How do you manufacture AAC blocks?

AAC (Autoclaved Aerated Concrete) blocks are manufactured through a precise process that involves the following steps:

Raw Materials Preparation: The primary ingredients used in AAC blocks production are sand or fly ash, cement, lime, gypsum, and water. These materials are carefully selected and proportioned to achieve the desired properties of the blocks.

Mixing: The raw materials are mixed thoroughly in a mixing plant or mixer to ensure uniform distribution. The mixing process may involve the addition of aluminum powder or paste, which acts as a foaming agent.

Foaming: To create the aerated structure of AAC blocks, a chemical reaction is induced by introducing aluminum powder or paste into the mix. This generates hydrogen gas, resulting in a foaming effect. The gas bubbles expand throughout the mixture, forming air pockets within the material.

Molding: The foamed mixture is poured into molds, which are often in the shape of rectangular blocks. The molds can be made of steel or other suitable materials. During the pouring process, care is taken to ensure proper filling and compaction of the mixture.

Curing: Once molded, the AAC blocks are subjected to a curing process, which typically involves placing them in a curing chamber or autoclave. The blocks are exposed to high-pressure steam at a specific temperature for several hours. This process facilitates the chemical reactions within the blocks, resulting in the formation of calcium silicate hydrate (CSH) and the development of strength and stability.

Cutting and Shaping: After curing, the solidified blocks are removed from the molds and undergo cutting and shaping processes. These processes can be done manually or with the help of specialized machinery. The blocks may be cut into various sizes according to the desired dimensions.

Quality Control and Finishing: The final AAC blocks are inspected for quality and dimensional accuracy. They may undergo surface finishing processes such as grinding, sanding, or coating to enhance their appearance or improve surface smoothness if required.

The exact manufacturing process can vary depending on the specific equipment, techniques, and formulations used by different AAC block manufacturers. It is important to follow established standards and guidelines to ensure the production of high-quality AAC blocks.