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AAC Block Production Line

Advantages
a) Smooth technology flow, independent circulating line of template, side plate and autoclave, non-intervene equipments enhance operation efficiency and safety.
b) Advanced overhead conveying system, special overhead cross moving system and hydraulic control system for demoulding machine, semi-product stacker, separator and brick clamp, low workshop investment for no need industrial travelling crane, simple workshop structure and close technology layout.
c) Flaying rotating table with patent offer a solution for cutting residual recovering completely.
d) Floor hauling engine coordinate with cross moving trolley and pushing device to drive the template and autoclave trolley move.
e) Mechanical drive for product out autoclave, the building block is conveyed onto the separator for separating, and then conveyed to the chain conveyor pallet by the brick clamp, at last, the packed brick is transferred to stock yard by the forklift. It is different mode from man transporting.

  • KEDA SUREMAKER

 

 

WHAT IS AAC?
The AAC production process includes raw material preparation, batching and mixing, pouring, precuring, cutting, autoclaving, and packing. With decades of experience in serving the AAC blocks production machinery industry, we can supply customers with quality AAC block production lines with capacity ranging from 80,000m3 to 40,000m3 per year.


Automatic AAC Block Making Machine with CE Approved
Chart 1 the parameter of the processes

Processes Parameter
Mixing period 5-6 minutes
Pouring slurry temperature 40-45ºC
Cake curing time 2.5-3.0h
Cake curing temperature 45~55ºC
Cake strength after curing 0.15~0.18MPa
Autoclaved curing system Before-after autoclave 0.5h
Vacuumize 0.5h(0~-0.06MPa)
Listing pressure 1.5h(-0.06~1.3MPa)
Constant pressure 8h(1.3MPa)
Releasing pressure 1.5h(1.3~0MPa)
total 12h

 

 RAW MATERIALS  
Siliceous materials : Sand / Fly ash / Tailings containing silicon / Ceramic waste 
Calcareous material: Lime block + cement + gypsum 
Others: Aluminum powder paste  
Automatic AAC Block Making Machine with CE Approved
THE ADVANTAGES OF AAC:

1. Low density : Can be 325kg /m3
2. Good thermal insulating properties
3. Cost few time to build, saving time
4. Easy to operate , saving labor cost
5. Good performance of preventing fire
6. Good sound-insulation properties
7. Durable , anti-seismic , recyclable

Automatic AAC Block Making Machine with CE Approved

Automatic AAC Block Making Machine with CE Approved


CUTTING SYSTEM 

Special cutting design : All the steel wire columns are fixed on two main oblique  beams of cutting machine and each pair of the columns is used to fix only one steel wire , so that the horizontal  cutting machine can avoid the settlement cracks problem in thin block and panel cutting , and achieve the minimum horizontal cutting thickness of 50MM block out of a whole mould. The integral swing frame of the vertical cutting machine can ensure the side plate replacement , the cutting action can be synchronized with ferry replacement. With automatic detection system . the broken wire can be timely detected.
 
Automatic AAC Block Making Machine with CE Approved


PACKING SYSTEM 

Automatic packing system can realize the automatic rotation stacking and splicing of blocks and  realize the packing function with pallet or non-pallet. The stacking specification can realize 1.2m×0.6m\ 1.2m×1m1.2m×12m\ 1m×0.6m multiple  stacking , and the height of the stacking can be 1.2m, 1.5m , 1.8m and 2.4m. 
Automatic AAC Block Making Machine with CE Approved

AAC FINAL PRODUCTS

 1.Product classification

Product classification is according to national standards GB/T 11968-2006 AAC block, also can be according to user's requirements to produce product with special specifications size.
 

Chart 2 Specification & Index
Name AAC block
Weight 300~600 Kg/m3(control led by formula)
After autoclave compressive strength average value≥3.5MPa, Min. value<=2.8Mpa
Drying shrinkage value Measured under condition of rapid method≤0.8mm/m;Measured under condition of standard method≤0.5mm/m
Frost-resistance After the cycle of freezing and thawing for 15 times,weight loss≤ 5%,strength loss≤ 20%
Coefficient of thermal conductivity ≤0.14~0.16W/m.k

 
1.2 The block is classified by compressive strength and volume density.
Strength level: A1.0, A2.0, A2.5, A3.5, A5.0, A7.5, A10.
Dry density level: B03, B04, B05, B06, B07, B08.

 
 
1.3 Block level
The block is divided into high-class(A), first-class(B), qualified product (C) according to the size variation, appearance quality, dry density, compression strength & frost-resistance.
 

 
1.4  AAC Block indicator
Chart 3  Size variation& appearance

Project Indicator
High-class
(A)
Qualified product
(B)
Permissible variation of dimension
mm
Length L ±3 ±4
Width B ±1 ±2
Height H ±1 ±2
Missing angle The min. size not more than /mm 0 30
The max. size not more than /mm 0 70
Missing angle no. larger than the above size, not more than 0 2
Crack length The crack length through one edge and two surfaces not more than crack directional size sum on crack surface 0 1/3
The crack length of any surface can not be larger than crack directional size 0 1/2
The cracks larger than the above size, not more than 0 30
The depth of cracking, sticking, damage can not be more than/mm 0 1030
Plain bending Not allowed
Surface porosity, lamination crack Not allowed
Surface oil Not allowed

 
 
Chart 4  Cubic compression strength for block  

Strength level Cubic compression strength (MPa)
Average not less than Single group min. not less than
A1.0 1.0 0.8
A2.0 2.0 1.6
A2.5 2.5 2.0
A3.5 3.5 2.8
A5.0 5 4.0
A7.5 7.5 6.0
A10.0 10 8.0

 
 
Chart 5  Dry density for block(kg/m3)

Dry density level B03 B04 B05 B06 B07 B08
Dry density High-class (A)≤ 300 400 500 600 700 800
Qualified product
 (B)≤
325 425 525 625 725 825

 
 
Chart 6  Strength level for block

Dry density level B03 B04 B05 B06 B07 B08
Strength level High-class (A)≤ A1.0 A2.0 A3.5 A5.0 A7.5 A10.0
Qualified product
 (B)≤
A2.5 A3.5 A5.0 A7.5

Main technical-economic indicator
 

No. Index content unit Index value
I Name    AAC block
Production scale(annual capacity)
150,000m³
Specification(cake: 4.2×1.2×0.6) m China national standard(GB)
II Working system(three-shift continuous weekly production)   300 days / year
22.5 hours / day
7.5 hours / shift
III Main raw material consumption    
1. sand Ton / year 63,000
2.lime Ton / year 15,300
3. gypsum Ton / year 2,700
4.cement Ton / year 9,000
IV Total capacity (ball mill power) KW 950(375)
V Annual  power consumption 10,000KW.h 215.11
VI Annual  water consumption Ton 81000
VII Annual  gas consumption Ton 27000
VIII Single-shift operators(including forklift and boiler gas distribution) people 16
IX Total plant construction area hectare 3
Construction area m2 7,000
Storage covering m2 6,000

 

 

Main technical-economic indicator
 

No. Index content Unit Index value
I Name
AAC Block
Scale (Annual capacity
200,000m³
Specification ( Cake:4.8×1.2×0.6) m  
China national standards(GB) 
 
II Working system (three-shift continuous weekly production)
300 days/year
22.5 hours/day
7.5 hours/shift
III Main raw material consumption

1.Sand Ton/Year 84,000
2. Lime Ton/Year 20,400
3. Gypsum Ton/Year 3,600
4. Cement Ton/Year 12,000
IV Total capacity (Ball mill power) KW 1,200510
V Annual Power Consumption 0,000KW.h 271.72
VI Annual water consumption T 108,000
VII Annual  gas consumption T 36,000
VIII Single-shift operators(including forklift and boiler gas distribution) People 16
IX Total plant construction area Hectare 3.5
Construction  area m2 7,000
Storage covering area m2 8,000

 

 

Main technical-economic indicator

No. Index content unit Index value
I Name 
AAC block
Production scale(annual capacity)
250,000m³
Specification(cake: 5.0×1.2×0.6) m China national standard(GB)
II Working system(three-shift continuous weekly production)
300 days year
22.5 hours / day
7.5 hours / shift
III Main raw material consumption

1. sand Ton / year 105,000
2.lime Ton / year 25,500
3. gypsum Ton / year 4,500
4.cement Ton / year 15,000
IV Total capacity (ball mill power) KW 1,350(625)
V Annual  power consumption 10,000KW.h 305.75
VI Annual  water consumption Ton 135,000
VII Annual  gas consumption Ton 45,000
VIII Single-shift operators(including forklift and boiler gas distribution) people 16
IX Total plant construction area hectare 35
Construction area m2 7,500
Storage covering m2 8,500
 

 

 

Main technical-economic indicator

No. Index content unit Index value
I Name 
AAC block
Production scale(annual capacity)
300,000m³
Specification(cake: 6.0×1.2×0.6) m China national standard(GB)
II Working system(three-shift continuous weekly production)
300 days year
22.5 hours / day
7.5 hours / shift
III Main raw material consumption

1. sand Ton / year 126000
2.lime Ton / year 30600
3. gypsum Ton / year 5400
4.cement Ton / year 18000
IV Total capacity (ball mill power) KW 1600815
V Annual  power consumption 10,000KW.h 362.3
VI Annual  water consumption Ton 162000
VII Annual  gas consumption Ton 54000
VIII Single-shift operators(including forklift and boiler gas distribution) people 16
IX Total plant construction area hectare 45
Construction area m2 9200
Storage covering m2 10000
 

 

 

Main technical-economic indicator

No. Index content unit Index value
I Name 
AAC block
Production scale(annual capacity)
350,000m³
Specification(cake: 6.0×1.5×0.6) m China national standard(GB)
II Working system(three-shift continuous weekly production)
300 days year
22.5 hours / day
7.5 hours / shift
III Main raw material consumption

1. sand Ton / year 147000
2.lime Ton / year 35700
3. gypsum Ton / year 6300
4.cement Ton / year 21000
IV Total capacity (ball mill power) KW 1650815
V Annual  power consumption 10,000KW.h 373.62
VI Annual  water consumption Ton 178500
VII Annual  gas consumption Ton 52500
VIII Single-shift operators(including forklift and boiler gas distribution) people 16
IX Total plant construction area hectare 50
Construction area m2 10000
Storage covering m2 12000
 

 

Process period

Mixing period    5-6 minutes

Pouring slurry temperature    40-45℃

Cake curing time    2.5-3.0h

Cake curing temperature    45~55℃

Cake strength after curing    0.15~0.18MPa

Autoclaved curing system

Before-after autoclave      0.5h

Vacuumize      0.5h(0~-0.06MPa)

Listing pressure        1.5h(-0.06~1.3MPa)

Constant pressure        8h(1.3MPa)

Releasing pressure       1.5h(1.3~0MPa)

total                     12h

 

 

 Process engineering brief

(1)The lime and gypsum will be crashed and ball milled after entering the factory, batch production for this section working system. The raw materials is continuous crashed into grain which granularity is less than or equal to 25mm, and then be put in the storage respectively through 3-pass splitting by bucket elevator. Lime and gypsum-grain will be fed in proportion through speed belt scale and into ball mill for mixture levitation through the respective baiting splitting, When the fineness reached 3500 ~ 4000cm2 / g, the lime and gypsum-grain will be sent into cement silo through bucket elevator for storage.

(2) The sand is transported to stacking place by dump truck for use.

(3) Sand will be transported to the hopper by loader car, then after measuring be transported to wet ball miller for milling by the belt conveyor, milled to mortar and be transported to storage tank stand-by through beating pool.

(4)Mortar poured into slurry measurement through slurry pump, the cement transported into powder measurement through screw conveyor; The measured mortar, cement poured into pouring mixer according to ratio order for mixing, the amount of steam passed into mixer based on process requirements, slurry temperature in the mixer reached about 40 ~ 45 ℃, mixing time is about 3 ~ 4mins, open the lower valve of aluminum paste mixer, make it flow into pouring mixer for mixing, mixing time is not more than 40s, then the slurry poured into mold. The whole period is about 5 to 6mins.

(5) The poured mold car transfers to curing area for gas-forming & initial setting, temperature in curing room is about 40 to 45 ℃, curing for 150 to 180mins, the mold car is pull out of curing room when reached the cutting strength.

(6)Mould will be transported to the cutting area when the curing reach to cutting requirements, turning table separates the mould and turns the cake to 90°spaced on the cutting car. The car carried cake achieves six sides cutting through horizontal and vertical cutting process(length±3mm~width±1mm~±1mm).

(7) Put the cake on the semi-finished product turning table by crane after cutting, the cake turned to 90 ° by turning table to be peeled the bottom & top leather, then be turned again to original position, next be stacked on the steam curing car by the semi-finished product stacker, marshaled steam curing car be put into the autoclave for high temperature (200 ℃), high pressure (1.3 MPa), autoclave (about 12 hours). Sweep gas in the autoclave be sent to curing area by the pipe.

(8) Finished curing cake will be combined, divided, transfer and packaging after classified placing, separating and clamping treatment. Then sent the after-package cake to the storage yard by forklift. Finished product separated bottom plates will be transported to compound die area by curing car for mould car compounding. After cleaning and oil brushed, the curing car will be poured for re-use. Then back to the curing car and process the autoclave curing after stacking and grouping.

(9) The recycled waste in production can be made into waste slurry by 

waste mixer , the stored waste slurry can be reused with raw material.

 

2.Raw material requirement


2.1 Cement
Producing AAC block adopts lime-cement mixing calcium system, can use standard 425# cement, and is according to technical requirements GB 175 General Silicate Cement. Before entering factory with manufacture quality certification, The cement should be used in sequence. Cement technical requirements as blow:
(1) Free CaO content should be not more than 1.5%, CaO content is 60%.
(2) NaCl & KCl content should be not more than1%~1.5%.
(3) Specific surface area 2500~3500cm3/g.
(4) Volume stability is qualified.
(5) Setting time initial setting 1~3h final setting 3~6h.
 

2.2 Sand
It should be according to the standard JC/T 662 Sand for Silicate Building Products to select. Generally, the higher quartz content in the sand, the better AAC block quality.


Chart 2-1 Main technical index for sand
Name
Grade
SiO2% K2O+Na2O% Organic matter Mica% SO3% Mud% Moisture content%
High-class ≥85 ≤1 Qualified ≤0.5 1 3 8
Firs-class ≥75 ≤3 5
Qualified product ≥65 ≤5 ≤1 2 8
 
Chart 2-2 Grain composition for sand
Name
Grade
Content,%
High-class First-class Qualified product
2.5~5.0(round hole) 0 0
1.25~2.5(square hole) 10 10
0.16~0.25(square hole) 60 45
<0.16(square hole) 30 45

 

2.3 Quick lime
Lime is also one of the main raw material. Its function is coordinating with cement to provide effective calcium oxide, than makes it working with SiO2, Al2O3 from silica material under hydrothermal condition to generate hydrated calcium silicate. So it should be according to JC/T621 Quick Lime for Silicate Building Product standard. Effective calcium oxide content should be more than 65%, the best is more than 80%.
 

2.4 Aluminum paste(powder)
Aluminum paste is according to JC/T 407 Aluminum Paste for AAC standard. Aluminum powder should be according to the current national standard, the requirements of Aluminum Powder Part 2: Ball Mill Aluminum Powder GB/T 2085. 2.
 

2.5 Gypsum
Gypsum is a modifier during gas processing in the AAC. The regulating effect of gypsum mainly reflects in deferring the speed of quick lime digesting & slurry thickening. Gypsum should be according to the current national standard, the requirements of Natural Gypsum GB/T 5483. The main chemical compositions of gypsum are CaSO4,CaSO4·2H2O>70%.
 

2.6Water
According to the standard, water ratio is advisable to 0.60.


Chart 2-3 water quality requirement
Content pH Cl-  (mg/L) SO42-(mg/L) Na+ +K+(mg/L) K+  (mg/L)
Operating range 6~9 <600 <1000 <450 <100

 

 

1.Product classification
Product classification is according to national standards GB/T 11968-2006 AAC block, also can be according to user’s requirements to produce product with special specifications size.
 

Chart 1 Specification & Index
●Name AAC block
●Specification 6.0×1.5×0.6 m³/mould, block size according to requirements
●Weight 400~600 Kg/m3(control led by formula)
●After autoclave compressive strength average value≥3.5MPa, Min. value≦2.8Mpa
●Drying shrinkage value Measured under condition of rapid method≤0.8mm/m;Measured under condition of standard method≤0.5mm/m
●Frost-resistance After the cycle of freezing and thawing for 15 times,weight loss≤5%,strength loss≤20%
●Coefficient of thermal conductivity ≤0.14~0.16W/m.k

 
 
1.1 Specification

Block specification is shown in Chart 2.

Charts 2  Block specification (mm)
Length L Width B Height H
600 100 120 125
150 180 200
240 250 300
200 240 250 300
Remark: It should be resolved through consultation by the two sides if need other specifications.
 

 
 
1.2 The block is classified by compressive strength and volume density.
Strength level: A1.0, A2.0, A2.5, A3.5, A5.0, A7.5, A10.
Dry density level: B03, B04, B05, B06, B07, B08.
 
 
1.3 Block level
The block is divided into high-class(A), first-class(B), qualified product (C) according to the size variation, appearance quality, dry density, compression strength & frost-resistance.
 
 
1.4  AAC Block indicator

Chart 3  Size variation& appearance
Project Indicator
High-class
(A)
Qualified product
(B)
Permissible variation of dimension
mm
Length L ±3 ±4
Width B ±1 ±2
Height H ±1 ±2
Missing angle The min. size not more than /mm 0 30
The max. size not more than /mm 0 70
Missing angle no. larger than the above size, not more than 0 2
Crack length The crack length through one edge and two surfaces not more than crack directional size sum on crack surface 0 1/3
The crack length of any surface can not be larger than crack directional size 0 1/2
The cracks larger than the above size, not more than 0 30
The depth of cracking, sticking, damage can not be more than/mm 0 1030
Plain bending Not allowed
Surface porosity, lamination crack Not allowed
Surface oil Not allowed
 

 

Chart 4  Cubic compression strength for block  
Strength level Cubic compression strength (MPa)
Average not less than Single group min. not less than
A1.0 1.0 0.8
A2.0 2.0 1.6
A2.5 2.5 2.0
A3.5 3.5 2.8
A5.0 5 4.0
A7.5 7.5 6.0
A10.0 10 8.0
 

 

Chart 5  Dry density for block(kg/m3)
Dry density level B03 B04 B05 B06 B07 B08
Dry density High-class (A)≤ 300 400 500 600 700 800
Qualified product
 (B)≤
325 425 525 625 725 825
 

 

Chart 6  Strength level for block
Dry density level B03 B04 B05 B06 B07 B08
Strength level High-class (A)≤ A1.0 A2.0 A3.5 A5.0 A7.5 A10.0
Qualified product
 (B)≤
A2.5 A3.5 A5.0 A7.5
 

 

Chart 7  Drying shrinkage, freeze-proof, heat conduction
Volume density level B03 B04 B05 B06 B07 B08
Drying
shrinkage value
 
·        
Standardized method
 /(mm/m) ≤
0.50
Rapid method /(mm/m) ≤ 0.80
Frost-resistance Quality loss/% ≤ 5.0
Frost-resistance /Mpa ≥ High-class(A) 0.8 1.6 2.8 4.0 6.0 8.0
Qualified product
(B)
2.0 2.8 4.0 6.0
heat conductivity coefficient (dry state)/〔W/(m•k)〕 ≤ 0.10 0.12 0.14 0.16 0.18 0.20
Block drying shrinkage value is measured by standardized method & rapid
method, decided by standardized method if the measured results conflict.
 

 

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