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AAC panel plant

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The AAC production process includes raw material preparation, batching and mixing, pouring, reinforcement, 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.
AAC Panel (Autoclaved aerated concrete slabs), it is mainly composed of silica sand, cement, aluminum powder, lime. The double layer, two-way steel net which is anti-rust & anti-corrosion inside the panel. The AAC panel which go trough high t

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 panel production machinery industry, we can supply customers with quality AAC production lines with capacity ranging from 150,000m3 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




No.

Index content

unit

Index value

I

Name  


AAC block& panel

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

5. Rebar steel

Ton / year

2500

IV

Total capacity (without ball mill power)

KW

≈1000

V

Annual  power consumption

10,000KW.h

≈400

VI

Annual  water consumption

Ton

≈76400

VII

Annual  gas consumption

Ton

≈30000

VIII

Single-shift  producing operators 

people

7

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

21

IX

Total plant construction area

hectare

≈45

Construction area

m2

≈9000

Storage covering

m2

≈10000


No.

Index content

unit

Index value

I

Name  


AAC block & panel

Production scale(annual capacity) 

200,000

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

129900

2.lime

Ton / year

31600

3. gypsum

Ton / year

5600

4. cement

Ton / year

18600

5. Rebar steel

Ton / year

5000

IV

Total capacity (without ball mill power)

KW

≈1250

V

Annual  power consumption

10,000KW.h

≈550

VI

Annual  water consumption

Ton

≈113500

VII

Annual  gas consumption

Ton

≈45000

VIII

Single-shift  producing operators 

people

7

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

21

IX

Total plant construction area

hectare

≈60

Construction area

m2

≈12000

Storage covering

m2

≈20000

Process Period

  • Mixing period: 7-8 minutes

  • Slurry temperature: 40-45℃

  • Cake curing: 2.5-3.0h

  • Temperature of curing: 45~55℃

  • Cake strength after curing: 0.15~0.18MPa

Autoclaved curing system

  • Before-after autoclave: 0.5h

  • Vacuumize: 0.5h(0~-0.06MPa)

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

  • Constant pressure: 8h(1.3MPa)

  • Releasing pressure: 1.5h(1.3~0MPa)

  • Total: 12h

 

Process

(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) Steel rebar rolls into factory by car, after straightening & cutting & welding to mesh cage, then put to yard storage after de-rusting & anticorrosive & drying.

(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. For panel, the cake transport to rebar insert area, insert the steel rebar into the mould car after curing, and then transport to curing area for forming, temperature of curing room is 40-45℃, stop for 180-240min, up to strength level, pull out from curing to draw-out steel rebar, then the mould car goes to cutting area after several minutes curing.

(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). For panel, mould transfer to rebar insert area after pouring, then insert the steel rebar into mould after pouring, then transport to curing area for forming, the temperature of curing room is 40-45℃, stop for 180~240min , up to cutting strength, pull out from curing room to rebar draw-out area, then transfer to cutting area for several minuets curing.

(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.

(10) The waste water after production, make waste slurry through waste mixer, for secondary using.


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3


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5


6


7


8


9


10

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.

2.2 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. 

Table 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

Table 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


2.3 Quick lime

Lime is also one of the main raw material. The 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%.


2.4 Aluminum paste(powder)
Aluminum paste is according to JC/T 407 Aluminum Paste for AAC standard. Aluminum powdery should be according to the current national standard, the requirements of Aluminum Powdery Part 2: Ball Mill Aluminum Powdery GB/T 2085. 2.
 
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%.
 
2.6 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


2.7 Steel Rebar

It should meet the standard of hot-rolled carbon steel wire rods GB/T701, reinforced concrete steel  the second part: hot-rolled deformed bar GB1499.2, cold rolled deformed bar GB13788 OR cold-drawn low-carbon wire for concrete product JC/T540

Table 2-4  Requirements of rebar rust-resistance

Item

Requirements

rust-resistance

Corrosion   area≤5%(After test)

adhesive force

≥1.0MPa

Table 2-5  Vertical rebar protection layer requirements

Item

Basic size

Allowable variation

Roof slab, floor slab,   external wall slab

Partition slab

protection layer thickness   from bedding face  c1

20

±5

-0.5

protection layer thickness   from top face c2

10

-0.5

Remark: Equipped with partition slab & other   special slab, its basic size & deviation should confirmed by both sides.    

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