A new state-of-the-art AAC plant for the Sichuan region
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A new state-of-the-art AAC plant for the Sichuan region

With the strong support of the Chinese government, the prefabricated construction industry entered a  “Golden Age” of rapid development. It is estimated that up to 15% of new buildings will be prefabricated  buildings until the end of 2020 and up to 30% until the end of 2025. Sichuan Province of China is actively  promoting the innovation of construction, in which some enterprises with strong comprehensive strength are  vigorously promoting the application of new prefabricated construction. With the development of prefabricated steel structures, the production and application technology of AAC panels gradually plays an important role in the construction market.

The Sichuan based Gaoyu Group Co., Ltd. was established in the 1970s. Today the group owns twelve sole  proprietorship enterprises and two joint ventures.  Gaoyu Group has always adhered to the concept of  “Scientifc Outlook on Development” following the  sustainable development path of environmental protection. The company mainly focuses on three business segments: the construction industry including  construction, building materials and exploitation of  real estate; the industrial circular economy industry  including chemical energy and mining industries as  well as the modern service industry with fnance,  medical treatment and education as the main industries.


Plant design

To speed up resource integration, Gaoyu Group  decided to vigorously develop the prefabricated green building materials business and establish  Sichuan Gaoyu building materials Co., Ltd. in Chengdu, Sichuan Province, to produce AAC products. After intensive investigation and research, in 2019,  Gaoyu signed an agreement with Keda Suremaker to  purchase an automatic AAC block/panel production  line with an annual output of 300,000 m3 .  Since the company already has a dry mixed mortar  production line, the new AAC production has to be  built in an area separated from the original plant.  Ingenious planning is highly encouraged for the  plant layout design.


After site investigation and careful study, the Keda  planning team made a customized design with  single head autoclaves. A closed grouping area heated by steam in front of the autoclaves was designed  to ensure the temperature of the green cake before  autoclaving, which improves the heating efciency of  the autoclave and ensures high quality of the AAC  panels. 


Pre-curing and cutting 

The roofs of the pre-curing room and the closed  grouping room are designed as working area, where  the mesh cages are processed. The steel coils can be  lifted by cantilever crane to the roof of the closed  grouping room and then be transferred by a single  beam crane to the section where the mesh cage will  be welded and fabricated automatically. After assembly the whole mould mesh cages can be dipped  automatically into anti-corrosion paint and be dried  on the roof of the pre-curing room by an automatic  reinforcement saddle frame cycle system; the steel  needles can be cleaned and waxed there automatically after they have been pulled out of the green  cake. The whole process reduces material consumption and labour costs efectively.

The cutting system of the plant can cut all six sides of  the green cake. Four sets of cutters can be adjusted  according to diferent production requirements and  grooving sizes, automatically and without shutting  down the whole cutting system. Panels and blocks  are produced in one mould at the same time, the cutters can partially groove the cake for panels. Waste  material can be fed through the cutting pit into the  slurry recovery system and then be recycled. The grooving of the green cake can greatly improve  the efciency of panel production and reduce the investment for equipment and civil construction work  for the white cake processing section. It also avoids  waste material, noise, and dust, that is caused by  white cake processing.

The horizontal cutting machine has two cable-stayed  beams aligned parallel to each other. On each one  of these two beams several small columns are lined  up in regular intervals to each other. A steel cutting wire is attached to a small column on one beam  and stretched to the respective small column that  is positioned at the same height on the other beam.  Accordingly each “pair of small columns” on the two  beams is used to hang only one steel wire, which  means that there will be only one cutting kerf settlement (0.6~0.8 mm) on one vertical plane during the  cutting process, so that the gravity settlement crack  impact will be lessened when producing thin panel.  Even when producing 5 cm thin panel and therefore  cutting the cake over the entire length of the mould,  only one steel wire is needed to be hung on each  pair of “wire hanging columns” – the settlement at  the same position has only one cutting gap, which  efectively solves the defect of cutting crack of thin  panel. In addition, obviously less friction will be  caused when the cutting wire is about to leave the  cake.


The vertical cutting machine combines a large swing  frame with low swing frequency to ensure a smooth  cutting surface. The swing guide of the swing frame  adopts the slide structure of the guide rail with high  precision. With the mechanical synchronous lifting  frame structure, the side plate exchange is done  smoothly and without shaking. 


The cutting conveyor adopts chain drive traction  mode and the transmission device is placed at the  end of the cutting pit to avoid pollution by sludge.  For this same purpose, the cutting track can be  covered with special cover boards.



Packing system solves problem of  product damage 

When block and panel are produced in the same  mould, and there are not enough blocks for one  whole pallet, the packing system can combine blocks  from several moulds/production cycles onto one  pallet without manual intervention of the machine  operator. The new packing system solves the problems of product damage, single packing specifcation  and limited transportation of a traditional packing  system. The stacking specifcation can realize 1.2  x 0.6 m, 1.2 x 1 m, 1.2 x 1.2 m, 1 x 0.6 m multiple  stacking, and the height of the stacking can be 1.5 m,  1.8 m and 2.4 m.

As a leading brand in China’s AAC industry, Keda  Suremaker is committed to advanced technical  innovation and customized design to achieve a winwin situation for its clients all over the world. With  its special R&D test center, Keda Suremaker can  do raw material analyses and of er its customers a  customized concrete mix.  The design of a customized production plant is  adapted to the real conditions at the respective  company premises. All the equipment will undergo  pre-delivery commissioning. Keda Suremaker will  also provide professional training for the local staf  of the customer, project installation supervision and  operation support during initial operation.


   +86-555-2113600
   2887, Tianmen Rd, Economic & Technological Development Zone, Ma’anshan, Anhui Prov., China

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