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AAC Panel Production Line

AAC Panel (Autoclaved aerated concrete slabs), it is mainly composed of silica sand, cement, aluminum powder, lime. The double layer, two-way steel net which is anti-rust & anti-corrosion inside the panel. The AAC panel which go trough high temperature, high pressure & curing, is a kind of new building materials with superior performance.
According to the different application, it can be divided into the partition slab (GJB), external wall slab (GQB), roof slab(GWB) and floor slab (GLB), each plate design based on the different load of reinforcement, material thickness, length etc. Usually the thickness from 50 mm to 300 mm, with 25 mm as interval, the biggest length up to 6 meters (150 mm thickness).
Product specifications according to the national standard GB15762-2008 autoclaved aerated concrete slabs, execution, can also make special size products based on client requests.

  • 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 panel production machinery industry, we can supply customers with quality AAC production lines with capacity ranging from 150,000m3 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

 

Process Period:

Mixing period: 7-8 minutes

Slurry temperature: 40-45℃

Cake curing  2.5-3.0h

Temperature of curing  45~55℃

Cake strength after curing  0.15~0.18MPa

Autoclaved curing system:

Before-after autoclave   0.5h

Vacuumize    0.5h(0~-0.06MPa)

Lifting pressure     1.5h(-0.06~1.3MPa)

Constant pressure     8h(1.3MPa)

Releasing pressure     1.5h(1.3~0MPa)

Total     12h

 

Process:

 

(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) Steel rebar rolls into factory by car, after straightening & cutting & welding to mesh cage, then put to yard storage after de-rusting & anticorrosive & drying.

(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. For panel, the cake transport to rebar insert area, insert the steel rebar into the mould car after curing, and then transport to curing area for forming, temperature of curing room is 40-45℃, stop for 180-240min, up to strength level, pull out from curing to draw-out steel rebar, then the mould car goes to cutting area after several minutes curing.

(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). For panel, mould transfer to rebar insert area after pouring, then insert the steel rebar into mould after pouring, then transport to curing area for forming, the temperature of curing room is 40-45℃, stop for 180~240min , up to cutting strength, pull out from curing room to rebar draw-out area, then transfer to cutting area for several minuets curing.

(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.

(10) The waste water after production, make waste slurry through waste mixer, for secondary using.

 

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.
 

Table 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

 

Table 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. The 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 powdery should be according to the current national standard, the requirements of Aluminum Powdery Part 2: Ball Mill Aluminum Powdery 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%.
 
 
2.6 Water
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

 
 
2.7 Steel Rebar
It should meet the standard of hot-rolled carbon steel wire rods GB/T701, reinforced concrete steel  the second part: hot-rolled deformed bar GB1499.2, cold rolled deformed bar GB13788 OR cold-drawn low-carbon wire for concrete product JC/T540

 

Table 2-4  Requirements of rebar rust-resistance

 

Item Requirements
rust-resistance Corrosion area≤5%(After test)
adhesive force ≥1.0MPa
 

 

Table 2-5  Vertical rebar protection layer requirements

 

Item Basic size Allowable variation
Roof slab, floor slab, external wall slab Partition slab
protection layer thickness from bedding face  c1 20 ±5 +5/-10
protection layer thickness from top face c2 10 +5/-10
Remark: Equipped with partition slab & other special slab, its basic size & deviation should confirmed by both sides.  
 

AAC Panel Ordinary Specifications

Table 1-1 Ordinary Specifications

Length(L)

Width(B)

Thickness(D)

1800~6000

600

75、100、125、150、175、200、250、300

120、180、240

Remark: Other special specification and actual size confirmed by both sides.

 

Internal slabs specifications:

Table 1-2  Ordinary Specifications of Internal slab(GJB)

Thickness(mm)

75

100

125

≥150

Length(mm)

≤3000

≤4000

≤5000

≤6000

 

External slabs specifications:                                     

Table 1-3  Ordinary Specifications of External slab(GQB)

 

  Thinkness

      Max length                      Design load

 

100mm

 

125mm

 

150mm

 

175mm

 

200mm

≤1.2kn/m2

3600

4200

5200

6000

6000

1.4 kn/m2

3500

4200

4900

6000

6000

1.6 kn/m2

3300

4000

4700

5700

6000

1.8 kn/m2

3100

3900

4500

5400

6000

2.0 kn/m2

3000

3800

4300

5200

6000

2.2 kn/m2

2800

3600

4200

5000

5800

2.3 kn/m2

2700

3400

4100

4700

5600

 

 

Floor slab specifications:                                      

Table 1-4  Ordinary Specifications of Floor slab(GWB)

   Thinkness               Max length                    Design load

 

100mm

 

125mm

 

150mm

 

175mm

 

200mm

1.4 kn/m2

2600

3100

3700

4600

5600

1.6 kn/m2

2500

2900

3600

4400

5400

1.8 kn/m2

2400

2700

3500

4200

5100

2.0 kn/m2

2300

2500

3300

4000

4800

2.2 kn/m2

2200

2300

3200

3800

4500

2.4 kn/m2

2100

2300

3100

3600

4200

2.6 kn/m2

2100

2300

3000

3400

3900

 

Standard load: standard construction layer load value except gravity + floor load standard value

 

 Level

Strength level: A2.5,A3.5,A5.0,A7.5.
Dry density level: B04,B05,B06,B07.

 

 

 

Table 1-5  Defects restriction & quality of appearance

Item

Defects restriction which can be repaired

Appearance quality

Bending face cracks which parallel to width(horizontal)

Not allowed

without

Bending face cracks which parallel to length(vertical)

width<0.2mm,less than 3. Whole length≤1/10L

without

Bending face hollow

area≤150cm2,depth t≤10mm,less than 2 places

without

Big bubble

Diameter≤20mm。

No diameter>8mm,depth>3mm bubble

Missing angle

Roof slab, floor slab

Each end width direction not more than one place, which size is b1≤100mm,d1≤2/3D,l1≤300mm

Each slab≤1place(b1≤20mm, d1≤20mm, l1≤100mm)

External slab, partition board

Each end width direction not more than one place, width direction  size b1≤150mm,width direction d1≤4/5D, length direction l1≤300mm

Side damage & leakage

≤3m slab less than 2,>3m slab less than 3; Every length l2≤300mm,depth b2≤500mm

Every side≤1处(b2≤10mm, l2≤120mm)

Remark1: Repair material color, texture should be consistent with AAC, performance should be matching

Remark2:If the panel has be repaired, the appearance quality requirements should be the repaired one.

 

 

 

 

 

Table 1-6  Size deviation

Item

index

Roof slab, floor slab

External slab, partition board

Length

±4

Width

0 -4

Thickness

±2

Lateral bending

≤L/1000

Diagonal difference

≤L/600

Flat surface

≤5

≤3

 

 

 

Table 1-7  Strength level requirements

Item

Strength level

Roof slab, floor slab, partition slab

A3.5、A5.0、A7.5

Partition slab

A2.5、A3.5、A5.0、A7.5

 

 

 

 

Table 1-8  Basic performance for AAC panel

Strength level

A2.5

A3.5

A5.0

A7.5

Dry density level

B04

B05

B06

B07

Dry density/(kg/m2)

≤425

≤525

≤625

≤725

 compressive strength/MPa

average value

≥2.5

≥3.5

≥5.0

≥7.5

min. value of each group

≥2.0

≥2.8

≥4.0

≥6.0

drying shrinkage value(mm/m)

 standardized

≤0.50

rapid

≤0.80

frost-resistance

quality loss/%

≤5.0

frost resistance/MPa

≥2.0

≥2.8

≥4.0

≥6.0

heat conductivity coefficient

(dry)/[W/(m·K)]

≤0.12

≤0.14

≤0.16

≤0.18

 

Table 1-9  Fireproof performance of AAC panel

Wall width(mm)

50

75

100

125

150

Fire-resistant time

(hour)

1.57

>2

3.42

>4

>4

 

 

 

Table 1-10  Sound-insulated standard for AAC panel

Wall width & combination form

Unit

Detection value

100mm width NALC slab+ both putty

dB

40.8

125mm width NALC slab+ both putty

45.1

150mm width NALC slab+ both putty

46.6

175mm width NALC slab+ both putty

48.1

200mm width NALC slab+ both putty

51.3

Form 1(Add the middle rook wool on both sides of side plate)150mm slab + Each side is 40mm rock wool+ Each side is 10mm gypsum board(decoration)+ both putty

55.2

Form 2(Add the middle rook wool on both sides of side plate)100mm thick slab+50mm thick rock wool+100mm thick slab + both putty

58.6

 

 

Table 1-11  Insulation performance of AAC external slab

Thickness

Thermal resistance

Index of thermal inertia

Resistance of heat transfer

Heat transfer coefficient

δ(mm)

R(m2.k/W)

D=∑RS

R0(m2.k/W)

K(W/ m2.k)

50

0.31

0.92

0.46

2.17

75

0.45

1.31

0.60

1.67

100

0.59

1.69

0.74

1.35

125

0.72

2.07

0.87

1.15

150

0.86

2.45

1.01

0.99

175

1.00

2.83

1.15

0.87

200

1.14

3.22

1.29

0.78

 

Table 1-12  Insulation performance of AAC roof slab

Thickness

Thermal resistance

Index of thermal inertia

Resistance of heat transfer

Heat transfer coefficient

δ(mm)

R(m2.k/W)

D=∑RS

R0(m2.k/W)

K(W/ m2.k)

150

0.81

2.28

0.96

1.04

175

0.93

3.20

1.08

0.93

200

1.05

3.59

1.20

0.83

225

1.17

3.97

1.32

0.76

250

1.29

4.36

1.44

0.69

Thermal calculation, AAC roof slab including AAC slab, cement mortar screed-coat, waterproof layer, etc.


 


 

 


 

 

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