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)
