The AAC block manufacturing process involves the following steps:
The key ingredient to manufacture AAC blocks is fly ash or pond ash. Fly ash is mixed with water to form fly ash slurry. Slurry thus formed is mixed with other ingredients like lime powder, cement, gypsum and aluminium powder in quantities consistent with the recipe.
A dosing and mixing unit is used to form the correct mix to produce Autoclaved Aerated Concrete (AAC) blocks. Fly ash/sand slurry is pumped into a separate container. Once the desired weight is poured in, pumping is stopped. Similarly lime powder, cement and gypsum are poured into individual containers using screw conveyors. Once required amount of each ingredient is filled into their individual containers control system releases all ingredients into mixing drum.
After thorough mixing, slurry containing fly ash (or sand), lime powder, cement, gypsum and aluminium is poured in moulds. Moulds can be of various sizes depending upon installed capacity. Before casting, moulds are coated with a thin layer of oil. This is done in order to ensure that green-cake does not stick to moulds.
Demoulding and cutting are very critical processes in AAC blocks manufacturing. These two processes play a major role in defining amount of rejection as well as dimensional accuracy of the final product. Once a mould is out of pre-curing room, it is lifted by a crane or rolled on tracks for demoulding operation. Two types of cutting are carried out: horizontal and vertical cutting.
The cut blocks then enter the autoclave and the semi-finished products are handed over to the trolley. In the autoclave, hardening takes place. Once it hardens, it leaves the autoclave. After which, hanging and stacking of finished products takes place.
Once the AAC blocks and panels are ready, they are packed with moisture-proof material and loaded onto the truck or transport vehicle.