buy the active lime

    OPC: This Project aims to utilize OPC cement as main binder material. It will give faster strength to the bricks, besides giving improved consistent quality. It also ensures a better cost effectiveness for the same. Using OPC will be a standardized practice.

    Gypsum: Gypsum is easily available industrial product. This is available as an industrial byproduct of Fertilizer Plant. Gypsum is responsible to give long term strength to the Blocks.

    Aluminum Powder: Finely ground Aluminum powder is used in very limited quantity (less than 0.5%), so that it reacts with active lime, and silica in base material to make the aeration, and swell the product, making it very light weight product.

    Water: Water is an important factor for AAC block, it is used in the entire process starting from Slurry preparation till the final curing block (Manual Water Curing or Automatic Steam curing)

    Which Machinery Used in AAC Plant?

    1.  1. Raw material Preparation Section for AAC Plant 

      1. - Material Storage Silo 

      2. - Pree Mixer 

      3. - Material Transport Systems 


    1.  2. Batching Section for AAC Plant

      1. - Dry and Slurry Batching Hopper

      2. - Poring Mixer 

      3. - Control Panel 


    1.  3. Casting Section for AAC Plant 

      1. - Shifter Trolley 

      2. - Mold Base and Cover

      3. - Track 

      4. - Pree-Curing Section 


    1.  4. Demoulding and Cutting Section for AAC Plant

      1. - Demoulding Machine

      2. - Cutting Machine

      3. - Wastage Recycling Section 


    1.  5. Boiler Section for AAC Plant 

      1. - Water Softener 

      2. - Soft Water Storage Tank 

      3. - APH/WPH Systems

      4. - High Pressure Boiler

      5. - PRS Systems 


    1.  6. Autoclaving Section for AAC Plant

      1. - Autoclave Loader 

      2. - Pressure Monitoring Systems 

      3. - High Pressure Autoclave

      4. - Water Condensation and Steam Utilization


    1.  7. Stocking and Segregation Section for AAC Plant

      1. - Forklift 

      2. - Block Loading Palate

      3. - Wastage Block Cutter

      4. - Transport Vehicle

    How to select AAC Block Plant?

    Before buying AAC Block plant machinery, you have to find an answer to the following questions. Which capacity plant is more suitable for your area? How to decide the plant capacity? How much area is required for AAC plant? Which is the best model to make standard AAC Blocks? if you have any answers to this question you are ready to buy one.

    If you want any guidance before you actually buy brick making plant our experts can guide you. you have to fix your budget first because the budget will have three main sections, the first is for machine cost, second is for the installation and setup cost and third one production cost.

    How much capacity of AAC plant is suitable for AAC Block production? this is the general question in our customer mind, It can start with 10 cubic meter and same AAC Block plant will be Expandable up to 100 cubic meters. If a customer is operating AAC Brick plant by putting labor then above 30 cubic meter AAC plant is best for labor basis plant and same AAC Block plant will be Expandable up to 200 cubic meters. if customer running plant by labor contractor then about 30 cubic meters and more capacity AAC plant is suitable for production so you have to decide first how you Operate your plant. If any capacity plant is driven by self + labor then it is the more profitable for the customer

    Brickvision Equipment Pvt ltd is recommended you to start plant with 50 Cubic meter and above our suggestion is if you are new in this field then and don not start plant about 200 cubic meters, normally 50 to 200 cubic meter plant is more successful in India. 30 or 50 cubic meters, both plants are expandable plant if you start with the 30 cubic meter AAC plant then in future,you can expand the same plant up to the 200 cubic meter

    How to make shed work? How to do RCC work in AAC plant? How much shade area required? How much height required for AAC Block Making Plant? the answer is for only batching system and boiler section required 25 feet height rest of the plant required 20 feet height for Mark and Power Technology, do not need crane and you have to make the normal shade height but for the Mega Series AAC Plant you have to total Shade height is 30 feet or depend upon manufacturer for all plant PCC and design is as per your land layout and machinery quotation How to help Brickvision to make site PCC and shed.

    After receiving an order from Customer to Brickvision. The process starts with the visit of technical person to customers site, after visit and data obtained from the customer our engineer will make the general sketch of AAC plant after that this sketch and data given by the customer is handover to our design team.

    Brickvision design team who make General layout for AAC plant and this layout is submitted to the customer, after customer reviewed on the drawing will make final drawing. With the help of this drawing customer makes his site ready, in between machinery set to be ready then Brickvision installation person calls to the customer and ask for the dispatch date.

    After machinery reached a site we will plan for installation.
    our engineer will guide you and he will help you with the installation of the plant.

    We plan a training program of AAC block plant production and Brickvision engineer train labor team and also he will give all the necessary maintenance and operation training to owner and labor

    Important points to be considered while manufacturing AAC Blocks.
    You have to focus on the four points of AAC Block first point is the Production cost, the second point is density (Weight of Block), the third point is strength and the fourth point is finishing of the product. This four-points are very important while making the production.

    and many of the AAC block manufacturers face the problem in production due to lack of know age or wrong machinery purchased so we recommend that Brickvision Equipments Pvt Ltd is the best option to purchase machinery of AAC block plant.

    How to convert our CLC plant to AAC plant
    In the last few years in the market there is too many CLC plant installed due to its low cost but when a customer finds that CLC can not fulfill the Indian market requirement
    most of the CLC plant is shut down but don not worry Brickvision can help you in Converting Your CLC block plant in AAC Block Plant
    For More Detail, You Can Directly Contact Our Customer Support on sales.brickvision@gmail.com.

    How to make AAC Block?

    Raw material Preparation Section for AAC Plant
    Brickvision Equipment AAC Plant Working procedure -
    AAC blocks manufacturing process starts with raw material preparation.
    List of raw materials and relevant details are mentioned Cement- 53-grade Ordinary Portland Cement (OPC) is required for manufacturing AAC blocks. Cement supplied by plants is not recommended due to variations in quality over different batches of cement.

    Fly ash or sand – Fly ash is mixed with water to form fly ash slurry. The slurry thus formed is mixed with other ingredients like lime powder, cement, gypsum and aluminium powder in proportionate quatity to form blocks.
    Limestone powder- Lime powder required for AAC production is acquired by crushing limestone to fine powder at AAC factory or by directly purchasing it in powder form from various plants.

    Gypsum- Gypsum is readily available in the market.
    You have to store raw material in storage systems, the main raw material is fly ash which is easily available in power plant, which is of two types first is Pound Ash and second is Bulker Ash.
    This Fly ash is transported by Screw Conveyor to Pree Mixer. In Pree mixer we mix water and fly ash with its desire proportion after Mixing it is ransfered to Batching Section.

    Batching Section for AAC Plant
    Batching Section is core machine which controls wastage because mixing is the main Part of processes.
    First fly ash Slurry will be sent to electronic scale in the batching building by the pump, When the slurry concentration arrives at batching requirement, the control system will turn off the pump to stop pump slurry. The measured the slurry will be directly discharged into casting mixer. As Same Lime and cement will be sent to Dry Material Weighing electronic scale in the batching building by single screw conveyor at the bottom of their silos. When measuring arrives at the required quantity, they will be sent to casting mixer by Butterfly Valve.
    All material comes in casting Mixer as per rotation and mold will be moved to the bottom of the casting mixer by ferry car. After mixing finally we can drop Aluminum Because Aluminum is the main rising agent in AAC.

    Casting Section for AAC Plant
    Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as acasting, which is ejected or broken out of the mold to complete the process.


    Demoulding and Cutting Section for AAC Plant
    Demoulding Machine is used to remove mold cover from a cake, Brickvision has launched Automatic Heavy-duty Demoulding Machine for AAC Block production, in mega-series Brickvision has launched Demoulding through tilting crane. After Demoulding cakes ready for the Cutting. Some waste remained is collected through wastage recycling section and store in a separate mixer and this waste slurry used as another aggregate slurry and it transfers to batching section.
    In cutting section Plant have many series like mark cut, Power Cut, and Mega cut and many more depend upon System Design and customer requirement. In this Stage cake cuts in Small Block, Stamping of a brand is placed after cutting. After Cutting Cake sent to Autoclaving Section till first autoclave cycle is done.

    High Pressure Boiler Section for AAC Plant
    Required high-pressure boiler for AAC. Helps to achieve good strength to aac block. We have to use specially designed boiler because at the time of autoclaving boiler play the main role because autoclave is only steam chamber and it fills through the boiler. At the time of boiler selection, first, a certified boiler is a must. Then many other specifications are required which help to smooth operation. Steam generation is doing by wood, cole, and much other raw material. This steam transfer using steam pipeline which is also IBR approved to PRS system and then connected to autoclave.

    Autoclaving section for AAC plant
    An autoclave is the most powerful machine in the aac block plant because of its help in achieving instant strength in AAC block. After cutting cakes placed in an autoclave with the help of track and then closes both doors of autoclave and start the curing process. In this process, we have to monitor steam pressure as per graph. This process takes max 12 hours and then we can transfer steam to the third autoclave and balance steam release. After that autoclave operator open door and pull out reddy finished aac block. Then it segregates as per sizes and date wise production Brickvision.

    Raw Material Composition in AAC Plant
    Raw Material Composition in Flyash Based AAC Plant

    Name

    Unite

    Cement lime fly ash

    Fly ash

    %

    70-80

    Cement

    %

    14-19

    Lime

    %

    4-8

    Gypsum

    %

    0.5-1

    Aluminum powder

    %

    0.05

    Bonding Agent

    %

    8-10

    Water 

    40-60

    Casting system Time

    Minute

    5-10

    Aluminum mixing time

    Second

    20-25


    Raw Material Composition in Sand Based AAC Plant

    Name

    Unite

    Cement lime fly ash

    Sand 

    %

    55-65

    Cement

    %

    20-25

    Lime

    %

    6-10

    Gypsum

    %

    0.5-1

    Aluminum powder

    %

    0.05

    Bonding Agent

    %

    2-4

    Water 

    40-60

    Casting system Time

    Minute

    5-10

    Aluminum mixing time

    Second

    20-25


    Raw Material Composition in Mixed AAC Plant

    Name

    Unite

    Cement lime fly ash

    Flyash

    %

    40-60

    Sand 

    %

    30-50

    Cement

    %

    16-18

    Lime

    %

    6-10

    Gypsum

    %

    0.5-1

    Aluminum powder

    %

    0.05

    Bonding Agent

    %

    2-4

    Water 

    40-60

    Casting system Time

    Minute

    5-10

    Aluminum mixing time

    Second

    20-25

    Our Product Range
    We Brickvision are one of the reputed Manufacturers and Exporters of AAC Block Making Machine, AAC Block Plant, AAC Plant, AAC Brick Plant, RMC Batching Plant and much more. The products offered by Brickvision are highly demanded by the customers due to the operational efficiency and low maintenance Easy to Operate and polished finish, our range of products is available in customized specifications to cater the diverse needs of the Our customers.

    1. 1. AAC Plant and Machinery

        1. - Mini AAC Plant

        2. - AAC block plant manufacturer

        3. - AAC Brick Plant Manufacturer

        4. - AAC block machine Manufacturers

        5. - AAC Block Making Machine 

    2. 2. Dry Mix Mortar Plant

        1. - JOIDING MORTAR MACHINE

        2. - DRY MIX MORTAR PLANT

        3. - MORTAR PLANT

        4. - AAC BLOCK JOINDING CHEMICAL PLANT

        5. - MINI DRY MORTAR PLANT

    3. 3. Concrete Batching Plant

        1. - RMC BATCHING PLANT

        2. - REDY MIX CONCREAT PLANT

        3. - AUTOMATIC RMC PLANT

        4. - RMC PLANT

        5. - MOBILE CONCREAT BATCHING PLANT

    4. 4. Civil Lab Testing Machine

        1. - Compressive Testing Machine

        2. - Concrete Testing Machine

        3. - Hand Operated CTM

        4. - CTM Machine

        5. - Lab Testing Instrument For AAC Plant

    5. 5. Brick Making Machine

        1. - FLY ASH Brick Making Machine

        2. - Concrete Brick Making Machine

        3. - Paver Making Machine

        4. - Color Paver Making Plant

        5. - Concrete Block Plant