AAC Block Report

Laxmi En Fab Pvt. Ltd.
AUTOCLAVED AREATED CONCRETE (AAC)

AUTOCLAVED AREATED CONCRETE
REG. OFFICE: 25 nilsin plot near patel alloy steelphase I , Vatva
G.I.D.C. AHMEDABAD,GUJARATPh. +91 9725012749/9712570097
Website : www.aacplant.co.in,www.aacautoclave.com
Email: info@aacplant.co.in , aaclaxmi@gmail.com
sales@aacplant.co.in
Laxmi En-Fab Pvt. Ltd

Ahmedabad Gujarat India,
+91 9712570097,9725012740/49
Web : www.aacplant.co.in, www.aacautoclave.com,

E mail: aaclaxmi@gmail.com,info@aacplant.co.in,
Page 1
Autoclaved aerated concrete (AAC), also known as autoclaved cellular concrete (ACC)
or autoclaved lightweight concrete (ALC), was invented in the mid-1920s by the
Swedish architect and inventor Johan Axel Eriksson
It is a lightweight, precast building material that simultaneously provides structure,
insulation, and fire and mold resistance. AAC products include blocks, wall panels, floor
and roof panels, and lintels
It has been refined into a highly thermally insulating concrete-based material used for
both internal and external construction. Besides AAC's insulating capability, one of its
advantages in construction is its quick and easy installation, for the material can
be routed, sanded, and cut to size on site using standard carbon steel band saws, hand
saws, and drills.
Even though regular cement mortar can be used, 98% of the buildings erected with AAC
materials use thin bed mortar, which comes to deployment in a thickness of
inch.
This varies according to national building codes and creates solid and compact building
members. AAC material can be coated with a stucco compound or plaster against the
elements. Siding materials such as brick or vinyl siding can also be used to cover the
outside of AAC materials
AAC has been produced for more than 70 years, and it offers advantages over
other cementations construction materials, one of the most important being its
lower environmental impact.
AACs improved thermal efficiency reduces the heating and cooling load in
buildings
AACs workability allows accurate cutting, which minimizes the generation of
solid waste during use
AACs resource efficiency gives it lower environmental impact in all phases of its
life cycle, from processing of raw materials to the disposal of AAC waste.
AACs light weight also saves cost & energy in transportation.
AACs light weight saves labors.

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Main ingredients include fly ash, water, quicklime, cement, aluminum powder
and gypsum. The block hardness is being achieved by cement strength, and instant
curing mechanism by autoclaving. Gypsum acts as a long term strength gainer. The
chemical reaction due to the aluminum paste provides AAC its distinct porous structure,
lightness, and insulation properties, completely different compared to other lightweight
concrete materials. The finished product is a 2.5 times lighter Block compared to
conventional Bricks, while providing the similar strengths. The specific gravity stays
around 0.6 to 0.65. This is one single most USP of the AAC blocks, because by using
these blocks in structural buildings, the builder saves around 30 to 35 % of structural
steel, and concrete, as these blocks reduce the dead load on the building significantly.
ASSUMPTIONS:
The major raw material Fly-Ash, an indispensable by-product of Thermal Power Plants, is an environmental
threat across the globe. Power plants are facing an ever increasing challenge disposal of this polluting agent. This
unit is proposed to manufacture AAC Bricks & Blocks by consuming the Fly-Ash as one of the prime raw
material. Secondly, it also helps environment by saving the invaluable top soil by not using them in brick making
like conventional brick making. Thirdly, they need no burning, thus further enhancing their Eco-Friendly Brand.
The steam curing requires far less fuel, compared to the backing for each cubic meter of Bricks. This is the
reason these bricks are also referred as Eco Bricks or popularly Green Bricks,
Carbon Credit is estimates are for reference purpose. The Project owner must handle his part of CDM project to
get Carbon credits, through independent consultants. Carbon credit can be transacted on registration. The PCN
preparation & presentation, the PDD preparation & presentation, host country approval and the UNFCCC
Registration might take somewhat 6 months to 2 years year. So it may be wise to start early.
Sale price at site is estimated a conservative Rs 3200/- per cubic meter. AAC Blocks of all sizes will be
manufactured according to the market requirement, though mainly stipulated sizes as per the BIS standards.
Production is estimated at 80% capacity, 300 working days is considered in a year during the first year

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Why AAC Bricks?

Energy saving
Easy to install
Less Weight
Endurance
Precision
Energy Efficient
Non Toxic
Thermal Insulation
Fire Resistance
Acoustic Performance
Moisture Resistance
Workability
Non Toxic
Thermal Insulation
Fire Resistance
Acoustic Performance
Moisture Resistance
Workability
Earthquake Resistant
cost saving
Fire Resistant
Pest Resistant
Water Barrier
High Strength

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Large size, however light weight

Light weight = saves foundation cost, helps the mason
High load-bearing strength
High durability = long life, impervious to rot or pest
Dimensional accuracy
High economy
Effortless handling, rapid construction
Best thermal insulation, 6 - 10 times better than regular dense concrete
Unsurpassed fire-resistance = life, property and insurance cost saver
Excellent sound absorption, ideal for the hospitality industry
Good workability, better than wood (can be sawn, drilled, nailed, milled at site)
Hurricane and earthquake resistance
Not rotting (contrary to timber)

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MARKET PLACE:
Fly ash is available incessantly and of satisfactory quality. Users are of the
opinion that strength, sturdiness, finish, availability, price are the important qualities in
blocks.
Very high attention is observed among traditional manufacturers regarding use of
fly ash in their products. Technical assistance & increased product awareness among
the public and considered important for promoting the shift in the manufacturing
practices.
High preference for fly ash products is observed among those customers
contacting manufacturers. Increased media coverage & favorable policies are
considered key to increasing utilization of fly ash bricks & blocks.
The current prices of fly ash blocks are in the same range of cement blocks &
traditional bricks. But comparatively fly ash blocks are having more strength, fire
resistance, earthquake resistance, light weight, lesser brakeage and saves structural
cost by 40%.
Average 60% of electricity comes from coal based power station, the country has
a huge stock of fly ash amounting to 60 million tons annually. Despite the entire efforts
present scenario is not too encouraging as only 5% countrys total ash has been
consumed in different sector.
With the rise in population and increase in constructional activities considering
the Improvement in the standard of living the demand for building bricks is increasing
day by day.
Market share of different walling materials
Type of walling material

Burnt Clay Brick
Fly Ash Bricks
Cement Concrete Blocks
Total
Market Size (Rs. Crores)

32825
1135
485
34445
% of Total market
95.3
3.3
1.4
100
The project activity product output AAC Blocks awareness levels were very low
and are yet to penetrate in the markets. As stated above the prime reason why clay
brick accounts for 95% of the share is that they are cheap and have traditionally been
believed to be the most suitable walling material for building construction

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RAW MATEERIALS, SOURCEES AND A

AVAILAB
BLITY:
FLY ASSH :
Fly ash raw material
m
is freely ava
ailable in Thermal
T
Po
ower plants. A lot has been sa
aid
w material in this prroject proffile itself. There are no taxes on this ite
em
about this raw
wha
atsoever. Transporta
T
ation charrges are on
nly to be attended
a
b
by the entrrepreneur..
Lime: Active pow

wered lime is a requ
uirement for
f
giving the real aeration to
o the
productt.
In phas
se 1 we ca
an aim to buy
b
the active lime directly.
d
In phas
se-2 we ca
an think off having ba
ack word integration and mak
king a lime
e
powerin
ng unit at site to have a more
e competitive advanttage, we can
c
also th
hink of
a lime burning
b
kiln inside the
t
factory
y premises
s
The pro
oject finan
ncials howe
ever have not considered the costs of powering
p
u
unit,
and the lime kiln
k
in this
s project.
Differen
nt qualitie
es of lime are
a availab
ble, and de
epending on the raw
w materialls. The
mix
x design ca
an be chos
sen to get the optimal quality of produc
ction
OPC
This Pro
oject aims
s to utilize
e opc ceme
ent as main binder m
material. It will give
e faster
strengtth to the bricks, besiides giving
g improve
ed consiste
ent quality
y. It also ensures
e
a better cost effe
ectiveness for the sa
ame. Using
g OPC will be a standardized
practice
e. The other prime advantage
a
e of using opc
o
(comp
pared to otther binde
ers) is
its easy
y availabillity locally
y through n
nationwide retail Ne
etwork of Cement
Compan
nies.
Gypsum
m
4%
Main row maaterial

OPC
10%
Aluminu
m
1%
Lime
15%
Fly Ash
F
70%
Laxm
mi En-F
Fab Pvt. Ltd
Ahm
medabad Gujarat In
ndia,
Web
b : www.aa
acplant.co.in
n, www.aaccautoclave.com,
Gypsu
um:
This too
o is an ind
dustrial wa
aste. This iis availablle as an industrial by
yproduct of
o
Ferttilizer Plan
nt. Gypsum
m is responsible to give
g
long term
t
stren
ngth to the
e Blocks.
Alumiinum Po
owder:
Fine
ely ground
d Aluminum
m powder is used in
n very limited quantity (less th
han 0.5%)
), so
thatt it reacts with activ
ve lime, an
nd silica in
n base matterial to m
make the ae
eration, an
nd
swe
ell the prod
duct, making it very
y light weight product.
PRO
OJECT AT
A A GLA
ANCE:
Prod
duct Detaiils:
AAC light weight B

Blocks
Type:
Fly Ash Based

B
or s
sand Based
d
A
Infra
astructure & Green- Tech
Technology Area:
pacity Utilization:
Cap
80%
CONSUMP
PTION OFF RAW MATERIA
M
ALS AND
D ENERG
GY NEEDED FOR
PRO
ODUCTION OF BUILDIN
B
G MATEERIALS:
1600
0
1400
0
1200
0
1000
0
conssumtion of raaw
mateerial in Kg/m
m3
800
0
600
0
Consumtion of energy
e
in
Kwhh/M3
400
0
200
0
0
Clay Bricks
p=1.22kg/m3
Porous Cllay
Masonryy
p=0.8kg/m
m3
Calccium silicatee Aac masoonary unit

maasonry unit
p=0.4kg/m3
p=
=1.4kg/m3
Laxm
mi En-F
Fab Pvt. Ltd
Ahm
medabad Gujarat In
ndia,
Web
b : www.aa
acplant.co.in
n, www.aaccautoclave.com,
BRIEF PRODUCTION PROCESS:

1.
COAL FLY ASH:

The fly ash of coal will be sent to the slurry preparing pond by wheel loader to be
prepared required concentration coal fly ash slurry by add rated water, which will
be pumped into slurry tank to be stored and ready to be used
2. QUICK LIME:
The powder will sent into the lime powder silo for storage and read to be used by
bucket elevator, after coming into the factory.
3. GYPSUM:
The gypsum in the storage shed will be added into slurry pond according to the
required proportion, while preparing slurry
4. CEMENT:
The cement will be transported into factory by tank truck and directly is pumped
into cement silo to be used
5. ALUMINUM POWDER PAST:
The purchased aluminum powder past in the bucket or bag will be stored in its
store house, When being used, it will be lifted to second floor of the batching
building, then measured and added in to aluminum mixer to prepare 5%
suspending liquid to be used.
6. SCRAPE AND WASTE SLURRY:
The cleaning waste water under the casting machine will be pumped to ball mill to
be used as grinding water. The scrape from the cutting machine will be prepared to
slurry and pumped into waste slurry tank to be used.
7. BATCHING, MIXING, CASTING:

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Page 12
Coal fly ash will be sent to electronic scale in the batching building by pump
at the bottom slurry tank to be measured. When the slurry concentration arrives at
batching requirement, the control system will turn of the pump to stop pump
slurry. The measured the slurry will be directly discharged into casting mixer.
Lime and cement will be sent to electronic scale in the batching building by
single screw conveyer at the bottom of their silos. When measuring arrives at the
required quantity, they will be sent to casting mixer by screw conveyer.
Aluminum Powder will be measured by manual and added in to aluminum
mixer to be prepared suspending liquid one by one for each mould. The finished
suspending liquid can be directly added into the casting mixer.
The slurry temperature should be arrived at required process temperature
before coasting. And mold will be moved to the bottom of the casting mixer by
ferry car.
8. CUTTING AND GROUPING:
After pre curing, the green block arrive at the required strength, the crane
will take it to the cutting machine section. After remove the mould, the green
block will be cut according to the required size.
The green block after cutting will be move to the curing trolley with the
bottom plate by crane in front of autoclave for grouping. The seven trolley for each
autoclave with 14 pieces of green block.
9. AUTOCLAVED AND FINISHED PRODUCT:
The green block after grouping, will be move into autoclave by windlass for
curing. The whole curing period is approx 12 hours, pressure approx 1.2mpa,
temperature approx 1850. After curing, the product will be pulling out of auto clave
and be sent to the store yard.
10. THE BOTTOM PLATE RETURNING, COMBINING WITH MOULD AND OILING:
After unloading, the side plate on the trolley will be lifted to returning rail by
crane, and be returned to the side of the cutting machine, which will be combined
with the mould and sent to mold returning line for cleaning and oiling to be reused.

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Equipments
Equipment is depend of selection of process , base material , selection of automization etc. below is given general base
equipment
Raw material processing equipment
Jaw crsher
Hoist conveyor
Block lime silo
Electronic vibrating feeder
Ball mill lime
Sand silo
Electronic vibrating feeder
Belt conveyor
Ball mill -wet -sand
Bucket elevator
Cement silo
Gypsum silo
Pouring processing equipment
Main Slurry mixer fly ash
Weighted / batch slurry mixer
Main Mixer desert mortar after

Cutting
Balance desert mortar for per mould
Lime OPC gypsum mixer
Screw conveyor for lime
Aluminum mixer
Main pouring mixer
Lime &gypsum measure
Spiral gate valve
Pneumatic controlling valve
Slurry measurer
PLC electric measuring controlling system
Air compressor
Mould
Mould bottom plate
Steam curing car
Electronic platform balance

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Cutting processing equipment
Hoist for mould move
Hoist for semi finish product
Tractor
Horizontal cutting machine with

Arrangement
Vertical cutting machine with arrangement
Cutting processing equipment
Hoist for mould move
Hoist for semi finish product
Tractor
Horizontal cutting machine with

Arrangement
Vertical cutting machine with arrangement
Hardening or curing process equipment
Autoclave
Steam boiler
Coal crushing and handling equipment
Chimany
Dust collector
Steam controlling valve
Steam controlling penal
Steam line

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Photograph of plant equipment
Storage silo
Fly ash mixing tank
Mould mover
final mixer
cutting machine
Steam curing car

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Boiler-dust collector-chimney
Mixing section
Autoclave
autoclave
mould goes to autoclave
Mould

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ready AAC block
fitting of AAC block
AAC block construction
AAC block wall
Housing make by AAC block
Housing make by AAC block

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LAYOUT
This is basic layout actual layout depend on plant size, design, degree
of automization,land size, scope of raw material coming as well
outgoing position, many factor affect on plant design

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RAW MATERIAL SUITABILITY:

Approximately 95% of the waste materials can be made suitable for AAC line through proper mix design. Also we
can have many different mix designs for the same densitysame strength of Blocks. We will help you to get the Best
quality blocks at optimal cost by means of designing proper Mix as per your input raw materials. The following are
basic guidelines (certainly not the final call) on the suitability of basic raw materials for AAC.
1. Fly Ash (65 70%)

Index Item
Degree of
fineness
Grade (%)
Gr II
Gr I
(0.045 square hole sieve left amount)
30
45
(0.080 square hole sieve left amount)
15
25
Ignition loss
5
10
SiO2
45 55
40
SO3
1
2
Reference: The fineness can be 0.045 or 0.080 square sieve left amount.
2. Lime (8 25%)
Item
A(CaO +MgO) Quailty Fraction%
MgO Quality Fraction %
SiO2 Quality Fraction %
CO2 Quality Fraction %
Digestion speed ,min
Digestion temperature ,
Undigested residue quality fraction ,%
Fineness (0.080 square hole sieve left amount) %
SiO2
21 23
Ai203
57
FE20
35
3. Cement (6 15%)
Cao
Mgo
C3S
64 48 4 5
44 59
Grade
Super Gr
90
2
2
2
1st Gr.
75
5
5
5
60 90
10
15
5
10
C2S
18 30
2nd Gr.
65
8
8
7
C3A
5 12
15
20
C4AF
10 18

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CaSO4
Mgo
Chloride
Preferably ground residue
4. Gypsum/Plaster (3 5%)
>
<
<
<
70%
2%
0.05%
10 15%
5. Aluminum Power (about 0.08%)

Type and recommendation for supply depend on raw materials and mix formula
Metal Content
Approx.
>=65%
Powder
NOTE: Use of Cement is depend on moisture, if moisture is high cement requirement becomes high. Soluble Oil
usage per process is 1 liter.
TECHNICAL COMPARISON :
Parameter
AAC Block
Size
(600x200x100-300) mm
Variation in dimensions
Compressive strength
Dry Density
+/-1mm
30-50 kg/cm2
550-700 kg/m3
4-6 Hour depending on
thickness
Fire Resistance
Sound Reduction Index
(dB)
Thermal Conductivity W/(Km)
Concrete Block
(400x200x100-200)
mm
+/-3mm
40-50 kg/cm2
1800 kg/m3
Brick
(230x115x75) mm
+/-5mm
25-30 kg/cm2
1950 Kg/m3
4 hours
2 hour
40 for 230 mm thick
wall
60 for 200 mm thick wall

0.122
0.51
0.81
Normal basic size

AAC BLOCKS TECHNICAL SPECIFICATIONS
Thickness
Height
Length
Density
Compressive strength
100 mm
200 mm
600 mm
550-700 kg/m3
30 - 50 kg/cm2
150 mm
200 mm
600 mm
550-700 kg/m3
30 - 50 kg/cm2
200 mm
200 mm
600 mm
550-700 kg/m3
30 - 50 kg/cm2

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Main Technical Specifications of AAC Lightweight Block Production Line
Mainly plant capacity
Model
Capacity per Annume Per day production

As per 300 day
50,000 CM
160 CM
100,000 CM
320 CM
150,000 CM
480 CM
2,00,000 CM
640 CM
3,00,000 CM
960 CM
5,00,000 CM
1600 CM
LAAC-50
LAAC-100
LAAC-150
LAAC-200
LAAC-300
LAAC-500
Cover
shed area
Model
Capacity per Annume
LAAC-50
50,000 CM
LAAC-100
100,000 CM
LAAC-150
150,000 CM
Total land for building and shed ,
material stock
2-5 acre
Work shed cover area

20,000 Square feet
25,000 Square feet
30,000 Square feet
raw material ,finish

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Raw material consumption for AAC block

Ingredients
Fly ash
Lime
Cement
Anhydride
Aluminioum ( metel powder )
Raw material consumption per CM of AAC

block
272 KG
71 KG
95 KG
12 KG
0.46 KG
Total solid
450 KG
Water in mix ( total ,excl. steam )

Condensate which can be reused
In the mix ( water consumption
Above reduce correspondingly)
370 KG
90 KG
Above data is not full and final but for better understanding project is given
Actual Ingredients mixing is depend on client & client technical team

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Page 26
Energy and mass flow and balance diagram
Compressed air
Electricity
Raw material
Fly ash,
lime,Gypsum
,aluminium,
cement
Raw material
pouring & mixing
Water
New grid
Moulding & cutting
Electricity
DG set
Diesel
Curing at autoclave
Steam
Finish product
Boiler
Fuel oil
The above figure represents the ENERGY and Mass Flow and the balance of the
system and equipments include in the project activit.in the project activity electricity,
steam & compressor air are the main type of energy used and main source of these
energy are as follows:
Electricity : from new NEgrid & DG set
Steam : from boiler fuel oil combustion
Compressed air from air compressor

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Page 27

AUTOCLAVED AREATED CONCRETE
REG. OFFICE: 25 nilsin plot near patel alloy steelphase I , Vatva
G.I.D.C. AHMEDABAD,GUJARATPh. +91 9725012749/9712570097
Website : www.aacplant.co.in,www.aacautoclave.com
Email: info@aacplant.co.in , aaclaxmi@gmail.com
sales@aacplant.co.in
..

+91 9712570097,9725012740/49

Page 28

AAC Block Report

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What is autoclaved aerated concrete?

What is autoclaved aerated concrete?

What are the main ingredients used to produce AAC?

What are the main ingredients used to produce AAC?

Laxmi En Fab Pvt. Ltd.

AUTOCLAVED AREATED CONCRETE (AAC)

Laxmi En Fab Pvt. Ltd.

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Why AAC Bricks?

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Large size, however light weight

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Type of walling material

Market Size (Rs. Crores)

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

RAW MATEERIALS, SOURCEES AND A

Lime: Active pow

Main row maaterial

AAC light weight B

Fly Ash Based

Calccium silicatee Aac masoonary unit

BRIEF PRODUCTION PROCESS:

COAL FLY ASH:

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Laxmi En-Fab Pvt. Ltd

Web : www.aacplant.co.in, www.aacautoclave.com,

Raw material processing equipment

Block lime silo

Electronic vibrating feeder

Ball mill lime

Electronic vibrating feeder

Ball mill -wet -sand

Pouring processing equipment

Main Slurry mixer fly ash

Weighted / batch slurry mixer

Main Mixer desert mortar after

Lime OPC gypsum mixer

Screw conveyor for lime

Main pouring mixer

Lime &gypsum measure

Spiral gate valve

Pneumatic controlling valve

PLC electric measuring controlling system

Mould bottom plate