Detailed Project Report on aac block manufacturing plant

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AAC BLOCK MANUFACTURING PLANT

[CODE NO.4004]

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.

During this steam pressure hardening process, when the temperature reaches 190°C (374°F) and the pressure reaches to a maximum limit of 12 bar, sand reacts with calcium hydroxide to form calcium silicate hydrate, which gives AAC its high strength and light weight properties, solid but soft in nature. After the autoclaving process, the material is ready for immediate use on the construction site. It has become one of the most used building materials in Europe and is rapidly growing in many other countries around the world. The characteristic of AAC is helpful in green housings and saves fertile lands and a solution for fly ash disposal.

Autoclaved aerated concrete is a versatile lightweight construction material and usually used as blocks. Compared with normal (ie: “dense” concrete) aircrete has a low density and excellent insulation properties.

The low density is achieved by the formation of air voids to produce a cellular structure. These voids are typically 1mm-5mm across and give the material its characteristic appearance. Blocks typically have strengths ranging from 3-9 Nmm-2 (when tested in accordance with BS EN 771-1:2000). Densities range from about 460 to 750 kg m-3; for comparison, medium density concrete blocks have a typical density range of 1350-1500 kg m-3 and dense concrete blocks a range of 2300-2500 kg m-3.

COST ESTIMATION

Plant Capacity 500 Cubic Mtrs/Day

Land & Building (20000 sq.mt.) Rs. 10.52 Cr

Plant & Machinery Rs. 7.74 Cr

Working Capital for 2 Months Rs. 6.98 Cr

Total Capital Investment Rs. 26.06 Cr

Rate of Return 27%

Break Even Point 55%

INTRODUCTION

FIGURE SHOWS THE AAC BLOCK.

AERATED CONCRETE BLOCKS

RAW MATERIALS

ADVANTAGES OF AUTOCLAVED AERATED CONCRETE BLOCKS:

PROPOSAL:

USES AND APPLICATIONS

AERATED CONCRETE BLOCKS

PROPERTIES

COMPOSITION OF PORTLAND CEMENT

ORDINARY PORTLAND CEMENT MAY HAVE THE COMPOSITION AS BELOW

B.I.S. SPECIFICATION

OVERVIEW OF CONSTRUCTION IN INDIA

KEY PLAYERS IN INDIA

NATIONAL

INTERNATIONAL

MARKET OVERVIEW 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:

ENVIRONMENTAL BENEFITS OF AUTOCLAVED AERATED CONCRETE

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

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

SUPPLIERS OF PLANT AND MACHINERY

COMPLETE PLANT AND 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)

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