Code #3662
Industry Overview
Autoclaved aerated concrete (AAC) is a versatile, lightweight construction material commonly used in the form of blocks. Compared with dense concrete, AAC has a lower density and provides excellent thermal insulation properties. Its lightweight cellular structure is created through the formation of numerous air voids, typically about 1mm-5mm across, which give the material its characteristic appearance. AAC blocks typically have strengths ranging from 3-9 Nmm-2 when tested in accordance with BS EN 771-1:2000, while densities generally range from about 460 to 750 kg m-3. In comparison, medium-density concrete blocks typically range from 1350-1500 kg m-3 and dense concrete blocks from 2300-2500 kg m-3. The report covers AAC raw materials, composition, properties, manufacturing processes, technical specifications, applications, environmental benefits, market conditions, investment opportunities, plant layout, machinery, suppliers, and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 200 Cubic Mtrs/Day |
| Land & Building (3 Acres) | Rs. 6.07 Cr |
| Plant & Machinery | Rs. 3.79 Cr |
| Working Capital for 1 Month | Rs.1.33 Cr |
| Total Capital Investment | Rs. 11.40 Cr |
| Rate of Return | 35% |
| Break Even Point | 51% |
Content Index
- INTRODUCTION
- AERATED CONCRETE BLOCKS
- AUTOCLAVED AERATED CONCRETE
- STACKED BLOCKS OF AAC (WRAPPED IN FOIL)
- RAW MATERIALS
- FLY ASH SAND LIME AERATED BLOCKS
- AUTOCLAVED AERATED CONCRETE BLOCKS
- ADVANTAGES OF AUTOCLAVED AERATED CONCRETE BLOCKS:
- USES AND APPLICATIONS
- AERATED CONCRETE BLOCKS
- PROPERTIES
- COMPOSITION OF PORTLAND CEMENT
- ORDINARY PORTLAND CEMENT MAY HAVE THE COMPOSITION AS BELOW
- B.I.S. SPECIFICATION
- MARKET SURVEY
- STRUCTURE AND DEVELOPMENT
- AAC BLOCK: AN EMERGING GREEN BUILDING MATERIAL IN INDIA
- SALIENT FEATURES OF AAC BLOCK: LEADING TO INCREASING ACCEPTANCE OF THE PRODUCT
- A QUICK COMPARISON BETWEEN AAC BLOCK AND CLAY BRICK
- FLY ASH: CHANGING STATUS FROM HAZARDOUS INDUSTRIAL WASTE TO USEFUL AND SALEABLE COMMODITY
- DEMAND-SUPPLY SCENARIO OF AAC BLOCKS
- INCREASING COMPETITION RESULTING INTO PRESSURE ON REALIZATIONS
- FINANCIAL PERFORMANCE OF AAC BLOCK MANUFACTURERS
- THE WAY FORWARD
- 1. SUSTAINABLE BRICKS
- AAC BLOCKS HAVE A POTENTIAL MARKET WORTH $5.5 BILLION (RS. 330 BILLION) BY 2030
- AAC VS. CLAY-FIRED BRICKS
- BRICK INDUSTRY IN INDIA
- INVESTMENT BOOST IN INFRASTRUCTURE THROUGH HIGHER PUBLIC FUNDING POSITIVE
- FUTURE OF CONSTRUCTION MARKET IN INDIA
- LATEST MARKET RESEARCH REPORT (2014) BY PWC HIGHLIGHTS:
- GROWTH DRIVERS
- INVESTMENT OPPORTUNITIES IN INDIA
- FDI POLICIES
- FDI POLICY FOR INDUSTRIAL PARKS
- ADVANTAGE INDIA
- 8 TOP REASONS TO INVEST IN INDIA
- 1. SIZE OF INDIA
- 2. ECONOMIC GROWTH
- 3. DIVERSITY
- 4. DEMOGRAPHICS
- 5. HIGH SAVINGS
- 6. DOMESTIC ECONOMY
- 7. A ROBUST FINANCIAL SECTOR
- 8. QUALITY OF INVESTMENT MARKETS
- DETAILED EXPORT DATA OF AUTOCLAVED BLOCK
- INDIA BRICKS AND BLOCKS MARKET TO 2021 – FOCUS ON AAC BLOCK
- SCENARIO OF AAC BLOCK MARKET
- OVERVIEW OF CONSTRUCTION INDUSTRY
- MARKET SHARE OF DIFFERENT WALLING MATERIALS
- COMPOSITION AND CHEMISTRY OF AAC
- THE FINAL HYDRATION PRODUCTS ARE THEN PRINCIPALLY:
- CALCIUM SILICATE HYDRATE COMPOSITIONS IN AAC
- OTHER HYDROTHERMALLY-FORMED MINERALS:
- ENVIRONMENTAL BENEFITS OF AUTOCLAVED AERATED CONCRETE
- ADVANTAGE AND DISADVANTAGE OF AAC BLOCK
- DISADVANTAGES
- BRICKS AND AAC BLOCKS
- TECHNICAL SPECIFICATION OF AAC BLOCK
- TECHNICAL SPECIFICATIONS & COMPARISON BETWEEN BRICK AND AAC BLOCK
- COMPARISION BETWEEN BRICK AND AAC BLOCK
- FORMULATION OF AAC BLOCKS
- MANUFACTURING PROCESS OF AAC BLOCKS
- DETAILS OF DOSING AND MIXING
- PROCESS FLOW DIAGRAM
- DETAILED MANUFACTURING PROCESS OF AAC BLOCKS
- BRIEF PRODUCTION PROCESS:
- COAL FLY ASH:
- QUICK LIME:
- GYPSUM:
- CEMENT:
- ALUMINUM POWDER PAST:
- SCRAPE AND WASTE SLURRY:
- BATCHING, MIXING, AND CASTING:
- CUTTING AND GROUPING:
- AUTOCLAVED AND FINISHED PRODUCT:
- THE BOTTOM PLATE RETURNING, COMBINING WITH MOULD AND OILING:
- AERATED CONCRETE BLOCK MACHINE
- PRODUCT DESCRIPTION
- 1. INTRODUCE
- 2. AERATED CONCRETE COMMON CONCEPTION
- 3. ADVANTAGES LIGHT WEIGHT
- KEEPING TEMPERATURE
- HAVE MANY KINDS MATERIAL, HAVE LOWEST WASTE
- AVAILABLE ABOVE MACHINE AT:
- COMPOSITION OF AAC BLOCK
- PLANT LAYOUT
- PRESENT MANUFACTURERS/SUPPLIERS OF AAC BLOCKS
- SUPPLIERS OF PLANT AND MACHINERY
- COMPLETE PLANT AND EQUIPMENTS SUPPLIERS FOR AERATED CONCRETE BLOCKS (FOREIGN)
- SUPPLIERS OF RAW MATERIALS
- FLYASH
- CEMENT
- GYPSUM
- LIME POWDER
- ALUMINUM POWDER
- COMPLETE PLANT AND MACHINERY SUPPLIERS AND TECHNICAL ADVISORS FOR AAC BLOCKS
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Autoclaved aerated concrete (AAC) is a lightweight cellular construction material commonly manufactured as blocks. Its low density results from numerous air voids formed within the material, giving AAC its characteristic porous structure. AAC provides a combination of reduced weight and thermal insulation properties compared with conventional dense concrete. The report also covers its composition, properties, applications, environmental benefits, technical specifications, manufacturing process, machinery, raw materials, market conditions, and investment considerations.
AAC blocks can be manufactured using materials such as coal fly ash, quick lime, gypsum, cement and aluminum powder paste. The report describes these materials as part of the production process and also discusses fly ash sand lime aerated blocks. Their proportions and processing conditions influence the composition and characteristics of the finished product. Proper batching, mixing and casting are followed by cutting and autoclaving to develop the required cellular structure and finished block properties.
AAC blocks are manufactured through a sequence of raw-material preparation, batching, mixing, casting, cutting, grouping and autoclaving. The process begins with the preparation and dosing of the required ingredients, followed by mixing into a suitable slurry. The material is cast and allowed to develop its cellular structure before cutting into blocks. The grouped blocks are then subjected to autoclaving, where controlled hydrothermal treatment develops the required properties. The report also covers bottom-plate return, mould preparation and related plant operations.
AAC blocks offer the principal advantages of low density, thermal insulation and reduced weight compared with conventional dense concrete blocks. Their cellular structure contributes to their lightweight characteristics, while the material can be manufactured in standardized block forms for construction applications. The report discusses additional advantages, environmental benefits, technical properties and applications. AAC is also examined as an alternative walling material in comparison with clay bricks and other construction products, with attention to material efficiency and changing construction requirements.
Fly ash can serve as an important raw material in AAC block production, particularly in fly ash-based formulations. The report examines fly ash as a material whose status has developed from an industrial waste product toward a useful and saleable commodity. In AAC manufacturing, fly ash is incorporated into the formulation and processed through batching, mixing, casting, cutting and autoclaving. Its use can also support resource utilization by incorporating an industrial by-product into a manufactured construction material.
An AAC block manufacturing plant requires equipment for raw-material handling, dosing, mixing, casting, cutting, grouping and autoclaving. The report specifically discusses an aerated concrete block machine, process flow, batching and mixing equipment, cutting operations, autoclaved finishing and mould-related operations. A complete plant also requires suitable utilities, material-handling arrangements and plant layout planning. Equipment selection depends on the production process, formulation, desired product specifications, plant capacity and level of automation.
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