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Autoclaved Aerated Concrete (AAC) is a precast structural product made with cement, lime, water and sand that expands by adding aluminum powder.
It is an economical, sustainable, solid block that provides thermal and acoustic insulation as well as fire and termite resistance. AAC is available in a variety of forms, ranging from wall and roof panels to blocks and lintels.
To manufacture AAC, Portland cement is mixed with lime, silica sand, or recycled fly ash (a byproduct from coal-burning power plants), water, and aluminum powder or paste and poured into a mold. The reaction between aluminum and concrete causes microscopic hydrogen bubbles to form, expanding the concrete to about five times its original volume. After evaporation of the hydrogen, the now highly closed-cell, aerated concrete is cut to size and formed by steam-curing in a pressurized chamber (an autoclave). The result is a non-organic, non-toxic, airtight material that can be used for wall, floor, and roof panels, blocks, and lintels which according to the manufacturers, generate no pollutants or hazardous waste during the manufacturing process
AAC features include structural capacity, thermal, fire, and acoustical resistance properties. Because of the thermal mass of AAC and its ability to store and release energy over time, AAC may be beneficial in climates where outdoor temperature fluctuates over a 24-hour period from above to below the indoor temperature conditioned air set point.
Main parameters of Novotek AAC plant
|
Description |
Item |
|
Capacity (103M3/a) |
10-45 |
|
Cake Size (m) |
4-6 x 1.2/1.5 x 0.6 |
|
Cutting grade (mm) |
Horizontal: 10; Vertical: 5 |
|
Cutting accuracy (mm) |
±2; ±1; ±1 |
|
Production cycle (min/mould) |
4-6 |
|
Pre-curing time (hrs) |
2.5-3 |
|
Autoclave time (hrs) |
8-12 |
|
Density (Kg/M3) |
400-700 |
Raw material preparing, mixing and pre-curing process description:
Sand (or flyash) and gypsum should be milled into slurry and storage in tank.
Aluminum powder (or paste) should be mixed with water and make into suspension liquid.
Powder material (cement and lime), slurry and aluminum suspension liquid will be first scaled separately, and after uniformity mixed then pouring into mould. (If produce AAC panel, here you should pre-put into reinforcement fabric in mould)
The green 'cake' will be pre-cured for about 2.5 ~ 3 hours in a certain temperature.
Cutting process description:
Pre-cured ‘Cake’ with mould will be carried by tilting crane and overturned 90o then demoulded in beginning of cutting line.
'Cake' will be cut in Horizontal and Vertical cutting stations respectively, male-female joints, handgrips also will be processed if required.
Top layer scrap will be removed by vacuum cover.
Bottom layer scrap will be removed on tilting crane, and all cut waste will be recycled.
Grouping and autoclave process description:
‘Cake’ in vertical (or horizontal) position with side plate (or steam plate) will be put on autoclave cart and then grouping, one cart can support for two or three cakes according to autoclave size.
Ferry (before autoclave) is used to transfer the grouped carts into each autoclave.
Autoclave time will be 8-12hrs according to actual situations.
Separating and packing process description:
The steamed 'cake' will be discharged from autoclave by another ferry (after autoclave) and then crane will transfer it to separating and packing track.
'Cake' will be separated into blocks by separator in vertical direction.
Blocks will be discharged from side plates by hydraulic clamp and then sent for packing.
Side plate will return to cutting station and reassembled with mould frame for next cycle.
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