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Autoclaved Aerated Concrete (AAC PLANT)

Quality from A to Z: For this highly sophisticated manufacturing process, LAXMI EN-FAB PVT. LTD has all the components and technology available

The manufacture of aerated concrete places great demands on the dosing of raw materials, the supervision of the fermentation process and the control of the following production steps. Many years of experience and the deployment of the latest automatic control algorithms in our control components guarantee the quality of the finished products.

  1. Raw material delivery
  2. Sand mill
  3. Slurry silos with integrated stirring device
  4. Mould turning crane
  5. Reinforcement element insertion crane
  6. Transfer platform fermentation area
  7. Profling
  8. Longitudinal saw Cross saw
  1. Cross saw
  2. Steam hardening / Autoclaving
  3. Loading and unloading crane
  4. Separating machine
  5. Packaging crane
  6. Gap elimination device
  7. Strapping device
  8. Transport of finished products

AAC BLOCKS AND REINFORCED ELEMENTS

The AAC-Block allows LAXMI EN-FAB PVT. LTD customers a flexible and economic plant concept for aerated concrete block manufacturing.

The green cake is in the start phase of the manufacture. It is automatically demoulded and set in an upright position where it is calibrated, profled and then cut in length and width. Also the grip pocket is formed while in the “green condition”.

By modifying installed components, the AAC Block process can be expanded to the AAC Panel system, which allows the production of reinforced elements up to 6 metres in length.

AGGREGATES STORING, MIXING, POURING

The basis for continuous high quality.

Aerated concrete is produced from Quartz Sand, Lime, Cement, Gypsum (anhydrous), and Water.

The process starts with quartz sand being milled in a wet ball mill into a fine sand slurry which is then stored in slurry silos with an integrated stirrer.

It is important to keep the defined density, which is controlled either manually or automatically. Sand slurry, recycled slurry, lime, cement, gypsum, aluminium and water are added to the mixer according to the desired product recipe.

Immediately after the mixing the pre-positioned moulds are filled and subsequently transported to the fermentation area. Here the mixture starts reacting by producing fine pores, allowing the mass to harden into an aerated concrete cake.

Aggregate Storing and Measurement

  • Sand storing
  • Sand preparation and transport
  • Milling devices
  • Storage of binding agent and additives

Mixing and Dispensing

  • Aggregate dosing and mixing devices
  • Moulds, hardening floors
  • Process / installation controls

CUTTING AND CONVEYING

Consistent precision

The fermentation process produces hydrogen, resulting in the creation of billions of tiny pores in the concrete cake. At the end of the process the cake is left with an enormous number of air cells. Simultaneously the aerated concrete cake starts to harden.

As soon as the material has enough resistance to be cut, the aerated concrete cakes are demoulded and placed onto the cutting line. Here they are first calibrated, profled, and cut both horizontally and vertically.

Cutting device

  • Pre-cutting device
  • Longitudinal-cut device
  • Cross-cut device
  • Grip pocket milling machine
  • Cut waste recycling device
  • Recycling of the cut waste

Mould transport

  • Moving car
  • Cubing device
  • Roller conveyors
  • Chain conveyors
  • Cleaning device

CURING AND PACKAGING

Quality products safely packaged

The aerated concrete achieves its final strength from the curing under steam pressure in the autoclaves. The steam pressure chambers work fully automatically and are highly energy efficient due to an optimised process in control technology. The curing process follows exact defined procedural steps. The curing time depends on the density and the grade of open pores of the cake.

Finally, before leaving the plant, the finished products are packaged in a way that they are protected from dirt and humidity. Depending on the installation concept the packaging process can be either fully or semi automatic.

Curing in Autoclaves

  • Autoclaves and accessories
  • Automatic steam control
  • Steam boiler with energy saving device
  • Recirculating moisture

Packaging

  • Cutting machine
  • Cubing installation
  • Packaging machine