AAC Block Plant (800 CBM)

AAC BLOCK PLANT (800 CBM)

[EIRI/EDPR/4678] J.C.: 2895XL

AAC blocks are light weight Aerated Autoclave Concrete Block. It is manufactured through a reaction of aluminium powder and a proportionate blend of lime, cement, and fly ash or sand. Autoclaved aerated concrete (AAC) is a lightweight cellular concrete that has been used for more than 80 years. Currently, however, no good recycling options for AAC from construction and waste exist. During this process, the hydrogen gas escapes create lots (billions) of tiny air cells, applying AAC with a strong cellular structure. The hydrogen gas or bubbles cause the concrete to expand to roughly thrice times its original volume, further strengthened by high pressure steam curing. The product thus formed is not only light weight concrete but also has higher compressive strength. AAC is a masonry material that is lightweight, easy to construct, and economical to transport. AAC is one of the materials which can cope up with the shortage of building raw materials and can produce a light weight, energy efficient and environmentally friendly concrete. This study deals with the manufacturing process of the autoclaved aerated concrete blocks.

Autoclave aerated concrete blocks are also known as Auto clavedlight weight concrete (ALC) Autoclaved Aerated Concrete (AAC) is one of the eco – friendly and certified green building materials.AAC was perfected in the mid of 1920s by the Swedish architect. It has become one of the most used building materials in Europe and is rapidly growing in many other countries around the world. Basically, AAC is a mixture of cement, fly ash, sand, water, and aluminum powder. When the materials are proportionally weighed, AAC is using no aggregate larger than sand. Here, Aluminum powder reacts with calcium hydroxide and water to form H2. The hydrogen gas foams and doubles the volume of the raw mix creating gas bubbles shown. At the end of the foaming process, the hydrogen escapes into the atmosphere and is replaced by air. When the airs are removed from the material, it is solid but still soft. It is then cut into blocks and placed in a cylindrical chamber for 11-12 hours. 

COST ESTIMATION

Plant Capacity            800 CBM/Day  

Land & Building (22,000 sq.mt.)    Rs. 17.36 Cr    

Plant & Machinery                    Rs. 13.54 Cr 

Working Capital for 1 Month    Rs. 6.80 Cr 

Total Capital Investment          Rs. 38.02 Cr 

Rate of Return                          31%

Break Even Point                      52%

CONTENTS

INTRODUCTION

FIGURE SHOWS THE AAC BLOCK

AERATED CONCRETE BLOCKS

RAW MATERIALS

CEMENT:-

FLY ASH:-

SAND:-

LIMESTONE:-

ALUMINIUM POWDER:-

GYPSUM:-

ADVANTAGES OF AUTOCLAVED AERATED CONCRETE BLOCKS:

STRENTH AND BENEFITS OF AAC BLOCKS

BENEFITS OF AAC BLOCKS:

LIGHT WIGHT:

RETAIN HEAT AND ENVIRONMENT FRIENDLY:

FIRE RESISTANCE:

DURABLE AND COST EFFECTIVE:

USES AND APPLICATIONS

AERATED CONCRETE BLOCKS

PROPERTIES

COMPOSITION OF PORTLAND CEMENT

ORDINARY PORTLAND CEMENT MAY HAVE THE COMPOSITION AS BELOW:-

B.I.S. SPECIFICATION

SCENARIO OF AAC BLOCKS

KEY PLAYERS IN THE GLOBAL AAC MARKET

KEY PLAYERS IN THE AUTOCLAVED AERATED CONCRETE MARKET ARE:

STRUCTURE AND DEVELOPMENT

AAC BLOCK: AN EMERGING GREEN BUILDING MATERIAL IN INDIA

COMPARISON BETWEEN AAC BLOCK AND CLAY BRICK

FLY ASH: CHANGING STATUS FROM HAZARDOUS INDUSTRIAL WASTE

TO USEFUL AND SALEABLE COMMODITY

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

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:

GLOBAL MARKET OF AAC [AUTOCLAVED AERATED CONCRETE]

AUTOCLAVED AERATED CONCRETE (AAC) MARKET TRENDS

GROWING DEMAND FROM THE CONSTRUCTION INDUSTRY

ASIA-PACIFIC TO DOMINATE THE MARKET

AUTOCLAVED AERATED CONCRETE (AAC) MARKET LEADERS

AUTOCLAVED AERATED CONCRETE (AAC) MARKET NEWS

MARKET OF AAC IN INDIA

MANUFACTURING PLANT IN INDIA

GREEN SOLUTIONS FOR THE GROWING URBANIZATION

ECONOMIC CONSIDERATIONS AND CONSTRUCTION SPEED ALSO

DRIVE THE GROWTH

FUTURE OF AAC BLOCKS

ENVIRONMENTAL BENEFITS OF AUTOCLAVED AERATED CONCRETE

THE USE OF AUTOCLAVED AERATED CONCRETE HAS A RANGE

OF ENVIRONMENTAL BENEFITS:

ADVANTAGE AND DISADVANTAGE OF AAC BLOCK

ADVANTAGES

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

OVERVIEW OF AAC BLOCK MANUFACTURING

RAW MATERIAL PREPARATION:

DOSING & MIXING:

CASTING, RISING AND PRECURING:

DEMOULDING AND CUTTING:

SEQUENCES IN AAC BLOCK MANUFACTURE

RAW MATERIAL PREPARATION

DOSING AND MIXING

CASTING, RINSING AND PROCURING

DEMOULDING

CURING

PACKAGING AND LOADING

PROCESSING DETAILS OF AAC BLOCKS

STEP 1– RAW MATERIAL PREPARATION-

STEP 2 – DOSING AND MIXING-

STEP 3 – CASTING, RISING AND CURING-

STEP 4 – DEMOULDING AND CUTTING –

MANUFACTURING PROCESS OF AAC BLOCKS

DETAILS OF DOSING AND MIXING

PROCESS FLOW DIAGRAM

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:

COMPOSITION OF AAC BLOCK

PRESENT MANUFACTURERS/SUPPLIERS OF AAC BLOCKS

ADDRESSES OF PLANT AND MACHINERY

COMPLETE PLANT & EQUIPMENTS SUPPLIERS FOR AERATED CONCRETE

BLOCKS (FOREIGN)

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF FLYASH

SUPPLIERS OF CEMENT

SUPPLIERS OF GYPSUM

SUPPLIERS OF LIME POWDER

SUPPLIERS OF ALUMINUM POWDER

COMPLETE PLANT AND MACHINERY SUPPLIERS AND TECHNICAL ADVISORS FOR AAC BLOCKS

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)