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The Concept Of AAC Block: AAC Block is based on siliceous materials (sand, fly ash, silica-containing materials, etc.) and calcareous materials (lime, cement) as the main raw materials, mixed with air-entraining agents (aluminum powder). After the process of raw materials batching, slurry mixing, pouring, pre-curing, cutting, autoclave curing, and packaging, AAC block finished products are produced. It is called aerated concrete because it contains a large number of uniform and small pores after it is aerated.
The production of AAC block is rich in raw materials, especially the use of fly ash as raw materials which can not only comprehensively use industrial waste residues, treat environmental pollution, and not damage farmland, but also create good social and economic benefits. It is a good substitute for traditional solid clay bricks. Promising wall products have been strongly welcomed by government, estate companies, and construction teams. The government has made tax policy and environmental protection policy support, foreseeing broad market development prospects.
Fly Ash / Quartz Sand is the main core raw material of AAC block products, and is the main source of the silicon and aluminum components of aerated concrete.
Cement is the main source of the strength of AAC blocks. It provides the main calcareous materials. Cement suitable for the production of AAC blocks should be selected mainly in terms of type and grade. In production, 52.5 grade Ordinary Portland Cement should be selected first. In general, to reduce production costs, 42.5 grade Ordinary Portland Cement can be used also.
Lime is also one of the main raw materials for the production of AAC blocks. Its main function is to cooperate with cement to provide effective calcium oxide, interacting with SiO2 and Al2O3 in siliceous materials under hydrothermal conditions to produce calcium silicate hydrate. Therefore, lime is one of the main strength sources of AAC blocks. The effective calcium oxide content of lime used to produce AAC blocks should be higher than 65%, preferably higher than 80%.
Gypsum is a regulator of the air evolution process in AAC block production. The regulating effect of gypsum is mainly reflected in delaying quicklime digestion and slurry thickening speed. The main chemical component of gypsum is CaSO4. There are three types of gypsum on the market: raw gypsum, anhydrite, and plaster of Paris. Waste gypsum produced in chemical production processes (such as phosphogypsum, fluorogypsum, and titanium dioxide gypsum) can also replace natural gypsum to reduce production costs.
AAC Block must have an air-generating agent to create pores in the block to form a lightweight porous structure.
After the air generating agent gasses, due to the thin foam wall, it is easy to break and destroy the foam under the interference of various conditions, affecting concrete quality. Therefore, it is necessary to add a foam stabilizer to the slurry.
Raw materials are transported into the factory by automobiles. Fly ash (sand, stone powder) is concentrated in the raw materials yard and conveyed into the hopper when used. Bagged or bulk cement is stored in the cement warehouse and transported into the hopper. Chemicals and aluminum powder are placed in storage and conveyed to the production workshop when needed.
Fly ash (or sand, stone powder) is sent to the ball mill through an electromagnetic vibrating feeder and belt conveyor, and ground fly ash slurry is sent to the slurry tank. Lime is crushed by a jaw crusher, conveyed to the storage tank by a bucket elevator, and sent to the ball mill. Aluminum powder is lifted to the batching building, poured into the mixer with water, and stirred into a suspension.
Lime and cement are sequentially sent to the automatic weighing scale. The slurry should meet process requirements (approximately 45℃) before pouring. Autoclave heating can be carried out in the slurry metering tank if needed, and the aluminum powder suspension is added 0.5-1 minute before pouring.
After pouring, the mold box is pushed into the initial curing room (50~70℃, 1.5-2 hours). A negative pressure hoist lifts the mold frame and wet block onto the cutting table. The cutting machine cross-cuts, longitudinally cuts, and mills the wet block. Waste materials are recycled into the slurry agitator.
After assembly in front of the autoclave, trolleys enter the autoclave for high-temperature and high-pressure steam curing. Finished products are hoisted to the warehouse and transported to the yard by forklift truck. Empty trolleys return to the carriage line for the next cycle.
The traditional process of slurry density control is not strict. The density of protoplasm is often measured artificially, causing bigger errors. Amulite uses the latest pipeline measurement method which offers real-time density feedback to the central control room to continuously correct real-time density and ensure overall high-precision slurry concentration.
Turns the mold box with block 90 degrees, puts it on the block dragging trolley, and processes demolding works. Reorganizes, cleans, and polishes mold boxes for reuse.
Takes the whole block into the cutting machine, completes horizontal cutting, peeling the whole block by two sides, and separating wasted materials.
This device is self-developed by Amulite Group to solve bottom material waste problems. It includes a turnover platform and crane to remove both top and bottom waste material, and can also act as a semi-product transport crane.
The separating machine completely separates adhesion blocks without damage. Each separating hand is controlled independently, lowering overall costs while ensuring top quality.
Includes conveying and packing lines for wooden pallets. Features automatic computer distribution, precise positioning during conveying, and automatic separation of loaded pallets for easy shipment.
