Technical parameters, process breakdown, and configuration matrices for modern manufacturing.
Our Autoclaved Aerated Concrete (AAC) manufacturing units are designed to combine high volume throughput with absolute safety. Incorporating automated dosage meters, heavy duty boiler vessels, and robust cutting wires, they produce concrete blocks with exact dimensional tolerances (+/- 1.5mm).
We provide full structural planning and raw material profiling to ensure your source sand, fly ash, lime, and gypsum are blended in the correct chemical ratios for cellular expansion.
Certified steel pressure vessels running at 12 bar steam pressure (190°C) to accelerate hydrosilicate crystallization, giving blocks high structural load bearing capacity.
Precision horizontal and vertical cutting mechanisms equipped with high tensile steel wires, minimizing waste slurry and ensuring smooth block surfaces.
Centralized control desk offering touch screen control for material batching, planetary mixer blending times, mold transport tracking, and steam cycles.
Expandable up to 64 CbM
Expandable up to 128 CbM
Expandable up to 192 CbM
Expandable up to 256 CbM
Investors are shifting away from traditional clay bricks due to rising production costs and tight emission rules. Autoclaved Aerated Concrete has emerged as the clear alternative, offering massive advantages in structural weight and thermal performance.
As environmental regulations tighten, the demand for fly ash based building materials is skyrocketing.
AAC blocks reduce the total weight of a high rise building by up to 30%, significantly lowering steel and cement costs for builders.
With government push for "Green Buildings," your product is already in high demand before the plant is even commissioned.
High speed ball mills wet grind fly ash or quartz sand with water into a fine slurry of specific gravity 1.40 to 1.45. Accurate slurry density is crucial, as it directly dictates the density class of the finished block (e.g., Grade I or Grade II per IS 2185).
In the mixer, fine aluminum powder is added as the aerating agent. Under alkaline conditions created by active lime (CaO) and cement, aluminum reacts with calcium hydroxide to release hydrogen gas:
2Al + 3Ca(OH)₂ + 6H₂O → 3CaO·Al₂O₃·6H₂O + 3H₂↑
This creates millions of microscopic hydrogen bubbles, expanding the slurry cake by 200% and forming the cellular structure.
The aerated mix is cast into steel molds. The cake expands and rises inside a temperature controlled pre curing chamber (38°C to 45°C) for 2 to 3 hours, achieving a semi solid "green state" with plaster like hardness suitable for wire cutting.
Equipped with high tensile steel wire cutting lines (0.8mm wire thickness), the green cake is stripped and sliced vertically and horizontally with exact precision (±1.5mm tolerance), minimizing dimensional mortar thickness for block masons.
The cut cakes are loaded into autoclaves for steam curing at 12 Bar (1.2 MPa) saturated pressure and 190°C for 10 to 12 hours. This forces a hydrothermal reaction between lime and silica, crystallizing into **Tobermorite** ($C₅S₆H₅$):
5Ca²⁺ + 6SiO₂ + 5H₂O → C₅S₆H₅ (Tobermorite Crystals)
This crystal matrix provides the block with permanent high strength, minimal shrinkage, and maximum structural fire resistance.
After autoclaving, blocks are cooled and sorted. Every production batch undergoes quality audits for dry density, moisture content, and compressive strength (exceeding 3.5 to 5.0 N/mm²) to comply with IS 2185 Part 3 specifications.
| Raw Material | Standard Mixing Ratio | Chemical & Grading Parameter requirements |
|---|---|---|
| Fly Ash (conforming to IS 3812) | 65% to 70% | Reactive silica (SiO₂) > 40%, CaO < 5%. Fineness: less than 15% residue on a 45-micron wet sieve. |
| Quicklime / Active Lime | 15% to 20% | Active CaO content > 75%. Slaking time: 5 to 15 minutes, hydration temperature: 60°C to 80°C. |
| Cement (OPC 53 Grade) | 10% to 15% | Conforming to IS 12269. Provides early hydration strength to block green cake before wire cutting. |
| Gypsum (Dihydrate) | 3% to 5% | Purity (CaSO₄·2H₂O) > 90%. Acts as a chemical retarder to prevent premature lime slaking. |
| Aluminium Powder / Paste | 0.07% to 0.08% | Active metallic aluminum content > 85%. Average particle size (D50): 15 to 30 microns. |
A standard 54 to 72 CuM daily capacity plant layout is designed by our engineers to minimize transport cycles and reuse 100% of cutting waste. The standard land allocation is divided as follows:
| Category | Strategic Importance |
|---|---|
| Machinery | 40-50% of budget. Focus on automation for consistent quality. |
| Infrastructure | Land for material storage, curing area, and finished goods yard. |
| Utilities | High pressure boiler systems and 3-phase industrial power connectivity. |
| Logistics | Proximity to raw materials (Fly Ash/Sand) is your biggest margin booster. |