AAC BLOCK MANUFACTURING PLANT

[EIRI/EDPR/3662] J.C.: 1747

INTRODUCTION

Autoclaved aerated concrete is a versatile lightweight construction material and

usually used as blocks. Compared with normal (ie: “dense” concrete) aircrete has a
low density and excellent insulation properties.

The low density is achieved by the formation of air voids to produce a cellular
structure. These voids are typically 1mm-5mm across and give the material its
characteristic appearance. Blocks typically have strengths ranging from 3-9 Nmm-
2 (when tested in accordance with BS EN 771-1:2000). Densities range from about
460 to 750 kg m-3; for comparison, medium density concrete blocks have a typical
density range of 1350-1500 kg m-3 and dense concrete blocks a range of 2300-
2500 kg m-3.

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Autoclaved aerated concrete blocks are excellent thermal insulators and are
typically used to form the inner leaf of a cavity wall. They are also used in the
outer leaf, when they are usually rendered, and in foundations. It is possible to
construct virtually an entire house from autoclaved aerated concrete, including
walls, floors - using reinforced aircrete beams, ceilings and the roof. Autoclaved
aerated concrete is easily cut to any required shape.

Aircrete also has good acoustic properties and it is durable, with good resistance
to sulfate attack and to damage by fire and frost.

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AERATED CONCRETE BLOCKS

Aerated Concrete Blocks exhibit their superiority over the conventional concrete
blocks by virtue of their light weight. This is attributed to the fact that these
blocks are porous with small air holes (Not for air pass).

Another specificity of Aerated concrete blocks is their strength being more than
the conventional concrete block.

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 CONTENTS

INTRODUCTION
AERATED CONCRETE BLOCKS
AUTOCLAVED AERATED CONCRETE
STACKED BLOCKS OF AAC (WRAPPED IN FOIL)
RAW MATERIALS
FLY ASH SAND LIME AERATED BLOCKS
AUTOCLAVED AERATED CONCRETE BLOCKS
ADVANTAGES OF AUTOCLAVED AERATED CONCRETE BLOCKS:
USES AND APPLICATIONS
AERATED CONCRETE BLOCKS
PROPERTIES
COMPOSITION OF PORTLAND CEMENT
ORDINARY PORTLAND CEMENT MAY HAVE THE COMPOSITION AS BELOW
B.I.S. SPECIFICATION
MARKET SURVEY
STRUCTURE AND DEVELOPMENT
AAC BLOCK: AN EMERGING GREEN BUILDING MATERIAL IN INDIA
SALIENT FEATURES OF AAC BLOCK: LEADING TO INCREASING
ACCEPTANCE OF THE PRODUCT
A QUICK COMPARISON BETWEEN AAC BLOCK AND CLAY BRICK
FLY ASH: CHANGING STATUS FROM HAZARDOUS INDUSTRIAL WASTE
TO USEFUL AND SALEABLE COMMODITY
DEMAND-SUPPLY SCENARIO OF AAC BLOCKS
INCREASING COMPETITION RESULTING INTO PRESSURE ON REALIZATIONS
FINANCIAL PERFORMANCE OF AAC BLOCK MANUFACTURERS
THE WAY FORWARD
1. SUSTAINABLE BRICKS
AAC BLOCKS HAVE A POTENTIAL MARKET WORTH $5.5 BILLION
(RS. 330 BILLION) BY 2030
AAC VS. CLAY-FIRED BRICKS
BRICK INDUSTRY IN INDIA
INVESTMENT BOOST IN INFRASTRUCTURE THROUGH HIGHER
PUBLIC FUNDING POSITIVE
FUTURE OF CONSTRUCTION MARKET IN INDIA
LATEST MARKET RESEARCH REPORT (2014) BY PWC HIGHLIGHTS:
GROWTH DRIVERS
INVESTMENT OPPORTUNITIES IN INDIA
FDI POLICIES
FDI POLICY FOR INDUSTRIAL PARKS

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ADVANTAGE INDIA
8 TOP REASONS TO INVEST IN INDIA
1. SIZE OF INDIA
2. ECONOMIC GROWTH
3. DIVERSITY
4. DEMOGRAPHICS
5. HIGH SAVINGS
6. DOMESTIC ECONOMY
7. A ROBUST FINANCIAL SECTOR
8. QUALITY OF INVESTMENT MARKETS
DETAILED EXPORT DATA OF AUTOCLAVED BLOCK
INDIA BRICKS AND BLOCKS MARKET TO 2021 – FOCUS ON AAC BLOCK
SCENARIO OF AAC BLOCK MARKET
OVERVIEW OF CONSTRUCTION INDUSTRY
MARKET SHARE OF DIFFERENT WALLING MATERIALS
COMPOSITION AND CHEMISTRY OF AAC
THE FINAL HYDRATION PRODUCTS ARE THEN PRINCIPALLY:
CALCIUM SILICATE HYDRATE COMPOSITIONS IN AAC
OTHER HYDROTHERMALLY-FORMED MINERALS:
ENVIRONMENTAL BENEFITS OF AUTOCLAVED AERATED CONCRETE
ADVANTAGE AND DISADVANTAGE OF AAC BLOCK
DISADVANTAGES
BRICKS AND AAC BLOCKS
TECHNICAL SPECIFICATION OF AAC BLOCK
TECHNICAL SPECIFICATIONS & COMPARISON BETWEEN BRICK
AND AAC BLOCK
COMPARISION BETWEEN BRICK AND AAC BLOCK
FORMULATION OF AAC BLOCKS
MANUFACTURING PROCESS OF AAC BLOCKS
DETAILS OF DOSING AND MIXING
PROCESS FLOW DIAGRAM
DETAILED MANUFACTURING PROCESS OF AAC BLOCKS
BRIEF PRODUCTION PROCESS:
COAL FLY ASH:
QUICK LIME:
GYPSUM:
CEMENT:
ALUMINUM POWDER PAST:
SCRAPE AND WASTE SLURRY:
BATCHING, MIXING, AND CASTING:
CUTTING AND GROUPING:
AUTOCLAVED AND FINISHED PRODUCT:
THE BOTTOM PLATE RETURNING, COMBINING WITH MOULD AND OILING:
AERATED CONCRETE BLOCK MACHINE

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PRODUCT DESCRIPTION
1. INTRODUCE
2. AERATED CONCRETE COMMON CONCEPTION
3. ADVANTAGES LIGHT WEIGHT
KEEPING TEMPERATURE
HAVE MANY KINDS MATERIAL, HAVE LOWEST WASTE
AVAILABLE ABOVE MACHINE AT:
COMPOSITION OF AAC BLOCK
PLANT LAYOUT
PRESENT MANUFACTURERS/SUPPLIERS OF AAC BLOCKS
SUPPLIERS OF PLANT AND MACHINERY
COMPLETE PLANT AND EQUIPMENTS SUPPLIERS FOR AERATED
CONCRETE BLOCKS (FOREIGN)
SUPPLIERS OF RAW MATERIALS
FLYASH
CEMENT
GYPSUM
LIME POWDER
ALUMINUM POWDER
COMPLETE PLANT AND MACHINERY SUPPLIERS AND TECHNICAL
ADVISORS FOR AAC BLOCKS

APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 200 Cubic Mtrs/Day

Land & Building (3 Acres) Rs. 6.07 Cr
Plant & Machinery Rs. 3.79 Cr
Working Capital for 1 Month Rs.1.33 Cr
Total Capital Investment Rs. 11.40 Cr
Rate of Return 35%
Break Even Point 51%

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