AAC Block Manufacturing Plant

At Maruti Hydraulics Pvt Ltd we understand that AAC block production demands specialized knowledge and experiance. It requires highly precise mixing , dozing and batching system. Every step of AAC production needs to be controlled and monitored .

With multiple turnkey AAC plant projects , our team has the ability to execute these projects with ease. Our understanding of both our customers and the technology helps us to build the bridge between the two, which in turn leads to a high quality of product.

Our AAC block lines are specifically designed to meet the needs of our customers. We are also designing smaller size plants which will help to reduce capital investment. The projects are developed and executed to keep initial plant cost low, though keeping in mind the need for expansion in the growing markets specially Indian.

AAC BLOCK PLANT – PROCESS OF  AAC BLOCK PRODUCTION

1. Raw Material Storage and Preparation

Fly ash/Pond Ash – Silo/Closed Shed

Gypsum- Silo/Closed Shed

Cement –Silo/Closed Shed 

Fly ash and water are mixed in a mixture to produce Fly ash slurry. This slurry is stored in Slurry tanks . Silos are used to store cement , lime & Gypsum. In a batching unit , Fly ash slurry is mixed with lime , Gypsum , Cement & Aluminum powder. This is an automatic batching system maintaining high precision measurement and accuracy.

Reaction of aluminium leads to hydrogen gas escaping from the mixture causing the mixture to expand considerably, giving it a honey comb like structure.

2. Casting , Flow & Rising unit

The prepared mixture is  poured into the moulds and allowed to rise in pre curing room at about 42-44 degree celcius for 1-2 Hrs.

3. Mould removal and Cutting

The aerated cake is de moulded via tilting process & put on cutting line. It is  then cut using a high precision wire cutting machine  both horizontally & vertically.

4. Curing

This wire cut cake is finally cured in Autoclaves . Autoclaves are pressure chambers that uses steam for curing. Curing time ranges between  10-12 hrs at 200 degree Celsius , 14.5 Kg / cm square pressure.

5. Separation & Segregation

The cured cake is segregated as per Size & Palletized. Process can be done manually as well as with automatic separator and packing line.

RAW MATERIALS  REQUIRED

Fly ash : 60 -75 %
Lime : 8 – 25 %
Cement : 6 – 15 %
Gypsum : 3 – 5 %
Aluminium : about 0.08%