/ العربية / Español / Pусский

AAC block plant

Share to:

The AAC production process includes raw material preparation, batching and mixing, pouring, pre-curing, cutting, autoclaving, and packing.
The entire line allows process to flow smoothly, from start to finish. The independent circulating line of mould, side plate and autoclaving car can lead the object to the original location and get ready for the next work cycle. The production line can achieve the real total automatic production without waste.
Making full use of the land with the advanced overhead conveying system, special overhead cross moving system and hydraulic control system for de-moulding machine, semi-product stacking machine, separator and clamping machine, the investment of simple workshop structure can be reduced.
With decades of experience in serving the AAC blocks production machinery industry, we can supply customers with quality AAC block production lines with capacity ranging from 150,000m3 to 40,000m3 per year.

  • KEDA

Product Description

WHAT IS AAC?
The AAC production process includes raw material preparation, batching and mixing, pouring, precuring, cutting, autoclaving, and packing. With decades of experience in serving the AAC blocks production machinery industry, we can supply customers with quality AAC block production lines with capacity ranging from 80,000m3 to 40,000m3 per year.


Automatic AAC Block Making Machine with CE Approved
Chart 1 the parameter of the processes
Processes Parameter
Mixing period 5-6 minutes
Pouring slurry temperature 40-45ºC
Cake curing time 2.5-3.0h
Cake curing temperature 45~55ºC
Cake strength after curing 0.15~0.18MPa
Autoclaved curing system Before-after autoclave 0.5h
Vacuumize 0.5h(0~-0.06MPa)
Listing pressure 1.5h(-0.06~1.3MPa)
Constant pressure 8h(1.3MPa)
Releasing pressure 1.5h(1.3~0MPa)
total 12h
 

 RAW MATERIALS  
Siliceous materials : Sand / Fly ash / Tailings containing silicon / Ceramic waste 
Calcareous material: Lime block + cement + gypsum 
Others: Aluminum powder paste  
Automatic AAC Block Making Machine with CE Approved
THE ADVANTAGES OF AAC:

1. Low density : Can be 325kg /m3
2. Good thermal insulating properties
3. Cost few time to build, saving time
4. Easy to operate , saving labor cost
5. Good performance of preventing fire
6. Good sound-insulation properties
7. Durable , anti-seismic , recyclable

Automatic AAC Block Making Machine with CE Approved

Automatic AAC Block Making Machine with CE Approved


CUTTING SYSTEM 

Special cutting design : All the steel wire columns are fixed on two main oblique  beams of cutting machine and each pair of the columns is used to fix only one steel wire , so that the horizontal  cutting machine can avoid the settlement cracks problem in thin block and panel cutting , and achieve the minimum horizontal cutting thickness of 50MM block out of a whole mould. The integral swing frame of the vertical cutting machine can ensure the side plate replacement , the cutting action can be synchronized with ferry replacement. With automatic detection system . the broken wire can be timely detected.
 
Automatic AAC Block Making Machine with CE Approved


PACKING SYSTEM 

Automatic packing system can realize the automatic rotation stacking and splicing of blocks and  realize the packing function with pallet or non-pallet. The stacking specification can realize 1.2m×0.6m\ 1.2m×1m1.2m×12m\ 1m×0.6m multiple  stacking , and the height of the stacking can be 1.2m, 1.5m , 1.8m and 2.4m. 
Automatic AAC Block Making Machine with CE Approved

AAC FINAL PRODUCTS

 1.Product classification

Product classification is according to national standards GB/T 11968-2006 AAC block, also can be according to user's requirements to produce product with special specifications size.
 
Chart 2 Specification & Index
Name AAC block
Weight 300~600 Kg/m3(control led by formula)
After autoclave compressive strength average value≥3.5MPa, Min. value<=2.8Mpa
Drying shrinkage value Measured under condition of rapid method≤0.8mm/m;Measured under condition of standard method≤0.5mm/m
Frost-resistance After the cycle of freezing and thawing for 15 times,weight loss≤ 5%,strength loss≤ 20%
Coefficient of thermal conductivity ≤0.14~0.16W/m.k
 
1.2 The block is classified by compressive strength and volume density.
Strength level: A1.0, A2.0, A2.5, A3.5, A5.0, A7.5, A10.
Dry density level: B03, B04, B05, B06, B07, B08.

 
 
1.3 Block level
The block is divided into high-class(A), first-class(B), qualified product (C) according to the size variation, appearance quality, dry density, compression strength & frost-resistance.
 

 
1.4  AAC Block indicator
Chart 3  Size variation& appearance
Project Indicator
High-class
(A)
Qualified product
(B)
Permissible variation of dimension
mm
Length L ±3 ±4
Width B ±1 ±2
Height H ±1 ±2
Missing angle The min. size not more than /mm 0 30
The max. size not more than /mm 0 70
Missing angle no. larger than the above size, not more than 0 2
Crack length The crack length through one edge and two surfaces not more than crack directional size sum on crack surface 0 1/3
The crack length of any surface can not be larger than crack directional size 0 1/2
The cracks larger than the above size, not more than 0 30
The depth of cracking, sticking, damage can not be more than/mm 0 1030
Plain bending Not allowed
Surface porosity, lamination crack Not allowed
Surface oil Not allowed
 
 
Chart 4  Cubic compression strength for block  
Strength level Cubic compression strength (MPa)
Average not less than Single group min. not less than
A1.0 1.0 0.8
A2.0 2.0 1.6
A2.5 2.5 2.0
A3.5 3.5 2.8
A5.0 5 4.0
A7.5 7.5 6.0
A10.0 10 8.0
 
 
Chart 5  Dry density for block(kg/m3)
Dry density level B03 B04 B05 B06 B07 B08
Dry density High-class (A)≤ 300 400 500 600 700 800
Qualified product
 (B)≤
325 425 525 625 725 825
 
 
Chart 6  Strength level for block
Dry density level B03 B04 B05 B06 B07 B08
Strength level High-class (A)≤ A1.0 A2.0 A3.5 A5.0 A7.5 A10.0
Qualified product
 (B)≤
A2.5 A3.5 A5.0 A7.5


No.

Index content

unit

Index value

I

Name 


AAC block

Production scale(annual   capacity)

150,000

Specification(cake: 4.2×1.2×0.6)

m

China national   standard(GB)

II

Working system(three-shift   continuous weekly production)


300 days / year

22.5 hours / day

7.5 hours / shift

III

Main raw material   consumption



1. sand

Ton / year

65000

2.lime

Ton / year

15800

3. gypsum

Ton / year

2800

4.cement

Ton / year

9300

IV

Total capacity (without   ball mill power)

KW

≈630

V

Annual  power consumption

10,000KW.h

≈260

VI

Annual  water consumption

Ton

≈57800

VII

Annual  gas consumption

Ton

≈22500

VIII

Single-shift  producing operators

people

6

Single-shift auxiliary   personnel (including forklift and boiler gas distribution )

10

IX

Total plant   construction area

hectare

≈30

Construction area

m2

≈7000

Storage covering

m2

6000


No.

Index content

unit

Index value

I

Name  


AAC block

Production scale(annual capacity)

200,000

Specification(cake: 4.8×1.2×0.6)

m

China national standard(GB)

II

Working system(three-shift continuous weekly production)


300 days / year

22.5 hours / day

7.5 hours / shift

III

Main raw material consumption



1. sand

Ton / year

86600

2.lime

Ton / year

21100

3. gypsum

Ton / year

3800

4.cement

Ton / year

12400

IV

Total capacity (without ball mill power)

KW

≈800

V

Annual  power consumption

10,000KW.h

≈320

VI

Annual  water consumption

Ton

≈76400

VII

Annual  gas consumption

Ton

≈30000

VIII

Single-shift  producing operators 

people

6

Single-shift auxiliary personnel (including forklift and boiler gas distribution )

10

IX

Total plant construction area

acre

≈7.5

Construction area

m2

≈7000

Storage covering

m2

≈8000

No.

Index content

unit

Index value

I

Name 


AAC   block

Production   scale(annual capacity)

250,000

Specification(cake: 5.0×1.2×0.6)

m

China   national standard(GB)

II

Working   system(three-shift continuous weekly production)


300 days   / year

22.5   hours / day

7.5 hours   / shift

III

Main   raw material consumption



1.   sand

Ton /   year

108300

2.lime

Ton /   year

26300

3. gypsum

Ton /   year

4700

4.cement

Ton /   year

15500

IV

Total   capacity (without ball mill power)

KW

≈800

V

Annual  power consumption

10,000KW.h

≈390

VI

Annual  water consumption

Ton

≈94900

VII

Annual  gas consumption

Ton

≈37500

VIII

Single-shift    producing operators

people

6

Single-shift   auxiliary personnel (including forklift and boiler gas distribution )

10

IX

Total   plant construction area

hectare

≈35

Construction   area

m2

≈7500

Storage   covering

m2

≈8500

No.

Index content

unit

Index value

I

Name 


AAC   block

Production   scale(annual capacity)

300,000

Specification(cake: 6.0×1.2×0.6)

m

China   national standard(GB)

II

Working   system ( three-shift continuous weekly production )


300 days   / year

22.5   hours / day

7.5 hours   / shift

III

Main   raw material consumption



1.   sand

Ton /   year

173200

2.lime

Ton /   year

42100

3. gypsum

Ton /   year

7500

4.cement

Ton /   year

24800

IV

Total   capacity (without ball mill power)

KW

≈1000

V

Annual  power consumption

10,000KW.h

≈500

VI

Annual  water consumption

Ton

≈150600

VII

Annual  gas consumption

Ton

≈60000

VIII

Single-shift    producing operators

people

6

Single-shift   auxiliary personnel (including forklift and boiler gas distribution )

10

IX

Total   plant construction area

hectare

≈50

Construction   area

m2

≈10000

Storage   covering

m2

≈13500

No.

Index content

unit

Index value

I

Name 


AAC   block

Production   scale(annual capacity)

400,000

Specification(cake: 6.0×1.5×0.6)

m

China   national standard(GB)

II

Working   system ( three-shift continuous weekly production )


300 days   / year

22.5   hours / day

7.5 hours   / shift

III

Main   raw material consumption



1.   sand

Ton /   year

129900

2.lime

Ton /   year

31600

3. gypsum

Ton /   year

5600

4.cement

Ton /   year

18600

IV

Total   capacity (without ball mill power)

KW

≈1000

V

Annual  power consumption

10,000KW.h

≈460

VI

Annual  water consumption

Ton

≈113500

VII

Annual  gas consumption

Ton

≈45000

VIII

Single-shift    producing operators

people

6

Single-shift   auxiliary personnel (including forklift and boiler gas distribution )

10

IX

Total   plant construction area

hectare

≈45

Construction   area

m2

≈9200

Storage   covering

m2

≈10000

Process period

  • Mixing period: 5-6 minutes

  • Pouring slurry temperature: 40-45℃

  • Cake curing time: 2.5-3.0h

  • Cake curing temperature: 45~55℃

  • Cake strength after curing: 0.15~0.18MPa

Autoclaved curing system

  • Before-after autoclave: 0.5h

  • Vacuumize: 0.5h(0~-0.06MPa)

  • Listing pressure: 1.5h(-0.06~1.3MPa)

  • Constant pressure: 8h(1.3MPa)

  • Releasing pressure:1.5h(1.3~0MPa)

  • total: 12h

 

Process engineering brief

(1)The lime and gypsum will be crashed and ball milled after entering the factory, batch production for this section working system. The raw materials is continuous crashed into grain which granularity is less than or equal to 25mm, and then be put in the storage respectively through 3-pass splitting by bucket elevator. Lime and gypsum-grain will be fed in proportion through speed belt scale and into ball mill for mixture levitation through the respective baiting splitting, When the fineness reached 3500 ~ 4000cm2 / g, the lime and gypsum-grain will be sent into cement silo through bucket elevator for storage.

(2) The sand is transported to stacking place by dump truck for use.

(3) Sand will be transported to the hopper by loader car, then after measuring be transported to wet ball miller for milling by the belt conveyor, milled to mortar and be transported to storage tank stand-by through beating pool.

(4)Mortar poured into slurry measurement through slurry pump, the cement transported into powder measurement through screw conveyor; The measured mortar, cement poured into pouring mixer according to ratio order for mixing, the amount of steam passed into mixer based on process requirements, slurry temperature in the mixer reached about 40 ~ 45 ℃, mixing time is about 3 ~ 4mins, open the lower valve of aluminum paste mixer, make it flow into pouring mixer for mixing, mixing time is not more than 40s, then the slurry poured into mold. The whole period is about 5 to 6mins.

(5) The poured mold car transfers to curing area for gas-forming & initial setting, temperature in curing room is about 40 to 45 ℃, curing for 150 to 180mins, the mold car is pull out of curing room when reached the cutting strength.

(6)Mould will be transported to the cutting area when the curing reach to cutting requirements, turning table separates the mould and turns the cake to 90°spaced on the cutting car. The car carried cake achieves six sides cutting through horizontal and vertical cutting process(length±3mm~width±1mm~±1mm).

(7) Put the cake on the semi-finished product turning table by crane after cutting, the cake turned to 90 ° by turning table to be peeled the bottom & top leather, then be turned again to original position, next be stacked on the steam curing car by the semi-finished product stacker, marshaled steam curing car be put into the autoclave for high temperature (200 ℃), high pressure (1.3 MPa), autoclave (about 12 hours). Sweep gas in the autoclave be sent to curing area by the pipe.

(8) Finished curing cake will be combined, divided, transfer and packaging after classified placing, separating and clamping treatment. Then sent the after-package cake to the storage yard by forklift. Finished product separated bottom plates will be transported to compound die area by curing car for mould car compounding. After cleaning and oil brushed, the curing car will be poured for re-use. Then back to the curing car and process the autoclave curing after stacking and grouping.

(9) The recycled waste in production can be made into waste slurry by waste mixer , the stored waste slurry can be reused with raw material.

1. Cement
Producing AAC block adopts lime-cement mixing calcium system, can use standard 425# cement, and is according to technical requirements GB 175 General Silicate Cement. Before entering factory with manufacture quality certification, The cement should be used in sequence. Cement technical requirements as blow:
(1) Free CaO content should be not more than 1.5%, CaO content is 60%.
(2) NaCl & KCl content should be not more than1%~1.5%.
(3) Specific surface area 2500~3500cm3/g.
(4) Volume stability is qualified.
(5) Setting time initial setting 1~3h final setting 3~6h. 

2. Sand
It should be according to the standard JC/T 662 Sand for Silicate Building Products to select. Generally, the higher quartz content in the sand, the better AAC block quality.

Chart 2-1 Main technical index for sand

Name

SiO2%

K2O+Na2O%

Organic matter

Mica%

SO3%

Mud%

Moisture   content%

Grade

High-class

≥85

≤1

Qualified

≤0.5

1

3

8

Firs-class

≥75

≤3

5

Qualified   product

≥65

≤5

≤1

2

8

Chart 2-2 Grain composition for sand

Name

Content,%

Grade

High-class

First-class

Qualified   product

2.55.0(round hole)

0

0

1.252.5(square hole)

10

10

0.160.25(square hole)

60

45

0.16(square hole)

30

45


3. Quick lime

Lime is also one of the main raw material. Its function is coordinating with cement to provide effective calcium oxide, than makes it working with SiO2, Al2O3 from silica material under hydrothermal condition to generate hydrated calcium silicate. So it should be according to JC/T621 Quick Lime for Silicate Building Product standard. Effective calcium oxide content should be more than 65%, the best is more than 80%.

4. Aluminum paste(powder)
Aluminum paste is according to JC/T 407 Aluminum Paste for AAC standard. Aluminum powder should be according to the current national standard, the requirements of Aluminum Powder Part 2: Ball Mill Aluminum Powder GB/T 2085. 2. 

5. Gypsum
Gypsum is a modifier during gas processing in the AAC. The regulating effect of gypsum mainly reflects in deferring the speed of quick lime digesting & slurry thickening. Gypsum should be according to the current national standard, the requirements of Natural Gypsum GB/T 5483. The main chemical compositions of gypsum are CaSO4,CaSO4·2H2O>70%.

6. Water
According to the standard, water ratio is advisable to 0.60.

Chart 2-3 water quality requirement

Content

pH

Cl-  (mg/L)

SO42-(mg/L)

Na+ +K+(mg/L)

K+  (mg/L)

Operating range

6~9

600

1000

450

100

1.Product classification
Product classification is according to national standards GB/T 11968-2006 AAC block, also can be according to user’s requirements to produce product with special specifications size.
 

Chart 1 Specification & Index

●Name

AAC block

●Weight

300600 Kg/m3(control led by formula)

●After autoclave   compressive strength

average   value≥3.5MPa, Min. value2.8Mpa

●Drying   shrinkage value

Measured under   condition of rapid method≤0.8mm/mMeasured under condition   of standard method≤0.5mm/m

●Frost-resistance

After the cycle   of freezing and thawing for 15 timesweight loss≤ 5%strength loss≤ 20%

●Coefficient of   thermal conductivity

≤0.140.16W/m.k

1.1 Specification
Block specification is shown in Chart 2.

Charts 2  Block specification (mm)

Length L

Width B

Height H

600

100 120 125

200 240 250 300

150 180 200

240 250 300

Remark: It   should be resolved through consultation by the two sides if need other   specifications.

1.2 The block is classified by compressive strength and volume density.

Strength level: A1.0, A2.0, A2.5, A3.5, A5.0, A7.5, A10.
Dry density level: B03, B04, B05, B06, B07, B08.
 
1.3 Block level
The block is divided into high-class(A), first-class(B), qualified product (C) according to the size variation, appearance quality, dry density, compression strength & frost-resistance.
  
1.4  AAC Block indicator

Chart 3  Size variation& appearance

Project

Indicator

High-class

Qualified   product

(A)

(B)

Permissible   variation of dimension

Length

L

±3

±4

mm

Width

B

±1

±2


Height

H

±1

±2

Missing angle

The min. size   not more than /mm

0

30

The max. size   not more than /mm

0

70

Missing angle   no. larger than the above size, not more than

0

2

Crack length

The crack length   through one edge and two surfaces not more than crack directional size sum on   crack surface

0

13

The crack length   of any surface can not be larger than crack directional size

0

12

The cracks   larger than the above size, not more than

0

30

The depth of   cracking, sticking, damage can not be more than/mm

0

1030

Plain bending

Not allowed

Surface   porosity, lamination crack

Not allowed

Surface oil

Not allowed

Chart 4  Cubic compression strength for block  

Strength level

Cubic   compression strength (MPa)

Average not less   than

Single group   min. not less than

A1.0

1

0.8

A2.0

2

1.6

A2.5

2.5

2

A3.5

3.5

2.8

A5.0

5

4

A7.5

7.5

6

A10.0

10

8

Chart 5  Dry density for block(kg/m3)

Dry density   level

B03

B04

B05

B06

B07

B08

Dry density

High-class (A)≤

300

400

500

600

700

800

Qualified   product

325

425

525

625

725

825

 (B)≤

Chart 6  Strength level for block

Dry density   level

B03

B04

B05

B06

B07

B08

Strength level

High-class (A)≤

A1.0

A2.0

A3.5

A5.0

A7.5

A10.0

Qualified   product

A2.5

A3.5

A5.0

A7.5

 (B)≤

Chart 7  Drying shrinkage, freeze-proof, heat conduction

Volume density   level

B03

B04

B05

B06

B07

B08

Drying

·          

0.5

shrinkage value

Standardized   method


 /(mm/m) ≤


Rapid method   /(mm/m) ≤

0.8

Frost-resistance

Quality loss/% ≤

5

Frost-resistance   /Mpa ≥

High-class(A)

0.8

1.6

2.8

4

6

8

Qualified   product

2

2.8

4

6

(B)

heat   conductivity coefficient (dry state)/W/m•k)〕

0.1

0.12

0.14

0.16

0.18

0.2

Block drying   shrinkage value is measured by standardized method & rapid

method, decided   by standardized method if the measured results conflict.


If you have any questions, please contact us!

Why KEDA

Products

Contact us

Contact Us

 +86-555-2113600
 +86-186-5559-0067
 marketing_ea@keda-suremaker.com
Copyright  KEDA INTERNATIONAL COMMERCE CENTRE

Contact Us Now