Production flow chart of AAC block plant in Bangladesh: Step-by-step process
Are you thinking about entering the highly prospective construction materials industry in Bangladesh? If you answer yes,
AAC block production is a solid starting point. AAC (autoclaved aerated concrete) blocks are
reshaping modern construction.
It has become one of the most popular go-to building materials globally.
Discover the AAC block production flow chart, the machinery required, and the benefits of running a fully
automated plant. Boost your production line business with durable AAC block machines.
AAC blocks are foam concrete building materials made from a mixture of quartz sand, gypsum, lime, cement,
water, and aluminum powder. The main feature of the block is that it has countless tiny air bubbles, which
make it super lightweight
without compromising its strength. This is one of the most preferred materials in construction because:
Lightweight: Reduces dead load of the structure to almost half.
Fire-resistant: It is compatible with high temperatures.
Thermal insulation: Keeps interiors cool in summer and warm in winter.
Eco-friendly: Its production line releases minimal waste, and recyclable materials are
used. The non-toxic blocks are perfect for interiors.
Fast construction: Larger blocks mean faster wall completion, which means on-time
project completion.
Pest resistance: AAC blocks are resistant to pests, especially rodents(rats, mice, etc)
and termites.
Manufacturing process of AAC block plant
The production of the AAC blocks involves “six key stages.” Each stage required proper factory
maintenance to ensure the best quality and performance. Let’s start with a simple overview of the stages,
and then we will explore
the detailed work process.
Stage 1
Raw materials preparation
Stage 2
Batching and Mixing
Stage 3
Pouring and Pre-curing
Stage 4
Cutting
Stage 5
Autoclaving
Stage 6
Separating and Packing
Detailed production flow chart of AAC block plant
01
Preparation of the raw materials
Well-sourced premium-grade raw materials are the first important step of the process. The primary raw
materials required are:
Sand or Fly ash
Lime
Cement
Gypsum
Aluminium
02
Batching and Mixing
The accuracy of mixing the raw materials is crucial. Precise quantities of raw materials that are
measured and mixed using a fully automated system ensure consistency.
The mixing proportion slightly varies with the local availability of the raw materials, budget, and
quality demand.
A standard mixing ratio of the raw materials for making AAC blocks is shown below:
Sand: 65-70%
Cement: 14-18%
Lime: 10-12%
Gypsum: 4-5%
Aluminium: 500-700g per cubic meter
Water
Mixing: There are two mixing functions, the slurry mixer and the pouring mixer.
The slurry mixer combines water with fly ash or sand to create a uniform slurry.
The pouring mixer blends slurry with cement, lime, gypsum, and aluminum powder.
Aluminum powder is added later as a foaming agent.
03
Pouring and Pre-curing
Pouring: Fly ash or sand is ground into a slurry with water and stored in tanks. The mixture is
then stirred continuously to prevent sedimentation. The mixed slurry is poured into molds to form large
shapes.
Pre-curing: The mixture is allowed to set for 2-3 hours. During this time, the mass expands due
to the gas bubbles and gains a semi-solid texture.
04
Cutting
The green cake is carefully demolded and passed through automatic cutting machines. The block is sliced
into the required size. The cake is cut both vertically and horizontally by an automatic machine.
05
Autoclaving
Autoclaving is the stage where the magic happens. The cut blocks are placed in an autoclave and
subjected to high temperature and high-pressure steam (180-204°C at 1.2-1.6 MPa) for 9-10 hours. This
process facilitates the
chemical reactions and strengthens the blocks.
06
Separating and Packing
After autoclaving, dimensionally accurate, durable blocks are ready for masonry use. At this point,
they are stacked and wrapped using packing machines for storage in the factory or for market delivery.
Machinery required in AAC block production
Specific machines are required in the factory for every stage of the AAC block production. Explore the
table where we show the required types of machinery in every stage:
A fully automated AAC block plant saves production time and cost. It requires less manpower and saves lots
of energy. Here are some benefits of a fully automated AAC Block plant-
Improved efficiency: Automation streamlines the entire process, from raw material
feeding to final packing, with minimal human intervention.
Quality control: Machines don’t make measurement errors. This means the consistent
size, strength, and density of AAC blocks remain in every production.
Energy savings: Modern automated plants are designed with energy-saving components,
reducing overall electricity and steam consumption.
Minimum waste: An automated AAC block plant minimizes waste through precise raw
materials dosing and efficient mixing. Cutting machines reduce material loss, and leftovers are recycled
into new batches.
Labor cost reduction: Fewer manual tasks mean fewer workers needed. This reduces
long-term labor costs, increases factory production, and increases business profitability.
Least error: Intelligent control systems prevent errors and optimize production.
Eco-friendly: The plant is exceptionally eco-friendly due to the use of non-toxic
materials and reduced CO2 emissions. It consumes less energy, and recycling is a continuous process of the
automated plant.
AAC block production is transforming the construction industry with its energy efficiency and
durability. If you are planning for a business, you need to set up a fully automated plant to ensure
consistent quality, higher production,
and lower operational costs.
Explore the history of AAC blocks from invention to rise in Bangladesh’s construction sector. Discover why more builders are switching. Call for details!
