AAC BLOCK MANUFACTURING PLANT

[EIRI/EDPR/4004] J.C.: 2134

INTRODUCTION

AAC blocks are light weight Aerated Autoclave Concrete Block. It is manufactured
through a reaction of aluminium powder and a proportionate blend of lime,
cement, and fly ash or sand. Autoclaved aerated concrete (AAC) is a lightweight
cellular concrete that has been used for more than 80 years. Currently, however,
no good recycling options for AAC from construction and waste exist. During this
process, the hydrogen gas escapes create lots (billions) of tiny air cells, applying
AAC with a strong cellular structure. The hydrogen gas or bubbles cause the
concrete to expand to roughly thrice times its original volume, further
strengthened by high pressure steam curing. The product thus formed is not only
light weight concrete but also has higher compressive strength. AAC is a masonry
material that is lightweight, easy to construct, and economical to transport. AAC
is one of the materials which can cope up with the shortage of building raw
materials and can produce a light weight, energy efficient and environmentally
friendly concrete. This study deals with the manufacturing process of the
autoclaved aerated concrete blocks.

Autoclave aerated concrete blocks are also known as Auto clavedlight weight
concrete(ALC) Autoclaved Aerated Concrete (AAC) is one of the eco – friendly and
certified green building materials.AAC was perfected in the mid of 1920s by the
Swedish architect. It has become one of the most used building materials in
Europe and is rapidly growing in many other countries around the world.
Basically, AAC is a mixture of cement, fly ash, sand, water, and aluminum
powder. When the materials are proportionally weighed, AAC is using no aggregate
larger than sand. Here, Aluminum powder reacts with calcium hydroxide and
water to form H2. The hydrogen gas foams and doubles the volume of the raw mix
creating gas bubbles shown. At the end of the foaming process, the hydrogen
escapes into the atmosphere and is replaced by air. When the airs are removed
from the material, it is solid but still soft. It is then cut into blocks and placed in a
cylindrical chamber for 11-12 hours.

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Figure shows the AAC Block.

During this steam pressure hardening process, when the temperature reaches
190°C (374°F) and the pressure reaches to a maximum limit of 12 bar, sand
reacts with calcium hydroxide to form calcium silicate hydrate, which gives AAC
its high strength and light weight properties, solid but soft in nature. After the
autoclaving process, the material is ready for immediate use on the construction
site. It has become one of the most used building materials in Europe and is
rapidly growing in many other countries around the world. The characteristic of
AAC is helpful in green housings and saves fertile lands and a solution for fly ash
disposal.

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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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 CONTENTS
INTRODUCTION
FIGURE SHOWS THE AAC BLOCK.
AERATED CONCRETE BLOCKS
RAW MATERIALS
ADVANTAGES OF AUTOCLAVED AERATED CONCRETE BLOCKS:
PROPOSAL:
USES AND APPLICATIONS
AERATED CONCRETE BLOCKS
PROPERTIES
COMPOSITION OF PORTLAND CEMENT
ORDINARY PORTLAND CEMENT MAY HAVE THE COMPOSITION AS BELOW
B.I.S. SPECIFICATION
OVERVIEW OF CONSTRUCTION IN INDIA
KEY PLAYERS IN INDIA
NATIONAL
INTERNATIONAL
MARKET OVERVIEW OF AAC BLOCKS
KEY PLAYERS IN THE GLOBAL AAC MARKET
KEY PLAYERS IN THE AUTOCLAVED AERATED CONCRETE MARKET ARE:
STRUCTURE AND DEVELOPMENT
AAC BLOCK: AN EMERGING GREEN BUILDING MATERIAL IN INDIA
COMPARISON BETWEEN AAC BLOCK AND CLAY BRICK
FLY ASH: CHANGING STATUS FROM HAZARDOUS INDUSTRIAL WASTE
TO USEFUL AND SALEABLE COMMODITY
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
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
ADVANTAGES
DISADVANTAGES
BRICKS AND AAC BLOCKS
TECHNICAL SPECIFICATION OF AAC BLOCK

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TECHNICAL SPECIFICATIONS & COMPARISON BETWEEN BRICK
AND AAC BLOCK
COMPARISION BETWEEN BRICK AND AAC BLOCK
FORMULATION OF AAC BLOCKS
OVERVIEW OF AAC BLOCK MANUFACTURING
SEQUENCES IN AAC BLOCK MANUFACTURE
RAW MATERIAL PREPARATION
DOSING AND MIXING
CASTING, RINSING AND PROCURING
DEMOULDING
CURING
PACKAGING AND LOADING
PROCESSING DETAILS OF AAC BLOCKS
STEP 1– RAW MATERIAL PREPARATION-
STEP 2 – DOSING AND MIXING-
STEP 3 – CASTING, RISING AND CURING-
STEP 4 – DEMOULDING AND CUTTING –
MANUFACTURING PROCESS OF AAC BLOCKS
DETAILS OF DOSING AND MIXING
PROCESS FLOW DIAGRAM
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:
COMPOSITION OF AAC BLOCK
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
SUPPLIERS OF FLYASH
SUPPLIERS OF CEMENT
SUPPLIERS OF GYPSUM
SUPPLIERS OF LIME POWDER
SUPPLIERS OF ALUMINUM POWDER
COMPLETE PLANT AND MACHINERY SUPPLIERS AND TECHNICAL
ADVISORS FOR AAC BLOCKS

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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 500 Cubic Mtrs/Day

Land & Building (20000 sq.mt.) Rs. 10.52 Cr
Plant & Machinery Rs. 7.74 Cr
Working Capital for 2 Months Rs. 6.98 Cr
Total Capital Investment Rs. 26.06 Cr
Rate of Return 27%
Break Even Point 55%

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