Equipment for the production of aerated concrete – a machine for autoclaved aerated concrete blocks

The building industry is seeing a rise in the use of autoclaved aerated concrete (AAC) blocks because of their superior insulation qualities, low weight, and favorable environmental effects. These blocks are made using a unique manufacturing procedure that calls for particular tools. Anyone wishing to invest in this sustainable building material may find that a basic understanding of the machinery used in the production of AAC blocks changes everything.

Sand, lime, cement, and water are precisely mixed to start the process of making AAC blocks. This is where the dosing and mixing unit, the first piece of equipment, is extremely important. It guarantees that every ingredient is precisely measured and combined, producing a homogenous mixture that serves as the foundation for premium aerated concrete blocks.

When the mixture is prepared, molds are filled with it and allowed to set. When aluminum powder is added, the mixture expands and tiny air bubbles form, which is when the magic happens. This explains the distinct qualities of AAC blocks. Following the first setting, a cutting machine is used to precisely and consistently cut each block into the appropriate sizes.

The process ends with autoclaving, which involves curing the blocks in a specialized autoclave at high pressure and temperature. This apparatus is necessary to increase the blocks’ strength and longevity. Additionally, the autoclaving procedure guarantees that the blocks maintain their distinctively light structure without sacrificing strength. Purchasing the appropriate machinery for the production of AAC blocks not only increases productivity but also guarantees the creation of superior-quality blocks that adhere to industry standards.

Equipment Type	Description
Autoclave	A high-pressure chamber where aerated concrete blocks are cured using steam. This process helps the blocks gain strength and durability.
Mixing Machine	Mixes raw materials such as cement, lime, and sand with water to create the aerated concrete mix.
Cutting Machine	Shapes and cuts the aerated concrete mix into blocks of desired sizes before they are cured.
Hydraulic Press	Applies pressure to mold the aerated concrete mix into blocks, ensuring uniform density and strength.
Control Panel	Manages and monitors the operation of the machinery, including temperature, pressure, and mixing times.

Technology

The method for creating aerated concrete blocks is very straightforward and applies to both autoclaved and non-autoclaved aerated concrete. The way the final product is processed is the only distinction. The primary characteristic of this kind of concrete is the existence of air holes in the monolith’s structure, which form when aluminum powder interacts with other mixture ingredients and solidifies.

All of the key qualities of aerated concrete, such as its low weight, low density, and ability to insulate heat and sound, are derived from the pores in the material. As much as 85% of the volume is made up of air bubbles.

• Mixing sand, cement, lime, water for 5 minutes, then adding aluminum powder in the form of an aqueous suspension. The powder reacts with lime with the release of hydrogen, which provokes the appearance of many pores, evenly distributed throughout the thickness of the material.

• Pouring the mass into special metal forms, where the mixture still increases in volume (therefore, it is necessary to fill not to the top, but to half, to 2/3, depending on the composition).
• Vibration impact – to speed up the process of setting, hardening.
• Removal of excess solution, uneven places from the mass, which is already beginning to harden, with a wire string. The raw materials that remain in the form are cut into pieces of the required dimensions.
• Aerated concrete is sent to an autoclave, where the blocks are exposed to high temperature, pressure, which significantly speeds up the drying process and gives the material more stable characteristics.
• Sending the product for calibration on special milling machines.

A production autoclave’s use is essential for assessing the quality of completed blocks and ensuring that they meet the required standards. Aerated concrete is heated above 1000 degrees for 12 hours while submerged in water vapor. This treatment initiates the hardening and setting processes, which prevent future shrinkage and result in a more uniform and superior-quality block.

Aerated concrete that has not been autoclaved sets naturally. High-tech machinery is not needed for its production; aerated blocks can be produced independently and even without installations, but the material’s quality is rarely guaranteed.

Raw materials for aerated concrete

For both autoclaved and non-autoclaved aerated concrete, the mixture composition is the same. The phases of combining and pouring the solution are unaffected by processing characteristics.

1. Fine sand (fraction size no more than 2.1 millimeter), with a minimum clay content of 20-40% of the total volume or 250-350 kilograms per cubic meter. The exact weight depends on the requirements for the final material – the denser and stronger the aerated concrete must be, the greater its compressive load. Quarry, sea, river sand, dolomite flour and ground limestone, mineral fillers, etc. can be used.d.
2. Lime – from 1 to 5%.
3. Cement – ​​50-70% or 360-320 kilograms depending on the selected brand (the brand can be different – ​​from M40 to M500, but usually M400 D20 or M500 D20 are taken, the choice depends on the brand of aerated concrete that is planned to be obtained in the end).
4. Aluminum powder – 0.04-0.09% or 500-700 grams per cubic meter of finished mixture.
5. Clean water – 250-300 liters per cubic meter of finished material. It is desirable that at the time of mixing the water be heated to +40-60 degrees, which activates the hydration process and rapid maturation of blocks with increased strength.

Overview of the necessary equipment for production gas blocks

Aerated concrete can be produced using a variety of equipment, ranging from a small installation that can produce a few dozen blocks at a time to a large automatic line that can produce industrial scale. Everything in this situation is based on the available funds, specifications, personnel, goals, and other factors.

A small installation—more akin to a machine—will do if the gas block is produced to lower the cost of building a house and other structures on the site, but when you intend to organize a business, it is preferable to buy high-quality, productive equipment right away that can ensure the idea’s development and provide a large output.

Finding any equipment in Moscow and the surrounding areas won’t be difficult, so determining the needs and selecting the best option are the most crucial steps.

Conveyor

This kind of equipment is predicated on high levels of automation, low worker participation in the production process, the highest cost of a device set, stringent space requirements resulting from high production volumes, the presence of all necessary equipment in the set to carry out all stages, and a respectable level of profitability.

• Raw material bins and tanks.
• Belt conveyors for components.
• Mixing device.
• Pouring molds.
• Autoclave units.
• Special complex for cutting raw materials into separate even blocks.
• Mixing conveyor.
• Crushing unit.
• Several trolleys.
• Remote control for efficient automatic process control.
• Forklift.

Such equipment can cost up to 55 million rubles on average. This is a significant quantity, so if you want to start a business, you should consider this option. The line will enable you to produce at least 300,000 cubic meters of material annually, so the investment will be profitable. For block production, this is the quickest, most effective, and automated method available.

You must locate a space that is roughly 4,000 square meters in order to fit all of the equipment. If buying a line is out of your price range, consider used machinery. There are benefits as well as hazards. Good reputation surrounds products produced on the 3 million ruble Inntech-100 type conveyor, despite its lower productivity.

The mixing unit’s immobility is a feature of this installation. However, the forms move and fill out on their own. Cutting with a mechanical complex requires human intervention.

German-made lines, which are regarded as the most robust and highly productive, have shown themselves to be effective. These lines produce the highest quality aerated concrete blocks that precisely match the required specifications.

Stationary

Although stationary aerated concrete production equipment is substantially less expensive, its productivity is also noticeably lower. As a result, these lines can only produce 50 cubic meters of finished material a day on average. The installation kit consists of the following items: raw material dispensers, belt-type conveyors for feeding components to the mixing apparatus, a vibrating screen, and a boiler for heating water.

Employers will need to be drawn in in order for stationary equipment to function fully—and not just one. A space of 500 square meters will be sufficient for installation. Excellent quality material makes this option a good place to start if you want to launch a profitable business.

Mobile

For those who wish to make their own aerated concrete, this kind of installation is ideal. All units can be made from purchased units and parts; no special equipment is needed; all units can operate on a 220 W network (other types of equipment require 360 W). The only production volumes required are small, 2–10 cubic meters of material per day.

The key benefits of mobile installations are their low cost, self-assembly and self-maintenance nature, and lack of need for expansive spaces. In one of the utility rooms at home, you can make gas blocks by separately loading the ingredients into the mixer and forming blocks out of them. True, there is no need for an autoclave during installation, but the material quality will suffer greatly as a result.

Independent production of gas blocks

This option works well if all you need to do is produce a certain amount of material at home and don’t want to set up a business or buy expensive equipment. A minimum set of tools needed for production includes a concrete mixer, block molds, and metal strings for trimming excess. In home production, an autoclave is not used; instead, the blocks are allowed to dry naturally. As a result, you must arrange for storage space ahead of time.

To make gas blocks at home, all you need to do is choose the qualities that are needed, look for a recipe that works, buy the ingredients, and measure them precisely. After achieving homogeneity, all dry ingredients—aside from the powder—are added to the mixer. Water is then added, and everything is mixed. Next, aluminum powder—or the powder in the form of a suspension—is added.

Since the solution will expand in volume as a result of the reaction, the finished mixture is poured into molds without filling them all the way to the top. After a few days, the mold is taken apart and left to dry and strengthen naturally while the mixture is allowed to set and any excess is chopped off.

Gas blocks manufactured at home are far less high-quality than those produced with autoclave processing and modern machinery. However, such material might be the best choice in some situations.

Autoclave processing

An essential step in the manufacturing process, processing aerated concrete in an autoclave improves the material’s strength and other qualities and speeds up setting and hardening.

• Blocks cut into pieces of the required size are sent to the autoclave chambers.
• Inside, they are exposed to high pressure and temperature, here the blocks are for 12 hours.
• After the time has passed, the blocks can be left to stand for a couple of days and immediately used in construction – no need to wait 28 days, the hardening and strength gain process is complete.

Blocks made without an autoclave must be stored under ideal circumstances for a full 28 days.

For the article "Equipment for the production of aerated concrete – a machine for autoclaved aerated concrete blocks" on your site "All about concrete," here"s a suggested thesis statement: The production of autoclaved aerated concrete (AAC) blocks requires specialized equipment that transforms raw materials into lightweight, durable building materials. This process involves machines that mix ingredients like sand, lime, cement, and water, which are then molded and cured under high-pressure steam in autoclaves. Understanding the various types of equipment used in this process, including mixers, cutting machines, and autoclaves, can help businesses choose the right setup for efficient AAC block production. Investing in the right machinery not only improves production efficiency but also ensures high-quality output, making AAC blocks a popular choice in modern construction.

Comparative analysis of autoclaved and non-autoclaved production

When comparing the two types of material, autoclaved material comes out on top in many aspects. However, there are situations in which a building material’s specific properties are not as crucial, so it is important to compare the features of the two technologies and assess whether an autoclave is necessary as well as how much it will cost.

• Strength and thermal conductivity – due to the effect of steam under pressure and at high temperatures, products become stronger and less thermally conductive. Aerated concrete is baked, as it were, without having time to collapse or experience stress, which eliminates shrinkage in the future.
• Frost resistance – non-autoclaved blocks tolerate the freezing/thawing process worse (they survive fewer cycles without destruction and deformation).
• Geometry and appearance – autoclaved aerated concrete is more ideal in size and demonstrates maximum dimensional accuracy.
• Complexity of the production process – an autoclave is expensive, but its use does not affect the block production process itself.
• Fragility – non-autoclaved aerated concrete is more vulnerable to impacts, mechanical impacts.
• Price – an autoclaved block costs on average 10% more than one produced without processing.
• Shrinkage – autoclaved aerated concrete practically does not shrink, non-autoclaved can assume small values.

Selecting the appropriate machinery for your needs is made easier when you are aware of the equipment used in the production of autoclaved aerated concrete blocks. These devices are necessary for producing lightweight, high-quality blocks that are well-liked in the construction industry for their fire and thermal resistance.

Think about things like capacity, efficiency, and the particular features that fit your production needs when choosing a machine. The effectiveness of the entire production process as well as the caliber of the aerated concrete blocks can be greatly impacted by the appropriate equipment.

Purchasing the appropriate autoclaved aerated concrete block machine guarantees a more efficient production process and superior results. You can make an educated choice that improves your building projects and satisfies your production targets by concentrating on the important features of these machines.

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