AAC Block PLANT
1. RAW MATERIAL:
FLYAsh: 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 by the entrepreneur.
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 directly. In phase -2 we can think of having backward integration and making a lime powering unit at site to have a more competitive advantage, We can also think of a lime burning link side the factory premises project financials however have not considered the costs of powering unit, and the lime kiln in this project. Different qualities of lime are available, and depending on the raw materials, the mix design can be chosen to get the optimal quality of production.
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. The other prime advantages of using OPC (compared to other binders) is it's easy availability locally through nationwide Retail Network of Cement Companies.
Gypsum: This too is an industrial waste. 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 power 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.
The whole aac production process:
The Production Process Of Autoclaved Aerated Concrete Block
1. Raw material storage
Flyash, sand, cement, lime, gypsum and aluminum powder should be stored separately in the corresponding stock yard. Then they will be disposed separately and transported to each work section when used.
2. Raw material disposed
Flyash and sand will be transported into the wet ball mill by the conveyor belt. Afterwards by slurry pump the slurry will be transported into slurry tank.
3. Batching, mixing and pouring
The lime and cement will be transported successively by the screw conveyor into automatic weigher for weighs, and the slurry will be transported by the slurry pump into automatic weigher for weighs. Afte weighing the powder and slurry will be transported into the mixer for uniformity and pouring into the mould box.
4. Curing, Cutting
The slurry which be poured into the mold box will pre-harden in the curing room which temperature is 40-50 degrees in one or three hours. When the body meets hardness of being cut, it will be transported with the mould box by reversal crane into the cutting cart. Then it will move with the cutting cart for level and vertical cutting.
5. Autoclaved and Finished product
The cut body will be putted on marshalling site by the crane. The marshalling body will be transported into the autoclaved kettle by the hauling engine or mobile windlass for 8-10 hours maintenance. Afterwards the finished products will be pulled away from the the autoclaved kettle by the hauling engine, with separating and packing they transported into stock by forklift.
| Parameter Name |
Parameter Value |
| Fly ash |
65-70% |
| cement |
6-15% |
| lime |
18-25% |
| gypsum |
3-5% |
| Aluminum powder paste |
8 |
| Water & material rate |
0.60-0.65 |
| Casting temperature |
36-40°C |
| Aluminum mixing time |
30-40s |
*For reference
Sand style aerated block raw material proportion:
| Parameter Name |
Parameter Value |
| Sand |
55-65% |
| Cement |
10-20% |
| Lime |
20-30% |
| Gypsum |
2-3% |
| Aluminum powder paste |
8 |
| Water & material rate |
0.65-0.75 |
| Casting temperature |
35-38°C |
| Aluminum mixing time |
30-40s |
Audited Supplier 
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