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Production flow chart of AAC block plant: Step-by-step process

Are you thinking about entering the highly competitive construction materials industry? 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 in Bangladesh and globally.

Production flow chart of AAC block plant

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.

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What is an AAC block?

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.

AAC block plant Manufacturing 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

Well-sourced premium-grade raw materials are the first important step of the process. The primary raw materials required are:

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.
Batching and Mixing
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.

Separating and Packing

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:

Production Stage Machinery Required
Raw materials preparation Silos, Screw conveyors, Bucket elevators
Batching and Mixing Batching plant, Mixer units
Slurry preparation Ball mill, Slurry tanks
Pouring (Casting) Pouring device, Casting molds
Pre-curing Pre-curing room/section
Demolding Demolding crane
Cutting Side, Horizontal and vertical cutting machine
Autoclaving Autoclave room (Steam curing chambers)
Packing Packing machine, palletizers, forklifts

Call +8801841119091 for durable and high-performance AAC equipment.

Benefits of a fully automated AAC block plant

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.
Fully automated AAC block plant benefits

For more details, you can read this blog - Benefits of AAC Blocks for Construction in Bangladesh.

Conclusion

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.

Zihan Tech is the only official business partner of the Dongyue Group in Bangladesh. As a trusted supplier of AAC block plant machinery from China, Zihan Tech provides all the related machines, equipment, and client support for factory arrangement.

Get a free quote now!

Frequently asked questions about AAC blocks

AAC blocks have a lifespan of over 50 years if properly installed and maintained.
While AAC blocks are moisture-resistant, they are not completely waterproof. External plastering is recommended.
Absolutely! Their lightweight nature reduces structural load, making them ideal for multi-story constructions.
It depends on the level of automation, production capacity, and the quality of the machinery.
Yes! AAC blocks are made from industrial waste (fly ash), require less energy, and have a lower carbon footprint than traditional bricks.