AAC Block Report

Laxmi En-Fab Pvt. Ltd

Laxmi En-Fab Pvt. Ltd

 Ahmedaba

 Ahmedabad – Gujarat –In

d – Gujarat –India,

dia,

Web :

Web : www.aacplant.co.in

www.aacplant.co.in

,, www.aacautoclave.com

www.aacautoclave.com

,,

+91 9712570097,9725012740/49

+91 9712570097,9725012740/49

E

E mail:

mail: [email protected],[email protected]

[email protected],[email protected]

,,

Page

Page

11

Laxmi En Fab Pvt. Ltd.

Laxmi En Fab Pvt. Ltd.

AUTOCLAVED AREATED CONCRETE (AAC)

AUTOCLAVED AREATED CONCRETE (AAC)

Laxmi En Fab Pvt. Ltd.

Laxmi En Fab Pvt. Ltd.

AUTOCLAVED AREATED CONCRETE

AUTOCLAVED AREATED CONCRETE

REG. OFFICE:

REG. OFFICE:

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2525

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 nilsin plot near patel alloy  nilsin plot near patel alloy steelphasesteelphase

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I , VatvaI , Vatva G.I.D.C. AHMEDABAD,GUJARATPh. +91

G.I.D.C. AHMEDABAD,GUJARATPh. +91

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 9725012749/9712570097 9725012749/9712570097

Website :

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

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

Email:

Email:

[email protected]

[email protected]

 ,

 , [email protected]

[email protected]

[email protected]

Laxmi En-Fab Pvt. Ltd

Laxmi En-Fab Pvt. Ltd

 Ahmedaba

 Ahmedabad – Gujarat –In

d – Gujarat –India,

dia,

Web :

Web : www.aacplant.co.in

www.aacplant.co.in

,, www.aacautoclave.com

www.aacautoclave.com

,,

+91 9712570097,9725012740/49

+91 9712570097,9725012740/49

E

E mail:

mail: [email protected],[email protected]

[email protected],[email protected]

,,

Page

Page

22 Autoclaved aerated concrete (AAC), also known as autoclaved cellular

Autoclaved aerated concrete (AAC), also known as autoclaved cellular concrete (ACC)concrete (ACC) or autoclaved lightweight concrete (ALC), was invented in

or autoclaved lightweight concrete (ALC), was invented in the mid-1920s by thethe mid-1920s by the Swedish architect and inventor Johan Axel Eriksson

Swedish architect and inventor Johan Axel Eriksson

It is a lightweight, precast building material that simultaneously provides structure, It is a lightweight, precast building material that simultaneously provides structure, insulation, and fire and mold resistance. AAC products include blocks, wall panels, floor insulation, and fire and mold resistance. AAC products include blocks, wall panels, floor and roof panels, and lintels

and roof panels, and lintels It has been refined into a

It has been refined into a highly thermally insulating concrete-based material used forhighly thermally insulating concrete-based material used for both internal and external construction. Besides AAC's insulating capability, one of its 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

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

be routed, sanded, and cut to size on site using standard carbon steel band saws, handsteel band saws, hand saws, and drills.

saws, and drills.

Even though regular cement mortar

Even though regular cement mortar can be used, 98% of can be used, 98% of the buildings erected with AACthe buildings erected with AAC materials use thin bed mortar, which comes to deployment in a thickness of

materials use thin bed mortar, which comes to deployment in a thickness of  _inch. inch.

This varies according to national building codes and creates solid and compact building 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 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 cov

elements. Siding materials such as brick or vinyl siding can also be used to cover theer the outside of AAC materials

outside of AAC materials



 AAC has been produced for more than 70 years, and it offers advantages overAAC has been produced for more than 70 years, and it offers advantages over other cementations construction materials, one of the most important being its other cementations construction materials, one of the most important being its lower environmental impact.

lower environmental impact.



 AAC’s improved thermal efficiency reduces the heating and cooling AAC’s improved thermal efficiency reduces the heating and cooling load inload in buildings

buildings



 AAC’s workability allows accurate cutting, which minimizes the AAC’s workability allows accurate cutting, which minimizes the generation ofgeneration of solid waste during use

solid waste during use



 AAC’s resource efficiency gives it lower environmental impact in all phases of itsAAC’s 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.

life cycle, from processing of raw materials to the disposal of AAC waste.



 AAC’s light weight also saves cost & energy in transportation.AAC’s light weight also saves cost & energy in transportation.



Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

3 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 U SP 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 B locks 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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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4

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

8 

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

9

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% country’s 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 Market Size (Rs. Crores) %of Total market

Burnt Clay Brick 32825 95.3

Fly Ash Bricks 1135 3.3

Cement Concrete Blocks 485 1.4

Total 34445 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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Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

12

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 pu mped

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.

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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13

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 buildin g by

single screw conveyer at the bottom of their silos. When measuring ar rives 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.

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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14

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 • Main Mixer desert mortar after

Cutting

• Weighted / batch slurry mixer • 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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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15

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

16 Photograph of plant equipment

Storage silo

Fly ash mixing tank

Mould mover

final mixer

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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17

Boiler-dust collector-chimney

Mixing section

Autoclave

autoclave

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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18

ready AAC block

fitting of AAC block

AAC block construction

AAC block wall

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

22

LAYOUT

This is basic layout actual layout depend on plant size, design, degree

of automization,land size, scope of raw material coming as well

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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23



RAW MATERIAL SUITABILITY:

Approximately 95% of the waste materials can be made suitable for AAC line through proper mixdesign. Also we can have many different mix designs for the same density…same 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 inp ut raw materials. The following are  basic guidelines (certainly not the final call) on the suitability of basic raw materials for AAC.

2. Lime (825%)

Item

Grade

Super Gr 1st Gr. 2nd Gr.

A(CaO +MgO) Quailty Fraction%  90 75 65

MgO Quality Fraction %  2 5 8

SiO2 Quality Fraction %  2 5 8

CO2 Quality Fraction %  2 5 7

Digestion speed ,min 

Digestion temperature , _{ 6090}

Undigested residue quality fraction ,%  5 10 15

Fineness (0.080 square hole sieve left amount) %  10 15 20

3. Cement (615%)

SiO2 Ai203 FE20 Cao Mgo C3S C2S C3A C4AF

2123 57 35 6448 45 4459 1830 512 1018

1. Fly Ash (6570%)

Index Item Grade (%)

GrI Gr II

Degree of fineness

(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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

24 4. Gypsum/Plaster (35%)

CaSO4 > 70%

Mgo < 2%

Chloride < 0.05%

Preferably ground residue < 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 Concrete Block Brick Size (600x200x100-300) mm (400x200x100-200)

mm (230x115x75) mm Variation in dimensions +/-1mm +/-3mm +/-5mm

Compressive strength 30-50 kg/cm2 40-50 kg/cm2 25-30 kg/cm2 Dry Density 550-700 kg/m3 1800 kg/m3 1950 Kg/m3 Fire Resistance 4-6 Hour depending on

thickness 4 hours 2 hour Sound Reduction Index

(dB) 60 for 200 mm thick wall

40 for 230 mm thick wall

Thermal Conductivity

W/(K-m) 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/m

3

30 - 50 kg/cm

2

150 mm

200 mm

600 mm

550-700 kg/m

3

30 - 50 kg/cm

2

200 mm

200 mm

600 mm

550-700 kg/m

3

30 - 50 kg/cm

2

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

25 Main Technical Specifications of AAC Lightweight Block Production Line

Mainly plant capacity

Model

Capacity

per Annume

Per day production

As per 300 day

LAAC-50

50,000 CM

160 CM

LAAC-100

100,000 CM

320 CM

LAAC-150

150,000 CM

480 CM

LAAC-200

2,00,000 CM

640 CM

LAAC-300

3,00,000 CM

960 CM

LAAC-500

5,00,000 CM

1600 CM

Cover shed area

Model

Capacity

per Annume

Work shed cover area

LAAC-50

50,000 CM

20,000 Square feet

LAAC-100

100,000 CM

25,000 Square feet

LAAC-150

150,000 CM

30,000 Square feet

Total land for building and shed , raw material ,finish

material stock

2-5 acre

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

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26

Raw material consumption for AAC block

Ingredients

Raw material consumption per CM of AAC

block

Fly ash

272 KG

Lime

71 KG

Cement

95 KG

Anhydride

12 KG

Aluminioum ( metel powder )

0.46 KG

Total solid

450 KG

Water in mix ( total ,excl. steam )

370 KG

Condensate which can be reused

In the mix ( water consumption

Above reduce correspondingly)

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

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

27

Energy and mass flow and balance diagram

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

Raw material Fly ash, lime,Gypsum ,aluminium, cement Raw material  pouring & mixing

Moulding & cutting

Curing at autoclave

Finish product

Compressed air Electricity

Water Electricity Steam  New grid DG set Boiler Fuel oil Diesel

Laxmi En-Fab Pvt. Ltd

 Ahmedabad – Gujarat –India,

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

+91 9712570097,9725012740/49

E mail: [email protected],[email protected] ,

Page

28

. .

Laxmi En Fab Pvt. Ltd.

AUTOCLAVED AREATED CONCRETE

REG. OFFICE:

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25

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 nilsin plot near patel alloy steelphase

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I , Vatva G.I.D.C. AHMEDABAD,GUJARATPh. +91

_

 9725012749/9712570097

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

Email:

[email protected] , [email protected]

[email protected]