GENERAL INFORMATION ON

Autoclaved aerated
concrete (AAC)
and its production
(blocks and panels)
8264/11/20
 AAC – ABOUT WEHRHAHN I A1

Thank you for your Interest in Wehrhahn

Equipment and AAC Technology

About Wehrhahn Wehrhahn’s Philosophy:

Wehrhahn - established 1892 - has a proud history

for more than 125 years and specialises on design, Supply always
the best and
manufacture and supply of industrial plants for the
production of construction materials, such as

·  AC (Autoclaved Aerated Concrete

A
Blocks and Panels)
provide great
·
·
Fibre Cement Boards
Dry Mix Mortar value for money
· Lime Processing
A number of satisfied clients operate several
Wehrhahn plants already after having purchased
Wehrhahn Automation the first one.

The automatic division has over 50 dedicated elec-

tric and electronic engineers to provide all types More information required?
of electric control systems for automatic plant op-
eration and data processing. This includes controls, Please contact us:
software, motor control centres, scada systems for · view our website: www.wehrhahn.com
data collections and process optimation. · ask for detailed printed presentation and spec-
ify plant type
Wehrhahn AAC machines and techno­ logy in · ask Wehrhahn for more information - you may
more than 100 AAC plants all over the globe. ask in English, German or Russian
100 plants mean hundredfold experience. A valu-
able asset available to operating clients and new Tel. +49 4221 1271 0
investors. email to: mail@wehrhahn.de

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 AAC – BLOCKS AND PANELS I B1

About AAC (Autoclaved Aerated Concrete) and its use

·  AC is one of the major achievements of the

A ·  AC is a steam-cured mix of sand or pulverized
20th century in the field of wall construction.
It is a revolutionary material offering an unique
combination of high durability and strength, low
weight, unprecedented buildability and superior
ecological green features.
· AAC is a high-quality, load-bearing and ex-
tremely well insulating building material pro-
duced as standard or mega blocks or panels.
A
fuel ash (PFA), cement, lime, anhydrite (gyp-
sum) and an aeration agent. The high-pressure
steam-curing in autoclaves achieves a physi-
cally and chemically stable product with an
average density being approx. one fifth of nor-
mal concrete. AAC comprises myriads of tiny
non-connecting air bubbles which give AAC its
diverse qualities and make it such an excellent
insulating material.

·  AC is a long proven material. It has success-

A
fully been used in Europe since early last cen-
tury and is now among the mostly used wall Excellent heat insulation
building materials in Europe with rapidly grow- 6 times superior to clay bricks.
ing market shares in Asia, the Middle East and
recently America. Fire resistant
more than 4 hours in 9 cm
·  AC is the material of choice for all building
A thickness.
applications, including homes, multi-family,
seniors housing, hotels, commercials, schools, Noise absorption
hospitals, sports halls, etc. - an excellent build- is superior than traditional
ing material for all climatic conditions. It is used clay bricks.
for all walls, external or internal, loadbearing
or non-loadbearing walls, basement walls, in- Easy workability
fill walls to framed structures, party walls, fire and 3 times faster than
break walls, etc. traditional masonry.

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 AAC – BLOCKS AND PANELS I B2

Qualities of AAC Blocks and Panels

Compare always cost and features of a ready- · l

installed wall of AAC with a wood stick wall or a
wall of bricks or concrete blocks. The finished
AAC wall features all benefits, such as:
owest energy consumption per cbm (cft)
during production in comparison to other wall
building materials
· saves resources: 1 m3 (1 cft) of AAC requires
0.2 - 0.25 m3 of raw materials only (0.2 - 0.25 cft)

Ecological Green Economic Qualities

Building Qualities
· energy efficient
· best thermal insulation, 6 to 10 times better
than regular concrete = heat and aircon saver
· environmentally friendly, non-toxic
· unsurpassed fire-resistance
– life saver
– property saver
– insurance cost saver
· excellent sound absorption, ideal for the hotel
industry
· production process develops non-toxic gases
· no waste of raw materials (water, fresh cut-offs,
etc. are all fully recycled into production)
· industrial byproducts like PFA (pulverized fuel ash
= fly ash) of coal fired power plants can be used
and are turned into useful building materials
· recycling of breakage, rejects, etc.
· competitive price = high economy
· high durability = long life, impervious to rot or
pest
· hurricane and earthquake resistant
· increased comfort and functionality of the buil­
d­ing
Physical Qualities
· ood workability, better than wood (can be
g
sawn, drilled, nailed, milled on site)
· large in size, however light weight = consider-
able savings of structural costs (load­bearing
walls, foundation, piling etc.)
· low weight results in easy handling and rapid
laying by the mason
· high load-bearing strength
· dimensional accuracy

Unsurpassed Fire-rating (average)*

Block thickness,     (mm) 50 75 115 150 175 200 240
minimum  (inch) (2) (3) (4 1/2) (6) (7) (8) (10)
Fire-rating (hours)
Non-load bearing wall DIN* 0.5 1 - 1.5 2 3
ASTM** 4 4 4 4
Load bearing wall ˘DIN* 0.5 - 2 1 - 3 1.5 - 2 2 - 3 3

* Ref. DIN 4102-4 ** Ref. ASTM E-119

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More about AAC?
Great Energy Efficiency
High energy efficiency is one of the determining
characteristics of autoclaved aerated concrete.
AAC’s cellular structure gives it a thermal efficiency
10 times higher than that of aggregate concrete
and six times better than clay brick. Consequently,
buildings made of AAC are warm in winter and cool
in summer.
With buildings consuming 40% of global energy,
greater use of AAC, both in construction and reno-
vation, offers an immediate solution to cutting the
energy consumption of residential and non-resi-
dential buildings across the globe.
AAC’s excellent inherent thermal insulation proper-
ties not only reduce the need for heating and cool-
ing, thereby cutting carbon dioxide emissions and
combating climate change, but also make the use
of additional insulation materials unnecessary. EU
insulation requirements can be met by using AAC
alone. By contrast, aggregate concrete, clay brick
and calcium silicate masonry units need to be used
in combination with insulation products, thereby
adding to their cost and environmental impact.
AAC is energy-efficient over its whole life cycle. Its
production requires less energy than other con-
struction materials and its light weight saves energy
in transportation.
Because of the considerable thermal mass AAC
has the ability to store and release energy over
time. An increased comfort in climates where out-
door temperatures fluctuate strongly over a 24 h
period.
Excellent Fire Resistance
Autoclaved aerated concrete provides the highest
security against fire and meets the most stringent
fire safety requirements. Due to its purely min-
eral composition, AAC is classified as a non-com­
bustible building material. It is both resistant to fire
up to 1,200° C and, unlike other construction ma-
terials, heat-resistant.
AAC – BLOCKS AND PANELS I B3
Therefore AAC can be used as a fire wall to prevent
fire from spreading, thereby protecting lives and
economic assets. In principle a fire wall should last
up to four hours, but tests have shown that an 150
mm thick AAC fire wall can resist at least for six
hours. In a real blaze, an AAC fire wall even sur-
vived intact for 120 hours.
Some insurance companies offer reductions in
fire premiums for buildings equipped with AAC fire
walls.
In addition to internal fire walls, constructing outer
walls of AAC contributes significantly to fire safety
as most blazes start outside buildings.
Besides being fire- and heat-resistant, AAC does
not give off any smoke or toxic gases, which can
endanger human life more than fire itself.
Outstanding Structural Performance
Autoclaved aerated concrete is extremely strong
and durable despite its light weight. AAC’s solidity
comes from the calcium silicate that encloses its
millions of air pores and from the curing process in
a pressurised steam chamber (autoclave). Its ex-
cellent mechanical properties make it the construc-
tion material of choice for earthquake zones.
AAC’s light weight ensures that the foundations of
a building are lightly loaded, yet it is strong enough
to bear several floors. It retains its properties for the
entire life of a building. AAC resists wind, rain and
storm and does not decay or rot. In general, chang-
ing outside temperatures cannot damage AAC.
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 AAC – BLOCKS AND PANELS I B4

Resources

Autoclaved Aerated Concrete (AAC) is an environ-
mentally responsible building material that con-
serves material and energy usage in manufacture
as well as energy efficiency of the building.
High Resource Efficiency,
Low Environmental Impact
Autoclaved aerated concrete’s high resource ef-
ficiency gives a low environmental impact in all
phases of its life cycle, from processing of raw ma-
terials to the disposal of AAC waste.
Raw Materials
AAC is made from naturally existing materials
that are found everywhere - lime, fine sand, other
siliceous materials, water and a small amount of
aluminium powder (manufactured from a by-
product of aluminium) - plus cement.
Production
Thanks to continuous efficiency improvements,
production of AAC demands relatively small
amounts of raw materials per m3 of AAC (1 m³
of raw materials results in 5 m3 of finished AAC),
5 times more than any other construction products.
No raw materials are wasted in the production pro-
cess and all production offcuts are fed back into
the production circuit.
The manufacture of AAC requires less energy than
for all other masonry products, thereby reducing
use of fossil fuels and associated emissions of car-
bon dioxide (CO2). Energy is also saved in the cur-
ing process since AAC is steam cured at relatively
low temperatures and the hot steam generated in
the autoclaves is reused for subsequent batches.
Industrial quality water is used and neither water
nor steam are released into the environment. Non-
toxic gases are created in the production process.
Transportation
AAC’s light weight also saves energy in transporta-
tion. As AAC is up to five times lighter than concrete
and two to three times lighter than clay brick CO2
emissions are significantly reduced during trans-
port.
Reuse, Recovery and Disposal
Throughout the life cycle of AAC, potential waste is
reused or recycled wherever possible to minimise
final disposal in landfill.

Consumption of raw materials and energy needed for production of building materials*

1600
1400
1200
1000
800
Consumption of raw
600
materials in kg/m3
400
200 Consumption of
0 energy in kWh/m3
Clay bricks Porous clay Calcium silicate AAC
masonry units masonry units masonry units
p = 1.2 kg/m3 p = 0.8 kg/m3 p = 1.4 kg/m3 p = 0.4 kg/m3

*Source: FeBeCel handbook 2000: Le Béton Cellulaire - Matériau d’ Avenir, p. 32

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 AAC – BLOCKS AND PANELS I B5

Typical Sizes (other sizes possible)

Blocks Megablocks Panels
Length up to 625 mm (2 ft) 500 - 1,500 mm (2 ft to 5 ft) – floor high ≤ 3.50 m ( ≤ 11 ft) as vertical wall panels
– long up to 6.00 m (20 ft) as horizontal or vertical
wall and roof/floor panels
Width ≥ 500 mm ( ≥ 1.5 ft)
Height 125 - 375 mm (5 ’’ to 15 ’’) 375 - 625 mm (15 ’’ to 25 ’’)
Thickness 50 - 500 mm (2 ’’ to 20 ’’) 115 - 500 mm (5 ’’ to 20 ’’) ≥ 100 mm ( ≥ 4 “)

Block Panel

Europe Physical Characteristics (DIN EN)

Strength Class according to DIN *Density *Average Compressive Strength Thermal Conductivity
t/m³ lb/cft N/mm² psi W/mk (BTU in/ft²h°F)
PP2-035 > 0.30 to 0.35 > 18 to 22 2.5 360 0.09 0.63
PP2-040 > 0.35 to 0.40 > 22 to 25 2.5 360 0.10 0.69
PP2-050 > 0.45 to 0.50 > 28 to 31 2.5 360 0.14 0.97
PP4-055 > 0.50 to 0.55 > 31 to 34 5.0 725 0.14 0.97
PP4-060 > 0.55 to 0.60 > 34 to 37 5.0 725 0.16 1.11
PP6-065 > 0.60 to 0.65 > 37 to 41 5.0 or 7.5 725 or 1,090 0.18 1.24
PP6-070 > 0.65 to 0.70 > 41 to 44 5.0 or 7.5 725 or 1,090 0.18 1.24
Note: The compressive strength and density to be achieved depend on the raw *Ref. DIN EN 771-4 and DIN 20000-404
material quality and on the mix formula.

USA Physical Characteristics (ASTM: C 1693)

Strength Class Nominal Dry Density Compr. Average Thermal Resistance
Bulk Density Limits Strength Drying (8 in, wall thickness)**
psi (MPa) Shrinkage R-value
lb / ft³ (kg / m³) lb / ft³ (kg / m³) min (%) hft² °F/BTU
25 (400) 22 - 28 (350) - (450) 290 (2.0)
AAC-2 11.5 - 9.2
31 (500) 28 - 34 (450) - (550)
31 (500) 28 - 34 (450) - (550) 580 (4.0)
37 (600) 34 - 41 (550) - (650)
AAC-4 9.2 - 7.4
44 (700) 41 - 47 (650) - (750) ≤ 0.02
50 (800) 47 - 53 (750) - (850)
37 (600) 34 - 41 (550) - (650) 870 (6.0)
AAC-6 44 (700) 41 - 47 (650) - (750) < 7.4
50 (800) 47 - 53 (750) - (850)
Ref. ASTM: C 1693 **including air film coefficients

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 AAC – RAW MATERIALS QUALITY I C1

Raw Materials Quality

SAND PULVERIZED FUEL ASH (PFA)
SiO2 > 75 % SiO2 > 45 %
Al2O3 < 10 % Al2O3 10 - 30 %
Fe2O3 < 3% Fe2O3 < 10 %
CaO < 5% CaO < 5%
MgO ≤ 2% MgO ≤ 2%
Na2O + K2O < 2% Na2O + K2O < 2%
SO3 < 3% SO3 < 3%
Loss on ignition < 5% Loss on ignition < 5%
Chloride < 0.05 % Chloride < 0.05 %
Silt (volume) < 3% Sulphide ≤ 0.1 %
Particle size 0 - 2 mm
Humidity ≤ 6% QUICK LIME
SiO2 < 5%
CEMENT
Al2O3 + Fe2O3 < 2.5 %
Standard Portland cement according to DIN EN 197-1,
CaO total > 90 %
preferably CEM I/42.5 R or better
CaO free ≥ 85 %
Tricalcium Silicate C3S > 50 %
MgO ≤ 2%
Calcium Aluminate C3A 7 - 10 %
Na2O + K2O < 1.5 %
Calcium Alumino-ferrite < 12 %
C2 (A,F) SO3 ≤ 0.3 %
Spec. Surface (Blaine) 3,000 - 4,200 cm²/g Loss on ignition < 5%
Na2O + K2O < 1% Residue: 90µm ≤ 8%
Sulphide ≤ 0.1 % Slaking time (t 60) prefer- 4 - 14 min
ably to DIN EN 459 Part 2
MgO ≤ 2%

FRESH WATER (= Plant Feeding Water) GYPSUM

Drinking or ground water. CaSO4 > 70 %
MgO ≤ 2%
ALUMINIUM Chloride < 0.05 %
Type and recommendation for supply depend on raw Particle size (before grinding) ≤ 30 mm
materials and mix formula
Residue: 90 µm (ground) ≤ 10 %
metal content approx. 95 % (powder)
approx. 80 % (paste)
REINFORCEMENT STEEL
Hot rolled carbon steel wire bars, minimum yield strength
ANHYDRITE 500 N/mm2.
CaSO4 > 90 %
MgO ≤ 2% VARIATION OF RAW MATERIALS
Chloride < 0.05 % Above basic requirements for raw material qualities are
Residue: 90 µm (ground) ≤ 10 % ideal figures. In some cases raw materials may vary from
these figures, but still marketable Autoclaved Aerated
Concrete (AAC) can be produced. The final basic data, lay-
REINFORCEMENT COATING MATERIAL
out and the equipment to be used should then be further
Water-based dipping paint. discussed.

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 AAC – RAW MATERIALS QUALITY I C2

Laboratory Tests

As a first step an analysis of the available raw ma-

terials should be sent to Wehrhahn. Wehrhahn may
ask for raw material samples for further laboratory
tests on suitability (laboratory tests are charged at
cost).

An efficient laboratory should be part of every AAC factory

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 AAC – FEASIBILITY FIGURES I D1

Minimum Required Area for Factory and Buildings (approximately)

Plant capacity 300 m³ 600 m³ 1,400 m³ 2,000 m³ 1,000 m3

per day (10,500 cft) (21,000 cft) (49,000 cft) (70,000 cft) (35,000 cft)
Factory area (total) m² 20,000 25,000 35,000 45,000 30,000

sqyd 24,000 30,000 42,000 53,600 36,000

thereof:
– Production building SMART SMART PLUS superSMART ecoPLUS
(minimum)
m² 3,000 4,500 6,500 8.500 5,000

sqyd 3,600 5,400 7,800 10,200 6,000

– Storage area for AAC m² 5,000 - 10,000 10,000 - 15,000 12,000 - 18,000 17,000 - 25,000 11,000 - 16,500

sqyd 6,000 - 12,000 12,000 - 18,000 14,400 - 21,600 20,000 - 32,500 13,200 - 19,800
+ Auxiliary buildings

Staff Requirement (approximately)

Block production Staff required (in total per day)

1 shift operation 2 - 4 operators
(1 x 8 h) + ? for 24 h autoclave supervision
+ 2 helpers in the yard
2 shifts operation 4 - 8 operators
(2 x 8 h) + ? for autoclave night shift supervision
+ 3 helpers in the yard

3 shifts operation 6 - 12 operators

(3 x 8 h) + 6 helpers in the yard

additionally, for panels only (per shift) 5 - 10 operators and helpers
Laboratory / Quality control 1 engineer or chemist

Maintenance 1 mechanic/electrician

Administration 1 plant manager

1 finance
1 sales manager
? sales
1 (2) forwarding clerk
1 (2) secretary

Spare parts approx. 1 - 3 % of machine value per year

Installation and commissioning 10 - 15 % of machine value
Manpower (except administration) 0.15 - 0.3 man-hour/m³ (depending on capacity and automation)

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 AAC – FEASIBILITY FIGURES I D2

Consumption of Raw Materials and Energy

Approximate consumption figures for the production of per 1 m³ at 500 kg / m³ dry density:
aerated concrete
· sand 310 - 320 kg
· cement 80 - 100 kg
· lime 40 - 60 kg
· anhydrite (gypsum) 10 - 20 kg
· aluminium (paste) 0.5 - 0.6 kg
· production water 250 kg

alternatively (instead of sand formulation)

· PFA (pulverized fuel ash) 320 - 330 kg
· cement 80 - 100 kg
· lime 40 - 60 kg
· anhydrite (gypsum) 0 - 10 kg
· aluminium (paste) 0.5 - 0.6 kg
· production water 230 kg

Other consumption per 1 m³ at 500 kg / m³ dry density:

· water for steam 140 kg
· heating value (is equivalent to) 70 - 110 kWh

· fuel oil 7 - 10 kg

· (or alternatively gas) 8  - 12 m3
· electric energy (for PFA/ sand process) (16 / 20 kWh)
· mould oil 0.15 ltr
· cylpebs or grinding balls (not required for PFA) 1 kg
· plastic film (packaging) according to pack size
· straps according to packing
· wooden pallets multiple use
· cutting wires 1 set per day

additionally, for panels only

PANELS LOAD-BEARING: per 1 m³ at 500 kg / m³ dry density:
· steel for reinforcement 15 - 30 kg (depending on
· coating (for reinforcement) 0.5 - 1 kg the type of panel)

PANELS NON-LOAD BEARING (upright wall panels):

· steel for reinforcement ~ 3 reinforcement bars/panel
· coating (for reinforcement) is not required

Note: The consumption figures give only an indication and are based on high quality raw materials which comply with the upper range of Wehrhahn’s
raw material specification.

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AAC Production Process
The following is a description of a typical process
of how to produce Autoclaved Aerated Concrete
(AAC) blocks and panels on Wehrhahn machinery
and equipment, starting with the supply, prepara-
tion, dosing and mixing of raw materials, cutting,
autoclaving of the blocks and panels up to packing
of the finished AAC product.
This description is representative, however, not nec-
essarily applicable in detail for all Wehrhahn AAC
plants. But major differences between the various
Wehrhahn AAC plant types (e.g. SMART and PLUS)
are described. The design of each Wehrhahn AAC
plant is individually and specifically made for any
demand: The automation may vary as well as the
scope of equipment to be incorporated or the used
raw material. Please take this description as a gen-
eral introduction and guideline.
Rubber lined sand mill for wet grinding
AAC – PRODUCTION PROCESS I E1
I. Raw Material
Sand / PFA (Silica, SiO2)
SiO2 is commonly used in form of silica sand or PFA
(Pulverised Fuel Ash).
Sand
Sand with high silica content is required. It is stored
in the storage building or in silo - depending on cli-
mate.
PFA (Pulverized Fuel Ash)
Dry fine PFA comes in trucks and is blown into
the PFA silo or dumped into the PFA receiver tank
which is filled already with the required quantity of
water, then mixed by the powerful stirrer to a pro-
duction slurry of the required density.
Silica Grinding
Normal silica sand (or coarse PFA) require wet
grinding in a rubber lined sand mill (overflow ball
mill). Then the fine silica becomes a slurry.
The production slurry from the pump sump of the
sand mill is pumped to one of the slurry tanks.
These slurry tanks are equipped with agitators to
keep the slurry in suspension.
Sand and returns slurry storage: Wehrhahn’s agi-
tators guarantee consistent density from top to
bottom
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II. Raw Material
Lime, Cement and Returns
Lime and Cement
Lime and cement are supplied by bulk trucks or rail
wagons and blown into separate silos.
The storage capacity of the silos depends on the
supply conditions and should be for at least 1.5 up
to 10 days.
Slurry Tanks
Returns slurry results from disperged cut-offs
(trimmed-off oversize of the cake in the cutting line).
It is stored in slurry tanks similar to the sand slurry.
Returns are a valuable raw material with positive
influence on the production process.
Raw material silos: Recommended storage for at
least 1.5 to 10 days
Mixing tower with WECOMIX computerized dos-
ing: reliable, fast and efficient
AAC – PRODUCTION PROCESS I E2
III. Dosing and Mixing
WECOMIX  – Computerized Dosing
Wehrhahn’s fully automatic control system WECO-
MIX weighs all materials assisted by a computer
operating to high accuracy according to a ‚self-
learning’ system. The system is self-adjusting to
consistent temperature and to consistent water
content in the mix.
Wehrhahn Automation
a division of Wehrhahn, designs state of the art
dosing systems „WECOMIX“.
Cakes
Aerated concrete or AAC (Aerated Autoclaved Con-
crete) is produced in moulds in form of „cakes“.
Consequently the dosing and mixing is batchwise.
Raw materials are automatically dosed into the
mixer, well blended and then poured into moulds
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Lime and Cement
Lime and cement are both individually dosed by
precision dosing screws into the batcher(s).
Water Content
The total weight of water is important in the mix for-
mula. Based on the required density the computer
calculates the water already contained in the slur-
ries and adjusts the water batcher to the required
residual water.
Slurries
The production slurry is pumped to the slurry
batcher and dosed as first component. Returns
slurry is pumped into the batcher and dosed as
second component. The slurries are dosed in
quantities which contain exactly the weight of dry
material required by the mix formula. That means
the actual density of the slurries is calculated as the
base. The slurry quantity is quickly new designed
for each mix-batch by Wehrhahn WECOMIX-sys-
tem and automatically adjusted in case of differ-
ences in the slurry density. This guarantees a con-
sistent quantity of dry materials at all times.
Temperature
The mix temperature is important to get consis-
tent uniform cakes.
The temperatures of all materials are measured to
receive the actual heat content. This will be com-
pared with the necessary heat content for the cake
to rise to the required height. The preselected slur-
ry temperature is achieved by adding hot and/or
cold water which is automatically adjusted by the
WECOMIX computer.
Dosing screw conveyors and balances
AAC – PRODUCTION PROCESS I E3
Aluminium
Fine aluminium particles are used to create the hy-
drogene bubbles forming the porous structure of
AAC. Aluminium is mixed with water in one of the
aluminium slurry mixers. This slurry is pumped to
the aluminium slurry batcher above the main mixer.
(In some factories aluminium is dosed batchwise.)
Mixing Sequence
· starts by dropping the slurries into the main
mixer
· cement or lime or both together and the resid-
ual water are added (details depend on the mix
formula and the raw material quality)
· preselected main mixing until a good blend is
achieved. At the end of the main mixing cycle,
aluminium slurry is added to the mixer.
· followed by „cleaning water“ from the alumini-
um dosing equipment
Once the aluminium is well distributed in the slur-
ry, the mixer discharges the mixed slurry into the
mould.
Wehrhahn’s advanced WECOMIX software: Au-
tomatical redesign of each batch based on tem-
peratures and densities of the components
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IV. 1 Precuring
The filled mould is moved by the intelligent transfer
car to one of the precuring tracks in the heated
precuring chamber. The moulds wait whilst the
cake is rising caused by the gas development from
the aluminium reaction and is stiffening due to the
reaction of the binders.
Once the cake has reached the required height
and sufficient hardness for cutting, the mould is
pulled from the precuring track and transferred
onto the track of the cutting line.
The mould wheels to the mould opening machine
where it is unlocked and all walls are turned down
by 90°.
The flat opened mould is pushed into the
Wehrhahn tilting machine where the cake is tilted
upright for transport through cutting and autoclave
hardening.
Tilting machine: The cake is tilted into upright po-
sition to allow high precision cutting with shortest
possible cutting wires and to allow the free fall of
the cut-offs into the returns slurry system
Automatic mould transport from mixing through
precuring, cutting, mould oiling and back to mixing
AAC – PRODUCTION PROCESS I E4
Once the upright standing cake is out of the tilt-
ing machine, the tilting machine tilts back so that
the empty mould can leave the tilting machine and
can pass through the cleaning and oiling machine
to the mould closing machine.
The closing machine turns the side walls up and
the locks are closed. The mould is now ready to
receive the next mix (cake) and is wheeled under-
neath the mixer.
IV. 2 Mould Transport
All Wehrhahn plants feature automatic mould
transport from mixer through precuring - tilting ma-
chine - cleaning and oiling. The mould walls open
flat for easy cleaning and oiling.
Intelligent mould transfer car: Rapid transport
through the pre-heated precuring chamber
Automatic mould transport system
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 AAC – PRODUCTION PROCESS I E5

Wehrhahn’s unique automatic oil saving, mould cleaning and oiling

Wehrhahn moulds: Four-walls-open-design, insulated, easy to clean, perfect to oil

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 AAC – PRODUCTION PROCESS I E6

V. Cutting

The trolley of the cutting line transport system picks
the cake for cutting.
The Wehrhahn side trimmer cuts the vertical sides
of the cake to achieve the block length (or panel
width) and profiles tongue and groove, if required.
The thickness cutter slices the cake precisely to
the required block or panel thickness.
The cutting wires of the thickness cutter are step-
wise off-set to minimize cutting stress in the green
cake.
Extremely short and thin cutting wires improve
thickness accuracy.
The cross cutter cuts vertically the block height
(or panel length). Precise block height is the most
important feature for thin bed laying.
The cut cake remains on the autoclave pallet or
autoclave grid and is ready to be placed onto the
autoclave trolley by the loading machine.
Patented Bed Remover =
Zero System Waste
All Wehrhahn plants feature removal of fresh bot-
tom cut, prior to autoclaving. PLUS and super­
SMART use Wehrhahn’s patented bed remover to
turn the cake flat and to remove the fresh bottom
cut for immediate recycling. The Wehrhahn bed re-
mover amortizes within short.
ecoPLUS, SMART and ecoSMART plants use the
patented universal tilting machine a second time to
remove the bed.

Top side cut-offs are removed by a vacuum suc-

tion machine and dropped into the returns (fresh
cut-offs) mixing system. Other cut-offs from the
four vertical sides have fallen into the returns mix-
ing system underneath.

Conveyors bring the returns into the mixing tank.

Once the returns mixing tank is full and the slurry
has the required density it will be pumped into one
of the storage tanks for returns slurry.

Side trimmer: For clean cut and tongue and

groove profiling

Handholds facilitate lifting of blocks by the ma- Cross cutter: Close tolerances due to shortest
son, a tremendous benefit for heavier blocks cutting wires; block height or panel length are cut
in the cross cutter

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 AAC – PRODUCTION PROCESS I E7

Super Smooth Surfaces

All SMART plants feature super smooth surface Market requirement is to avoid plastering and to
cutting as an interesting option for panel produc- apply paint or wall paper directly to the AAC panel
tion. without any prior treatment.

Thickness cutter for highest precision by shortest possible cutting wires

Handhold cutting machine Wehrhahn’s patented Bed Remover amortizes

within short

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VI. Autoclaving and Transport
The loading machine loads a number of cut cakes
on autoclave pallets or grids, with the fresh cakes
onto autoclave trolleys. These go on storage tracks
into a covered and heated room in front of the au-
toclaves.
A full set of autoclave trolleys is wheeled into the
autoclave. After closing the door the autoclave is
set under vacuum.
The steam hardening process starts by feeding
steam and gradually increasing the pressure up to
approx. 12 - 13 bar overpressure (188 psi) equiva-
lent to 194° C (381° F). This pressure / temperature
is kept for several hours for hardening and forming
calcium silicate hydrates.
At the end of the autoclave cycle the pressure /
temperature is gradually reduced to ambient pres-
sure. The temperature difference - especially at the
Vertical autoclaving at PLUS and ecoPLUS Wehrhahn autoclave pallets: Match the
block length or panel width; facilitate precise cutting, save space at autoclaving
AAC – PRODUCTION PROCESS I E8
beginning of the autoclave cycle - causes conden-
sate. The condensate is automatically drained by
the autoclave drainage system.
With continuously rising energy cost, the conden-
sate water should be collected, the heat used and
then the condensate water can be cooled for reuse.
The whole autoclave cycle is controlled by
Wehrhahn’s computerized autoclave control
WACO operating with special motorised valves.
After autoclaving the door opens. The autoclave
trolleys are one by one pulled out by the transfer
car #3 and pushed to an extra track ready for un-
loading.
Usually there are approx. 2 autoclave cycles in
24 hours. The autoclaves should always run 24 h/
day, even if the production of the factory runs on
less hours.
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 AAC – PRODUCTION PROCESS I E9

Fully automatic transfer car #3 with autoclave trolley push-pull: Automatic charging, smooth transport

Usually there are 2 autoclaving cycles in 24 hours

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VII. Steam Boiler Plant
Energy Efficiency
With rising energy cost and to conserve environ-
ment all heat must be used to optimize energy ef-
ficiency.
The steam boiler plant for approx. 16 bar (230 PSI)
with burner, chimney, feed water preparation, heat
exchange, piping system, electric control and more
accessories supplies steam for:
· autoclaving
· hot water of section III (dosing and mixing)
· heating of the precuring chamber (section IV)
· heating of the waiting area in front of the
autoclaves (section VI)
· the heating of the factory buildings
Part of the heat can be taken from the heat con-
tained in the condensate.
Condensate recycling system on Wehrhahn plants
Efficient steam boiler plant
AAC – PRODUCTION PROCESS I E10
VIII. Handling, Sorting and
Palletizing
The autoclave trolleys with the autoclaved cakes
on autoclave pallets are moved to the loading / un-
loading machine which takes each autoclave pallet
with the hardened cake from the autoclave trolley
and places it onto the autoclave pallet transport.
When all cakes are unloaded the empty autoclave
trolley is grabbed by the loading machine and
placed onto a storage track in front of the autoclave
to be reloaded with fresh cakes on autoclave pallets.
The hardened cake on the autoclave pallet moves
into the separating machine where all layers are
separated one by one.
The sorting and palletizing machine removes the
complete cake from the autoclave pallet and places
it onto wooden pallets. The sorting and palletiz-
ing machine can also sort two or more different
block thicknesses, a tremendeous benefit of the
Wehrhahn system.
The empty autoclave pallet is cleaned and returns
to the autoclave pallet feeder at the tilting machine.
The blocks on the wooden pallets move forward
by the pack transport to the film wrapping machine
and further out.
A forklift brings the packs to the storage yard.
Truck transport: Large volume, low weight
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 AAC – PRODUCTION PROCESS I E11

Automatic loading machine: Universal for green

and hard cakes

Automatic highly effective separating machine of

the PLUS systems

Film wrapping: Securing, protecting and advertising

Packing: Automatic sorting and palletizing

Sorting: The PLUS system

facilitates sorting of differ-
ent block thicknesses for
separate palletizing

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 AAC – PRODUCTION PROCESS I E12

IX. Panel Production (if applicable)

Panel production is similar to block production. The The assembled reinforcement cage is coated for
significant difference is the steel reinforcement re- rust protection by dipping and drying individually or
quired to provide the panels with sufficient strength. as a complete mould size unit.

Reinforcements are manufactured in a separate sec- The finished reinforcement cage is fixed to the
tion of the AAC production plant unless purchased assembly frame.
ready-made from sub-suppliers (outsourced).
The assembly frame with the required number of
For load-bearing panels two mats are welded to assembled and coated reinforcement cages for
cages by using spacers with special holes, which one cake is fixed into the empty mould.
snap into proprietary fixing pins.
The further process is similar to the block produc-
The wire straightening and cutting machine uncoils, tion: filling the mould, precuring, cutting etc., except
straightens the steel wire and cuts it to the required that the reinforcement assembly frames together
lengths for the longitudinal bars and cross bars. with the holding pins have to be pulled out of the
cake prior to cutting.
The mat welding machine automatically or manu-
ally spot-welds the cross bar to the longitudi-
nal bar to form mats corresponding in width and
length to the desired panel size and strength.
They are then welded to cages.

Automatic mat welding

Reinforcement coating: Effective rust protection, Typical reinforcement cage coated with anticorro-
easy automatic operation sion material

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 AAC – PRODUCTION PROCESS I E13

Assembly frame inserter: Cages are exactly posi-

tioned in the mould

Panel packing: After autoclaving panels are destacked and singled for quality control, and if required, dry
cut and stacked or bundled for further handling and storage

Profiled floor slabs and wall panels: Attractive business with first class products

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 AAC – PLANT TYPES I F1

Wehrhahn’s 5 Plant Concepts all Featuring

Zero System Waste

Wehrhahn’s advanced, modular and versatile plant systems allow investors to select the best suited plant from
a choice of 5 AAC plant systems all formed by repositioning and combining the proven Wehrhahn machines
in different sequences and positions.

Wehrhahn Plant SMART ecoSMART superSMART PLUS ecoPLUS

Systems
capacity (m³ / d) 300 - 1.250 200 - 500 up to max. 2.000 up to max. 1.400 up to max. 950

(cft / d) (10,500 - 44,000) (7,000 - 17,500) (up to max. 70,000) (up to max. 50,000) (up to max. 33,500)
cake size (m) 6.0 x 1.2 x 0.625 -- -- 6.0 x 1.2 x 0.625 6.0 x 1.2 x 0.625
or
6.0 x 1.5 x 0.625 4.0 x 1.5 x 0.625 6.0 x 1.5 x 0.625 -- --
(ft) (20 x 4 x 2) -- -- (20 x 4 x 2) (20 x 4 x 2)
(20 x 5 x 2) 12 (13) x 5 x 2 (20 x 5 x 2) -- --
cake position at vertical vertical vertical vertical vertical
cutting
cake position at flat flat flat vertical vertical
autoclaving
number of tilting 1x 1x 2x 2x 1x
machines
(patented)
zero system-
waste process / yes yes yes yes yes
bed remover
panel production yes yes yes yes yes
possible
super smooth yes yes yes no no
surface cutting
modular system,
when starting at
low capacity ex- yes yes yes yes yes
tension to higher
capacity possible
Note: All Wehrhahn plants feature high-precision cutting in upright cake position which allows highest cutting accuracy and efficiency.

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1) Wehrhahn SMART
(flat cake autoclaving)
· Capacities: 300 to 1.250 m³/day
(10,500 to 44,000 cft/day)
· The choice for investors looking for small to
 · the choice for less investment
middle-size plants without compromising on
top-class quality and precision cutting.
· The choice for investors still developing their
market place and to grow as the market de-
mand grows.
Qualities of the SMART Plant:
· The cake - still flat in the mould  –  is 90° tilted
upright by Wehrhahn’s patented universal tilting
machine.
· The cake rests on a separate cutting pallet.
· The upright cake is moved forward through the
cutting line and is precisely cut as well as milled
to the required dimensions.
· The cut and milled cake returns to the universal
tilting machine and is tilted back flat onto the
autoclave grid.
· The bottom cut is removed in fresh condition for
immediate recycling.
· Autoclave grids with cakes are loaded on auto-
clave trolleys.
· Autoclaving as a flat cake (blocks stand upright)
reduces sticking.
· Palletizing:
– palletizing can easily be arranged with fork lift
and turn grab.
– automatic palletizing is an available option.
· Panel production is an available option.
AAC – PLANT TYPES I F2
2) Wehrhahn ecoSMART
… just another innovative variation of Wehrhahn’s
well proven SMART.
· Capacities: 200 to 500 m³/day
(7,000 to 17,500 ft³/day)
Difference to SMART Plant:
ecoSMART is the compact SMART feasible for the
developing market place, featuring:
· shorter cake length and less autoclave diameter
· modified mould design
· less investment
· drastically reduced building length, width and
height (1.800 - 2.200 m²) (19,000 - 23,500 ft²)
· capacity: 200 - 500 m³ (7,000 - 17,500 cft/day)
3) Wehrhahn superSMART
(flat cake autoclaving)
·  apacities: 1.100 - 2.000 m³/day
C
(38,000 to 70,000 cft/day)
· Similar to SMART (flat cake)
· The choice for mature markets with demand for
highest possible production capacities and at
feasible investments.
· Typically equipped with green cake separator to
separate prior to autoclaving.
Difference to SMART Plant:
· There are two tilting machines to speed up
cycle time:
– first to enter the cutting line.
– second to leave the cutting line.
· Automatic packing is added.
Loading machine with automatic stacking pin
inserter (super SMART)
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 AAC – PLANT TYPES I F3

4) Wehrhahn PLUS 5) Wehrhahn ecoPLUS

(vertical cake autoclaving)
· Capacities: 600 - 1.400 m³/day · Capacities: 500 - 950 m³/day
(21,000 to 50,000 cft/day)
· The choice for the investor of high duty produc-
tion capacities.
Qualities of the PLUS Plant:
· W ehrhahn’s mostly sold well-proven AAC plant.
· Economic investment for high duty production.
· The cake - still flat in the mould  –  is 90° tilted
upright by Wehrhahn’s patented tilting machine.
· The cake rests on a separate autoclave pallet
(through cutting, autoclaving, separating) and
not on the mould wall.
· The upright cake is moved forward through the
cutting line and is precisely cut and milled to the
required dimensions.
· The cut and milled cake on the autoclave pallet
continues to Wehrhahns patented bed remover.
· The cake is tilted flat, the bottom cut is removed
in fresh condition for immediate recycling and
the cake is tilted back into upright position for
autoclaving.
· The Wehrhahn PLUS facilitates sorting and pal-
letizing as the blocks lay already horizontal.
(vertical cake autoclaving)
(17,500 to 33,500 cft/day)
· The choice for middle-size capacity and limited
space available using the proven Wehrhahn cut-
ting technology.
Difference to PLUS Plant:
· The universal tilting machine is used twice (tilt-
ing into cutting and tilting to remove bottom cut).
· The upright cake is moved forward through
cutting.
· The cut and milled cake returns to the universal
tilting machine.
· The cake is tilted flat and the bottom cut is re-
moved in fresh condition for immediate recy-
cling.
· The cake is tilted back into upright position for
autoclaving.

Wehrhahn gladly assists investors

with advice to select the plant best
suitable for their needs.

Please contact us!

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 AAC – WEHRHAHN SERVICES AS YOUR PARTNER DURING PLANT CONSTRUCTION
Wehrhahn –
Your Partner in AAC Production
Wehrhahn is a privately owned family business for
more than 125 years.
Wehrhahn has always specialized in equipment
and complete plants to produce lime- or cement-
based building materials such as aerated con-
crete blocks and panels.
During the past 35 years Wehrhahn has concen-
trated on the aerated concrete industry  – and with
more than 100 manufacturing plants purchased
by clients across the world Wehrhahn has become
the global leader to supply state of the art manu-
facturing plants and technology for AAC.
Additional Wehrhahn’s high-tech specialities are
· fibre-cement sheets
· dry mortar plants
· lime processing
The Wehrhahn Group provides
· plant design incorporating the latest technology
· innovative machinery and equipment
· s pecialized engineers for installation and start-up
· expert assistance in production technology
· laboratory services (quality control of raw
materials and AAC products including
XRD [X-Ray Diffraction] analyses)
· professional support in marketing and
application
· dry mortar plants producing glue type thin-set
I G1
Based on the exchange of experience with world-
wide clients and own research works Wehrhahn
permanently improves technology and design
of the production plants.
Wehrhahn is a group of companies combining the
full service from the initial plant design up to com-
missioning, start-up of the plant and after-sale-
service.
As a part of Wehrhahn’s corporate philosophy
to supply buyers with the best and most reliable
equipment all machines are completely assem-
bled and painted at Wehrhahn and – as far as pos-
sible – dry-tested.
They are then partly disassembled for transport.
This results in short installation time at the site.
mortar for AAC or wall tiles, skim coat, plasters or
just premixed dry mortar in consistent quality
In close cooperation with world-wide clients
Wehrhahn offers training of the buyer’s engineers
in plants producing with Wehrhahn machines. In
addition, and possibly more important, Wehrhahn
provides training at site and valuable assistance
on production questions.
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 AAC – RELATED PRODUCTS: FIBRE CEMENT BOARDS
Fibre Cement Sheet Production Plant
Fibre Cement Sheets in today’s
Market Place
Fibre cement –  especially flat sheets  –  are used for
standard and innovative architectural solutions in a
large variety of different applications.
1. Façades
2. Interior construction = dry walls
3. Interior construction = architectural design
4. Floors
5. Fences
6. Roofing
Features
Fibre cement sheets are a world wide used envi-
ronmentally friendly cementitious building material.
Fibre cement is water resistant, fire proof, flexible,
can be nailed or drilled and is long lasting.
Fibre cement sheets are produced as
· large size sheets up to 2.5 (3.0) x 1.25 m
(6 - 12 mm thick)
· sidings up to 3.6 m long x approx. 200 mm
wide (8 - 10 mm thick)
· small size slates for roofing (4 - 6 mm thick)
Dry walls on metal studs
I H1
Raw Materials
Fibre cement consists of natural and / or man
made fibres embedded in a cement based matrix.
· cellulose or synthetic fibres for reinforcement
· cement
· silica sand (when autoclaving)
· water
Façades
Façade sheets are a durable alternative to stucco
and
· can be applied even during heavy frost when
stucco cannot be applied
· can cover and protect exterior wall insulation
· are used for exterior wall cladding of cottages
and townhouses, beautiful (naturally looking)
wood grain planks (sidings) and provide archi-
tectural beauty
For the surface treatment of fibre cement, many
options and colours are applicable.
Easy installation of fibre cement façades
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 AAC – RELATED PRODUCTS: FIBRE CEMENT BOARDS I H2

Building with Fibre Cement Sheets

Weatherproof fencing Home with fibre cement sidings Wood grain siding

Architectural beauty with weatherproof fibre cement sheets

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 AAC – RELATED PRODUCTS: DRY MIX MORTAR I H3

Dry Mix Mortar Production Plant

Upgrade your product portfolio – high quality AAC
requires high quality thin bed ( Dry Mix Mortar)

What is Dry Mix Mortar? Wehrhahn Supplies

· Dry mortar is a well-mixed blend of various raw
materials and is supplied as a ready mix in bags
or in bulk, ready to be stored and to be used
at site.
· Stringent regulations to control and guarantee
consistent quality of mortar have encouraged
contractors in Europe not to rely on „home-
made“ mortar.
What are the Benefits
of Dry Mix Mortar?
Wehrhahn supplies dry mortar plants suitable for
practically all demands, such as:
· dry mix mortar and glue for aerated concrete
blocks
· skim coat for aerated concrete blocks
· render/stucco and plaster for internal or exter-
nal walls
· decorative stucco
· self-levelling floor screed for easy and accurate
floor making
· adhesive for wall tiles

·  he easiest and safest way to ensure consis­

T Capacities of Dry Mix Mortar
tently high quality is pre-fabricated dry mix mor- Production Plants for Glue,
tar.
Plaster and Stucco
· Quality variations due to variations of raw mate-
rials or poor on job-site mixing can be excluded · Standard Plant: Capacity 10 - 50 t/h
and consequently cannot be contributed to the · Mini Plant: Capacity 3 - 5 t/h
contractor. The quality is controlled by the mor-
tar producer and guaranteed by a sophisticated Production Know-how and
dry mortar mixing plant. Mix Formula
· Only dry mix mortar plants can fulfill the in-

creased demand of dry mortar in Europe. The The mix formulae can individually be developed in
use of prefabricated dry mortar on site keeps cooperation with a world-wide leading dry mortar
the contractor competitive. On site mixing has producer.
practically disappeared.
· The same tendency is predicted world-wide
 Typical Raw Materials
over the next years as due to some recent con-
struction disasters the demand for quality con- · dried sand or alternatively limestone powder
struction is expected to rise rapidly. · AAC hard scrap
· cement
How to apply Dry Mix Mortar · hydrated lime
· various additives depending on the application
·  ry mortar is simply mixed with water on the
D to get the mortar easier to use and to get a bet-
job-site. Application both, manually or auto- ter quality
matically with rendering/plastering machines is
possible.
· Masons appreciate the consistent quality of
 Dry mix mortar is for the wall builder what ready-
bagged dry mortar giving always the same mix concrete is for the concrete user.
application conditions. – the best value –

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 AAC – WORLD-WIDE REFERENCES I I1

Wehrhahn
Equipment and AAC Technology

Some of the World-Wide References

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 AAC – WORLD-WIDE REFERENCES I I2

Country Buyer Supplied Equipment

UZBEKISTAN OOO “East Mining Invest“ Block Production

Akhangaran City
RUSSIA ZAO IST Kazbek Block Production
Chiri-Yurt, Region Shalinskiy
CHINA Jingneng Power Co., Ltd. Block and Reinforced Panel Production
Beijing
RUANDA Remote Group Block Production
Kigali
RUSSIA ZAO IST Kazbek Dry Mortar Production
Chiri-Yurt, Region Shalinskiy Quick Lime Production

UKRAINE AEROC Extension of Block Production

Obukhov, Region Kiev Obukhovskiy zavod poristykh izdeliy

GREAT BRITAIN H+H UK Ltd. Block Production

Borough Green (fly ash)

GERMANY Xella Deutschland GmbH Equipment for Unloading and Packing

Cologne
MALAYSIA Stärken AAC Sdn. Bhd. Block Production
Ipoh
INDONESIA P.T. Broco Aerated Concrete Industries Reinforced Panel Production
Tangerang
RUSSIA OOO “Eko-Zoloprodukt Ryazan “ Reinforced Panel and Reinforced Lintel
Region Ryazan Production

UKRAINE AEROC Upgrading of Transfer Car for Block

Obukhov, Region Kiev Obukhovskiy zavod poristykh izdeliy Production

GERMANY Porit Emsländische Baustoffwerke Panel Sorting and Palletizing Plant

Surwold
GERMANY Xella Porenbeton AG Equipment for Block Packing
Rotenburg/Wümme
RUSSIA OOO “EKO“ Extension of Block Production
Jaroslavl
U.A.E. Exeed Litecrete L.L.C. Equipment for Panel Production
Abu Dhabi
RUSSIA OOO “Zavod Stroitelnykh Materialov“ Quick Lime Production
Dagestan
TURKMENISTAN HK Beýik Bina Blocks and Reinforced Panel Production
Ashgabat Dry Mortar Production

INDIA Shree Cement Ltd. Block Production

Delhi (fly ash)

SAUDI ARABIA Saudi Aerated Concrete Extension in Capacity of

Jubail Industries Co. Ltd. (ACICO) Block Production

RUSSIA Poritep Block Production

Nishni Novgorod

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 AAC – WORLD-WIDE REFERENCES I I3

Country Buyer Supplied Equipment

CHINA, P.R. Baopeng Construction Block and Reinforced Panel Production

Changzhou Industrial Material Co. Ltd.

INDIA Hyderabad Industries Limited Block Production (3rd plant)

Jhajjar (fly ash)

RUSSIA OOO “Kombinat Stroitelnykh Materialov“ Block Production

Stary Oskol
RUSSIA Tekhnoservice Block Production
Kaliningrad
GERMANY Schlamann KG Extension in Capacity of Block
Marklohe Production

GERMANY Porit Cirkel Dosing and Mixing

Haltern am See
THAILAND Autoclaved Aerated Extension / Increase in
Chonburi Concrete Product Co. Ltd. Capacity of Block Production

INDIA Hyderabad Industries Limited Extension / Increase in Capacity of

Surat Block Production (2nd plant) (fly ash)

CHINA, P.R. Tianjin House Block and Reinforced Panel Production

Tianjin (3rd plant)

MALAYSIA Stärken AAC Sdn. Bhd. Block Production

Kuala Lumpur
INDONESIA P.T. Broco Aerated Concrete Industries Block and Reinforced Panel Production
Tangerang (2nd plant)

CHINA, P.R. Tianjin House Block Production (2nd plant)

Tianjin (fly ash)

RUSSIA ZAO INSI Extension / Increase in

Chelyabinsk Capacity of Block Production

RUSSIA OAO “Lipetskiy Kombinat Upgrading of Block Production

Lipetsk Silikatnych Izdeliy”

RUSSIA OOO “Eko-Zoloprodukt Ryazan” Block Production

Region Ryazan (fly ash)

RUSSIA OOO Sibirskiy Stroitel Block and Reinforced Panel Production

Novosibirsk Dry Mortar Production

LIBYA Economic Inmaa Co. Block Production

Tripolis
RUSSIA ZAO Stroikomplex Increase in Capacity of Block
Angarsk Production (fly ash)

TURKMENISTAN Construction Materials Block Production

Ashgabat and Ministry of Industry

RUSSIA OOO Firma Baskal Block Production

Kurgan (fly ash)

RUSSIA OOO Upravlyayushchaya Block Production

Ulyanovsk Kompaniya KPD-2

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 AAC – WORLD-WIDE REFERENCES I I4

Country Buyer Supplied Equipment

RUSSIA OOO Elgad Inc. Block Production

Moscow
UKRAINE OAO Ezyabii Upgrading of Block Production
Belgorod Dnestrovskiy
RUSSIA ZAO Stroikomplex Block Production
Angarsk (fly ash)

U.S.A. AAC East, LLC / Carolina AAC, LCC Block Production

Chapel Hill, North Carolina
ROMANIA SOCERAM Block Production
Cordun
RUSSIA “DSK Gras“ Block Production (2nd plant)
Yurev-Polskiy
INDIA Hyderabad Industries Limited Block Production (2nd plant)
Surat (fly ash)

RUSSIA Evrokhim-Shina Block Production

Volzhskiy Volgogradskaya
AZERBAIJAN Aikon CPIT Block Production
Baku
AZERBAIJAN Aikon CPIT Quick Lime Production
Baku
RUSSIA H+H RUS LLC Block Production (4th plant)
St. Petersburg
TURKEY AKG GAZBETON Block Production
Izmir
POLAND Grupa Prefabet S.A. Block Production
Reda
LATVIA Bloks - M. J. Block Production
Vangazi
POLAND Grupa Prefabet S.A. Block Production (2nd plant)
Zelislawice
CZECH REPUBLIC H+H Çeská republika s.r.o. Block Production (3rd plant)
Most
GERMANY Hansa Baustoffwerke Block Production
Parchim
RUSSIA Glavstroy-Ustlabinsk Block Production
Ustlabinsk
CHINA, P. R. Tianjin House Block and Reinforced
Tianjin Panel Production

UKRAINE AEROC Block Production

Obukhov, Region Kiev Obukhovskiy zavod poristykh izdeliy

RUSSIA “DSK Gras“ Block and Reinforced

Kaluga Region Panel Production

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 AAC – WORLD-WIDE REFERENCES I I5

Country Buyer Supplied Equipment

ITALY RDB S.p.A. Block Production

Pontenure
RUSSIA OAO Liskinski Gasosilikat Block Production
Voronesh
JORDAN General Lightweight Block Production
Amman Concrete Industries

RUSSIA OOO Woskresenski Block Production

Moscow Gasosilikatni Kombinat

KUWAIT Union Construction Material Block Production

Safat Manufacturing Co.

LATVIA SIA Texoblock Block Production

Ogre
UKRAINE Chernihiv Baumaterialbetriebs - GmbH Block Production
Chernigiv
U.A.E. Emirates International Block and Reinforced
Abu Dhabi Investment Co. Panel Production

RUSSIA Teplit Extension / Increase in Capacity of

Ekaterinburg (AG Korporation “Atomstroykomplex”) Block Production (1st plant) (fly ash)

RUSSIA Teplit Block Production (2nd plant)

Ekaterinburg (AG Korporation “Atomstroykomplex”) (fly ash)

RUSSIA ZAO INSI Block Production

Chelyabinsk Dry Mortar Production

LATVIA AEROC Extension / Increase in Capacity of

Riga SIA Poribet Block Production

KASACHSTAN Concrete Products LLP Extension / Increase in Capacity of

Almaty Block Production

RUSSIA OOO “Omskij Savod Avtoklavnogo Block Production

Omsk Jacheistogo Betona“ (fly ash)

RUSSIA ZAO “EvroAeroBeton” Block Production

Region St. Petersburg
GERMANY Porit Rodgauer Baustoffwerke Block Production
Rodgau / Frankfurt am Main
CHINA, P. R. New Century Group Block and Reinforced
Hangzhou Panel Production

INDONESIA P. T. Broco Aerated Concrete Industry Block Production

Tangerang
BELARUS OAO Grodnenskij KSM Block Production
Grodno
RUSSIA OOO “EKO” Block Production
Jaroslavl
THAILAND Autoclaved Aerated Concrete Block Production
Chonburi Product Co. Ltd.

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Country Buyer Supplied Equipment

RUSSIA AEROC Block Production

St. Petersburg OOO LSR Gasobeton

RUSSIA OOO “Build Fast Technology” Block Production

Region Moscow
RUSSIA Zinvest Block Production
Selenograd – non-autoclaved –

RUSSIA Wesawa Machines and Equipment for

Kaliningrad Block Production

LATVIA AEROC Block Production

Riga SIA Poribet

GERMANY Schlamann KG Handhold Cutter

Marklohe
GERMANY Wüseke Gasbetonwerke Handhold Cutter
Paderborn
RUSSIA AG Korporation “Atomstroykomplex” Block Production
Ekaterinburg (fly ash)

KUWAIT Hebel ACICO K.S.C.C. Bed Remover

Safat
KASACHSTAN Concrete Products LLP Block Production
Almaty
KUWAIT Hebel ACICO K.S.C.C. Block Production
Safat
GREAT BRITAIN H + H Celcon Ltd. Cutting Machine
Westbury
DENMARK H + H Celcon A/S Separating Machine
Olsted
GERMANY Porit Porenbetonwerk Havelland Reinforced Lintel Production
Germendorf
GERMANY Hansa Baustoffwerke Bed Remover
Parchim
GERMANY Wüseke Baustoffwerke Handhold Cutter
Füchtorf
GERMANY Schlamann KG Bed Remover
Marklohe
GERMANY Porit Emsländische Baustoffwerke Block Production
Surwold
U.S.A. Acco Building Products Reinforced Panel Production
Apopka, Florida
GERMANY FELS-Werke GmbH (Ytong Licensee) Cutting Line for Block Production
Salzgitter
DENMARK H + H Industri A/S Block and Reinforced
Olsted Panel Production

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 AAC – WORLD-WIDE REFERENCES I I7

Country Buyer Supplied Equipment

U.S.A. Acco Building Products Blocks and Reinforced

Apopka, Florida Panel Production

U.S.A. Enviro-Crete Products, Incorporation Block Production

Phoenix, Arizona
U.S.A. Babb Cellular Concrete LLC Block Production
Ringgold, Georgia (fly ash)

INDIA Hyderabad Industries Limited Block Production

Chennai (fly ash)

TAIWAN Taa Jan Industries Block Production

Kaohsiung
GERMANY Schlamann KG Block Production
Marklohe
GERMANY Wüseke Gasbetonwerke Short Block Production
Paderborn
THAILAND Superblock Ltd. Glue and Mortar Plant
Singburi
THAILAND Superblock Ltd. Block Production
Singburi
GERMANY Porit Porenbetonwerk Havelland Handhold Milling
Germendorf
GERMANY Hebel Block Profiling and Packing
Melle
RUSSIA Sibaj Block Production
Bashkiria
GERMANY Porit Emsländische Baustoffwerke Handhold Milling
Surwold
N.-IRELAND Sean Quinn Concrete Ltd. Block Production
Derrylin
GERMANY Wüseke Gasbetonwerke Handhold Milling and Packing
Füchtorf
GERMANY Porit Rodgauer Baustoffwerke Handhold Milling
Rodgau / Frankfurt m Main
GERMANY Hebel Block Profiling and Packing
Stulin
U.S.A. North American Cellular Concrete Mobile Block Production
Virginia (fly ash)

GERMANY Hansa Baustoffwerke Block Production

Parchim
KOREA Kirin Industrial Co. Ltd. Blocks and Reinforced Panels
Seoul
GERMANY Hebel Block Profiling and Packing
Hennersdorf

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 AAC – WORLD-WIDE REFERENCES I I8

Country Buyer Supplied Equipment

KOREA Silla Trading Co. Ltd. Blocks and Reinforced Panels

Seoul
TURKEY Beteks Tekstil Sanayi ve Block Production
Istanbul Subesi Dis Ticaret A.S. (Ytong)

GERMANY Wüseke Gasbetonwerke Block Production

Füchtorf
KOREA Samick Co. Ltd. Blocks and Reinforced Panels
Seoul
MALAYSIA Soon Seng Group Block Production
Kuala Lumpur
GERMANY Gebr. Schlamann Handhold Milling
Marklohe Block Profiling and Packing

AUSTRALIA BGC Blocks Block Production

Perth
GREAT BRITAIN H+H Celcon Blocks Ltd. Block Production
Borough Green (fly ash)

GERMANY Wüseke Gasbetonwerke Block Production

Paderborn
GERMANY Porit Emsländische Baustoffwerke Block Profiling and Packing
Surwold
GERMANY Wüseke Gasbetonwerke Block Profiling and Packing
Paderborn
GERMANY Porit Rodgauer Baustoffwerke Block Production
Rodgau / Frankfurt am Main
GERMANY Porit Cirkel Block Profiling and Packing
Flaesheim
GERMANY Porit Emsländische Baustoffwerke Block Production
Surwold
GERMANY Gebr. Schlamann Block Production
Marklohe
GERMANY Porit Cirkel Block Production
Flaesheim
IRAQ Ministry of Industries Blocks and Reinforced Panels
Baghdad, Najaf
IRAQ Ministry of Industries Blocks and Reinforced Panels
Baghdad (Kerbala)

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 AAC – FLOW CHARTS AND PLANT LAYOUTS I J1

Wehrhahn
Equipment and AAC Technology

Flow Charts and Plant Layouts

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 AAC – FLOW CHARTS AND PLANT LAYOUTS I J2

AAC Production Process

AAC PRODUCTION PROCESS

SAND
SLURRY ALUMINUM CEMENT LIME
WATER

SAND

SAND MILLING
DOSING

PANEL
REINFORCEMENT MIXING
(OPTIONAL)

FILLING MOULDS

PRECISION CUTTING

AUTOCLAVING

STEAM

SALES STORAGE PACKING SORTING AND PALLETIZING

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 AAC – FLOW CHARTS AND PLANT LAYOUTS I J3

90m
112m
42m
22m

SMART

12m 18m 18m 18m

(blocks)

67,6m

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AAC – FLOW CHARTS AND PLANT LAYOUTS I J4

SMART
(blocks)

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 120m
90m

1.-Etage Erdgeschoß
9m

Upper floor 2000m³ Ground floor

+4m 0.00

1500m³
9m

1000m³
9m
13m

24m
15m

1000m³
15m
124m

1500m³

55m
2000m³
25m
12,5m
16,5m
AAC – FLOW CHARTS AND PLANT LAYOUTS
I

SMART

WWW.WEHRHAHN.DE
J5

(blocks and panels)

AAC – FLOW CHARTS AND PLANT LAYOUTS I J6

(blocks and panels)

SMART

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 AAC – FLOW CHARTS AND PLANT LAYOUTS I J7

42m
20m
160m
190m
76m
22m

superSMART
(blocks and panels)
30m

15m 15m 15m 30m 25m

45m 55m
100m

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AAC – FLOW CHARTS AND PLANT LAYOUTS I J8

superSMART
(blocks and panels)

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 AAC – FLOW CHARTS AND PLANT LAYOUTS I J9

h=8m
h=11m

h=8m
30m

h=3m
132m

78m
48m

ecoPLUS
(blocks)
24m

22m 20m 12m

54m

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AAC – FLOW CHARTS AND PLANT LAYOUTS I J10

ecoPLUS
(blocks)

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