AAC Block Report

Laxmi En-Fab Pvt. Ltd Ahmedabad Gujarat India, Web : www.aacplant.co.in, www.aacautoclave.com,

+91 9712570097,9725012740/49 E mail: [email protected],[email protected], Page 1

Laxmi En Fab Pvt. Ltd.

AUTOCLAVED AREATED CONCRETE (AAC)

Laxmi En Fab Pvt. Ltd. AUTOCLAVED AREATED CONCRETE REG. OFFICE: 25 nilsin plot near patel alloy steelphase I , Vatva G.I.D.C. AHMEDABAD,GUJARATPh. +91 9725012749/9712570097

Website : www.aacplant.co.in,www.aacautoclave.com

Email: [email protected] , [email protected] [email protected]



Autoclaved aerated concrete (AAC), also known as autoclaved cellular concrete (ACC)

or autoclaved lightweight concrete (ALC), was invented in the mid-1920s by the

Swedish architect and inventor Johan Axel Eriksson

It is a lightweight, precast building material that simultaneously provides structure,

insulation, and fire and mold resistance. AAC products include blocks, wall panels, floor

and roof panels, and lintels

It has been refined into a highly thermally insulating concrete-based material used for

both internal and external construction. Besides AAC's insulating capability, one of its

advantages in construction is its quick and easy installation, for the material can

be routed, sanded, and cut to size on site using standard carbon steel band saws, hand

saws, and drills.

Even though regular cement mortar can be used, 98% of the buildings erected with AAC

materials use thin bed mortar, which comes to deployment in a thickness of inch. This varies according to national building codes and creates solid and compact building

members. AAC material can be coated with a stucco compound or plaster against the

elements. Siding materials such as brick or vinyl siding can also be used to cover the

outside of AAC materials

AAC has been produced for more than 70 years, and it offers advantages over other cementations construction materials, one of the most important being its

lower environmental impact.

AACs improved thermal efficiency reduces the heating and cooling load in buildings

AACs workability allows accurate cutting, which minimizes the generation of solid waste during use

AACs resource efficiency gives it lower environmental impact in all phases of its life cycle, from processing of raw materials to the disposal of AAC waste.

AACs light weight also saves cost & energy in transportation. AACs light weight saves labors.



Main ingredients include fly ash, water, quicklime, cement, aluminum powder

and gypsum. The block hardness is being achieved by cement strength, and instant

curing mechanism by autoclaving. Gypsum acts as a long term strength gainer. 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. 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.

ASSUMPTIONS: The major raw material Fly-Ash, 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,

Carbon Credit is estimates are for reference purpose. The Project owner must handle his part of CDM project to

get Carbon credits, through independent consultants. Carbon credit can be transacted on registration. The PCN

preparation & presentation, the PDD preparation & presentation, host country approval and the UNFCCC

Registration might take somewhat 6 months to 2 years year. So it may be wise to start early.

Sale price at site is estimated a conservative Rs 3200/- per cubic meter. AAC Blocks of all sizes will be

manufactured according to the market requirement, though mainly stipulated sizes as per the BIS standards.

Production is estimated at 80% capacity, 300 working days is considered in a year during the first year



Why AAC Bricks?

Energy saving

Easy to install

Less Weight Endurance

Precision

Energy Efficient

Non Toxic

Thermal Insulation

Fire Resistance

Acoustic Performance

Moisture Resistance Workability

Non Toxic

Thermal Insulation

Fire Resistance

Acoustic Performance

Moisture Resistance Workability

Earthquake Resistant

cost saving

Fire Resistant Pest Resistant

Water Barrier

High Strength



Large size, however light weight Light weight = saves foundation cost, helps the mason High load-bearing strength High durability = long life, impervious to rot or pest Dimensional accuracy High economy Effortless handling, rapid construction Best thermal insulation, 6 - 10 times better than regular dense concrete Unsurpassed fire-resistance = life, property and insurance cost saver Excellent sound absorption, ideal for the hospitality industry Good workability, better than wood (can be sawn, drilled, nailed, milled at site) Hurricane and earthquake resistance Not rotting (contrary to timber)



MARKET PLACE:

Fly ash is available incessantly and of satisfactory quality. Users are of the

opinion that strength, sturdiness, finish, availability, price are the important qualities in

blocks.

Very high attention is observed among traditional manufacturers regarding use of

fly ash in their products. Technical assistance & increased product awareness among

the public and considered important for promoting the shift in the manufacturing practices.

High preference for fly ash products is observed among those customers

contacting manufacturers. Increased media coverage & favorable policies are

considered key to increasing utilization of fly ash bricks & blocks.

The current prices of fly ash blocks are in the same range of cement blocks &

traditional bricks. But comparatively fly ash blocks are having more strength, fire

resistance, earthquake resistance, light weight, lesser brakeage and saves structural cost by 40%.

Average 60% of electricity comes from coal based power station, the country has

a huge stock of fly ash amounting to 60 million tons annually. Despite the entire efforts

present scenario is not too encouraging as only 5% countrys total ash has been

consumed in different sector.

With the rise in population and increase in constructional activities considering

the Improvement in the standard of living the demand for building bricks is increasing

day by day.

Market share of different walling materials

Type of walling material Market Size (Rs. Crores) % of Total market

Burnt Clay Brick 32825 95.3

Fly Ash Bricks 1135 3.3

Cement Concrete Blocks 485 1.4

Total 34445 100

The project activity product output AAC Blocks awareness levels were very low and are yet to penetrate in the markets. As stated above the prime reason why clay

brick accounts for 95% of the share is that they are cheap and have traditionally been

believed to be the most suitable walling material for building construction

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BRIEF PRODUCTION PROCESS:

1. COAL FLY ASH:

The fly ash of coal 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

2. 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.

3. GYPSUM:

The gypsum in the storage shed will be added into slurry pond according to the

required proportion, while preparing slurry

4. CEMENT:

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

into cement silo to be used

5. ALUMINUM POWDER PAST:

The purchased aluminum powder past in the bucket or bag will be stored in its

store house, When being used, it will be lifted to second floor of the batching

building, then measured and added in to aluminum mixer to prepare 5%

suspending liquid to be used.

6. 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.

7. 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 in to 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 mold will be moved to the bottom of the casting mixer by

ferry car.

8. CUTTING AND GROUPING:

After precuring, 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.

9. AUTOCLAVED AND FINISHED PRODUCT:

The green block after grouping, will be move into autoclave by windlass for

curing. The whole curing period is approx 12 hours, pressure approx 1.2mpa,

temperature approx 1850. After curing, the product will be pulling out of auto clave

and be sent to the store yard.

10. 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 mold returning line for cleaning and oiling to be reused.



Equipments Equipment is depend of selection of process , base material , selection of automization etc. below is given general base

equipment

Raw material processing equipment

Jaw crsher Hoist conveyor Block lime silo Electronic vibrating feeder Ball mill lime Sand silo Electronic vibrating feeder Belt conveyor Ball mill -wet -sand Bucket elevator Cement silo Gypsum silo

Pouring processing equipment

Main Slurry mixer fly ash Main Mixer desert mortar after Cutting

Weighted / batch slurry mixer Balance desert mortar for per mould Lime OPC gypsum mixer Screw conveyor for lime Aluminum mixer Main pouring mixer Lime &gypsum measure Spiral gate valve Pneumatic controlling valve Slurry measurer PLC electric measuring controlling system Air compressor Mould Mould bottom plate Steam curing car Electronic platform balance



Cutting processing equipment

Hoist for mould move Hoist for semi finish product

Tractor Horizontal cutting machine with Arrangement

Vertical cutting machine with arrangement

Cutting processing equipment

Hoist for mould move Hoist for semi finish product

Tractor Horizontal cutting machine with Arrangement

Vertical cutting machine with arrangement

Hardening or curing process equipment

Autoclave Steam boiler

Coal crushing and handling equipment Chimany Dust collector Steam controlling valve Steam controlling penal Steam line



Photograph of plant equipment

Storage silo Fly ash mixing tank

Mould mover final mixer

cutting machine Steam curing car



Boiler-dust collector-chimney Mixing section

Autoclave autoclave

mould goes to autoclave Mould



ready AAC block fitting of AAC block

AAC block construction AAC block wall

Housing make by AAC block Housing make by AAC block



LAYOUT This is basic layout actual layout depend on plant size, design, degree

of automization,land size, scope of raw material coming as well

outgoing position, many factor affect on plant design



RAW MATERIAL SUITABILITY:

Approximately 95% of the waste materials can be made suitable for AAC line through proper mix design. Also we

can have many different mix designs for the same densitysame strength of Blocks. We will help you to get the Best

quality blocks at optimal cost by means of designing proper Mix as per your input raw materials. The following are

basic guidelines (certainly not the final call) on the suitability of basic raw materials for AAC.

2. Lime (825%)

Item

Grade

Super Gr 1st Gr. 2nd Gr.

A(CaO +MgO) Quailty Fraction% 90 75 65 MgO Quality Fraction % 2 5 8 SiO2 Quality Fraction % 2 5 8 CO2 Quality Fraction % 2 5 7 Digestion speed ,min Digestion temperature , 6090 Undigested residue quality fraction ,% 5 10 15 Fineness (0.080 square hole sieve left amount) % 10 15 20

3. Cement (615%) SiO2 Ai203 FE20 Cao Mgo C3S C2S C3A C4AF

2123 57 35 6448 45 4459 1830 512 1018

1. Fly Ash (6570%) Index Item

Grade (%)

Gr I Gr II

Degree of

fineness

(0.045 square hole sieve left amount) 30 45 (0.080 square hole sieve left amount) 15 25

Ignition loss 5 10 SiO2 4555 40 SO3 1 2

Reference: The fineness can be 0.045 or 0.080 square sieve left amount.



4. Gypsum/Plaster (35%) CaSO4 > 70%

Mgo < 2%

Chloride < 0.05%

Preferably ground residue < 1015%

5. Aluminum Power (about 0.08%)

Type and recommendation for supply depend on raw materials and mix formula

Metal Content Approx. >=65% Powder

NOTE: Use of Cement is depend on moisture, if moisture is high cement requirement becomes high. Soluble Oil

usage per process is 1 liter.

TECHNICAL COMPARISON :

Parameter AAC Block Concrete Block Brick

Size (600x200x100-300) mm (400x200x100-200)

mm (230x115x75) mm

Variation in dimensions +/-1mm +/-3mm +/-5mm

Compressive strength 30-50 kg/cm2 40-50 kg/cm2 25-30 kg/cm2

Dry Density 550-700 kg/m3 1800 kg/m3 1950 Kg/m3

Fire Resistance 4-6 Hour depending on

thickness 4 hours 2 hour

Sound Reduction Index (dB)

60 for 200 mm thick wall

40 for 230 mm thick wall

Thermal Conductivity W/(K-m)

0.122 0.51 0.81

Normal basic size

AAC BLOCKS TECHNICAL SPECIFICATIONS

Thickness Height Length Density Compressive strength

100 mm 200 mm 600 mm 550-700 kg/m3 30 - 50 kg/cm

2

150 mm 200 mm 600 mm 550-700 kg/m3 30 - 50 kg/cm

2

200 mm 200 mm 600 mm 550-700 kg/m3 30 - 50 kg/cm

2



Main Technical Specifications of AAC Lightweight Block Production Line

Mainly plant capacity

Model Capacity per Annume Per day production As per 300 day

LAAC-50 50,000 CM 160 CM

LAAC-100 100,000 CM 320 CM

LAAC-150 150,000 CM 480 CM

LAAC-200 2,00,000 CM 640 CM

LAAC-300 3,00,000 CM 960 CM

LAAC-500 5,00,000 CM 1600 CM

Cover shed area

Model Capacity per Annume Work shed cover area

LAAC-50 50,000 CM 20,000 Square feet



Total land for building and shed , raw material ,finish material stock 2-5 acre



Raw material consumption for AAC block

Ingredients Raw material consumption per CM of AAC

block

Fly ash 272 KG

Lime 71 KG

Cement 95 KG

Anhydride 12 KG

Aluminioum ( metel powder ) 0.46 KG

Total solid 450 KG

Water in mix ( total ,excl. steam ) 370 KG

Condensate which can be reused

In the mix ( water consumption

Above reduce correspondingly)

90 KG

Above data is not full and final but for better understanding project is given

Actual Ingredients mixing is depend on client & client technical team



Energy and mass flow and balance diagram

The above figure represents the ENERGY and Mass Flow and the balance of the

system and equipments include in the project activit.in the project activity electricity,

steam & compressor air are the main type of energy used and main source of these

energy are as follows:

Electricity : from new NEgrid & DG set

Steam : from boiler fuel oil combustion

Compressed air from air compressor

Raw material

Fly ash,

lime,Gypsum

,aluminium,

cement

Raw material

pouring & mixing

Moulding & cutting

Curing at autoclave

Finish product

Compressed air Electricity

Water

Electricity

Steam

New grid

DG set

Boiler

Fuel oil

Diesel



. .

Laxmi En Fab Pvt. Ltd. AUTOCLAVED AREATED CONCRETE REG. OFFICE: 25 nilsin plot near patel alloy steelphase I , Vatva G.I.D.C. AHMEDABAD,GUJARATPh. +91 9725012749/9712570097

Website : www.aacplant.co.in,www.aacautoclave.com

Email: [email protected] , [email protected] [email protected]

AAC Block Report

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