New Style Autoclaved Aerated Concrete Plant Sand Lime Brick
1.AAC block plant preparation work
1. Land of 4 Acres is Required
2. Workshop area –approximately 6000 Sq Mt
3. Total Plant area( construction area ) = 15000 Sq Mt
4. Power connection needed – 500 KVA
5. Ideal manpower requirement is 40 nos. (Skilled – 10, semi
skilled-10 and unskilled 20)
6. Skill division 40 workers = Main plant 2 nos of 10 hour shifts
15 people each + Boiler & Autoclave section 3 people in 3
shifts of 8 hours
7. Water requirement approximately 225 Tons per Day.
8. Fly Ash requirement approximately 225 Tons per day
9. The above power and plant calculations are based on Fly ash
based AAC without Lime Crushing Unit and Ball mill for sand. If the
process so require, we may add them at a later stage. But surely we
give provisions for them at site right from installation stage
10. 300 working days is considered in a year through 333 days a
year is possible.
11 Fly to be provided free of cost by power plants. Only
transportation to be arraigned by Project. Average distance of 250
12. 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. Please check the form of
CDM after 2012
13. AAC Blocks of all sizes will be manufactured according to the
market requirement, though mainly stipulated sizes as per the BIS
2.AAC BLOCK PLANT WORKING PROCESS
The Process of manufacture is simple t follow, and complex to
First, the Fly Ash or sand is mixed with water, and made Slurry in
a slurry mixture. If Sand is used as a base material, we need a
ball mill to grind the sand to fine power. The slurry making
process is same sand.
After Slurry is made, the slurry is stored in slurry storage tank,
where the slurry is constantly agitated. Care is taken to run the
slurry storage tank all the time, so that is never settles down the
Then a weigh batcher weighs the Slurry, lime, OPC, Gypsum and
aluminum power in preset quantities, and mixes thoroughly. The
mixture also pours the mix into the Mould carried n the mould cart.
The full pouring of the mixture is just enough to fill around 50%
of the mould.
Then the mould is kept in a warm chamber for 2 hours, so that the
aeration and the light initial setting takes place. Next process is
de-molding process of the big block, in which a sophisticated
overhead hoist takes the mould, demoulds the block.
Next process is the level wire cutting of the Block, while the
block passes on the cutting trolley through the series of wires.
This process follows a vertical wire cutting where as the block
remains stationary, and the cutter cuts the block vertically.
3.AAC block advantages
1. Environmental friendly: needs no burning/backing
2. Strength: Higher Strength Bricks.
3. Uniform Shape: Easier and faster Brick working.
4. Uniform Shape: Less Mortar in Brick work.
5. Uniform Shape: Less Mortar in Plaster.
6. Natural Concrete: Gains strength over time.
7. Natural Concrete: Walls can be left exposed/un pl
8. Better heat & sound insulation compared to red B
9. Far Lesser brakeage during handling & transporta
10. Better Vibration resistance compared to red Brick
11. Light weight : Faster and easier transportation
12. Light weight : Faster and easier brickwork
13. Light weight : saves structural concrete by 35%