Amidst the growing global demand for green building materials, Autoclaved Aerated Concrete (AAC) Blocks, thanks to their lightweight, energy-saving, and environmentally friendly properties, have become a mainstream choice in the overseas construction market. Aiming to meet the capacity planning needs of small and medium-sized building materials companies, we offer a comprehensive 50,000 cubic meters/year AAC Block Production Line solution. This solution covers localized raw material procurement, customized equipment configuration, standardized production processes, and cross-border technical services, helping customers quickly establish compliant AAC block manufacturing plants and achieve efficient production.
I. Raw Material Solution: Adapting to a Localized Raw Material System
The raw material planning for the 50,000 cubic meters/year production line is based on "local sourcing and cost reduction." With this as the core, we provide flexible adaptation solutions tailored to the resource characteristics of different countries:
Core Raw Materials and Localized Substitutions
The production line utilizes a classic formula of "siliceous raw materials + calcium raw materials + aeration agent." The siliceous raw materials are preferably locally available fly ash/quartz sand (60%-70%). If fly ash is unavailable, sandstone or slag (crushed to a particle size ≤2mm) can be substituted. The calcium raw materials are locally compliant cement and quicklime (25%-35%), with the quicklime requiring an effective calcium oxide content of ≥75%. The aeration agent is industry-standard aluminum paste (0.05%-0.08%), which can be easily sourced through international chemical supply chains. All raw materials comply with international standards for autoclaved aerated concrete (such as EN 771-4), ensuring the quality of AAC aerated concrete. Strength and gas generation stability.
Raw Material Storage and Pretreatment Equipment Configuration
The raw material pretreatment stage is equipped with a jaw crusher (for crushing lumpy lime to a particle size of ≤50mm), a high-frequency vibrating screen (for screening sand impurities; the screen mesh can be customized according to the local sand particle size), and a high-precision electronic weighing scale (accuracy ±0.5%). This ensures precise raw material ratios and lays a stable foundation for subsequent production.
II. Equipment Configuration Plan: Efficient Equipment Cluster Suitable for Cross-Border Transportation
The AAC aerated brick production line equipment configuration takes into account the three principles of "capacity compliance, convenient transportation, and easy installation," covering the entire process from raw material processing to finished product stacking. The core equipment and functions are as follows:
Core Production Equipment and Function Description
One Pouring Mixer (each unit has an effective volume of 3m³ and a stirring speed of 25r/min), capable of mixing three batches of slurry per hour, eliminating the need for waiting for raw materials. Three Slurry Tanks (volume) are also included. 50m³), adapted to the slurry temperature control requirements of different climate zones, ensuring stable gasification.
The material transfer stage is equipped with four belt conveyors, each with a belt width of 600mm and a conveying speed of 1.2m/s. The modular design allows for disassembly and transportation, and facilitates on-site assembly. They connect raw material pretreatment, batching, and pouring processes, enabling continuous material transfer.
Key forming equipment includes one automatic cutting machine, with a cutting accuracy of ±1mm and a cutting speed of 0.8m/min. It can cut the gasified green body into AAC blocks of standard sizes, such as 600×200×240mm. Custom cutting specifications are also available.
The curing stage is equipped with two autoclaves, each with a diameter of 2m, a length of 31m, and an operating pressure of 1.2MPa. They feature a stainless steel liner and a high-efficiency insulation layer, allowing for rapid temperature increases (from room temperature to 180°C in just 10 seconds). 2.5 hours), and the curing cycle is shortened to 8 hours, ensuring a stable daily production capacity of 150 cubic meters, meeting the production target of 50,000 cubic meters/year.
Equipped with 30 mold cars, each measuring 4000×1200×600mm and capable of bearing a load of ≥5 tons. The mold cars are constructed of high-strength steel, durable and wear-resistant, and can carry the blanks through the entire process of pouring, gasification, cutting, and autoclaving, ensuring continuous production line operation.
III. Production Process Plan: Standardized Full-Process Control
The 50,000 cubic meter/year production line follows a standardized process of "raw material pretreatment → batching and mixing → pouring and gasification → cutting → autoclaving and curing → finished product stacking." Each step complies with the environmental and safety regulations of the target country, ensuring compliant and efficient production:
Raw material pretreatment (1-1.5 hours)
Locally sourced fly ash / Sand is conveyed via a belt conveyor to a high-frequency vibrating screen to remove stones, impurities, and other foreign matter. Lumpy lime is crushed to a particle size of ≤50mm by a jaw crusher and then stored in sealed silos to minimize dust leakage and meet international environmental standards. Aluminum paste is dissolved in a dedicated water tank to create aluminum slurry, which is stored in a sealed container with low-temperature refrigeration to prevent premature aeration and affect product quality.
Mixing and Mixing (0.5 Hour)
An electronic weighing scale automatically measures the various raw materials according to a preset ratio (e.g., fly ash 65%, cement 10%, lime 23%, aluminum paste 0.07%). The materials are then transported to the pouring mixer via sealed pipes and belt conveyors, where they are mixed for 10-15 minutes to form a uniform slurry. During mixing, the system monitors the slurry temperature (controlled at 40-50°C) and viscosity in real time to ensure consistent aeration and avoid product failures due to ratio errors.
Pouring and Stalling (4-5 (hours)
The uniformly mixed slurry is poured into a mold car via a pouring machine. The mold car is then automatically transported to a constant temperature and humidity aeration chamber (50-60°C, ≥85% humidity). The aluminum paste reacts with the active ingredients in the lime to produce hydrogen, causing the slurry to expand and form a porous green body. After 4 hours of quiescence, the green body reaches a strength of 0.5 MPa, ready for cutting.
Automatic Cutting (0.5 hours)
The mold car carrying the green body is transported to an automatic cutting machine, which precisely cuts the green body in three dimensions: horizontal, vertical, and vertical. Cutting accuracy is controlled to ±1mm, ensuring that the AAC block size meets local building standards (such as European EN standards and Southeast Asian local regulations). Manual secondary trimming is eliminated, improving production efficiency.
Autoclave Curing (8 hours)
The cut green body is transported by the mold car to an autoclave, where saturated steam (pressure 1.2 MPa, temperature 1.2 MPa) is introduced. Autoclaving and curing at 190°C (190°C) allows the silicon and calcium components in the green body to fully react and form a stable hydration product. After curing, the blocks reach strength grade A3.5 or higher, meeting the strength and density requirements of the AAC Block IS Code (the international standard for AAC blocks) (density controlled at 600-700 kg/m³).
Finished Product Stacking and Inspection (1 hour)
Autoclaved AAC blocks are transported to the finished product area via a belt conveyor and stacked using a robot or simple lifting equipment to reduce manual handling. Quality inspectors sample each batch to test the blocks for compressive strength, thermal conductivity, and dimensional deviation. Qualified products are labeled and stored for distribution to the local construction market (such as commercial housing and public building projects).
IV. Cross-border Technical Service Solutions: A Remote Support System Adapted to Overseas Customers
We build a "remote, local, and standardized" approach. Our technical service system addresses customers' core pain points from factory construction to operation:
Pre-sales: Customized Cross-border Planning and Compliance Support
We assist customers with site planning (e.g., plant area ≥ 2,500 m2, safety distance ≥ 10 m between the autoclave area and production area), ensuring the layout complies with target country building safety regulations (e.g., fire and environmental protection spacing requirements). We also provide AAC block factory cost estimates, including detailed expenses for equipment procurement, cross-border transportation, and local construction, to help customers manage their investment budgets.
Post-sales: Installation Guidance and Operation Training
Our technical team provides on-site installation guidance and operator training (covering equipment operation procedures, safety regulations, and troubleshooting common problems), helping them quickly master core processes such as batching, mixing, and autoclaving.
Post-sales: 24-hour remote technical support and local collaboration
We have established a 24-hour online technical support team (available via multiple channels, including email, WhatsApp, and Zoom). Customers can submit reports of equipment failures via photos and videos, and the technical team will provide a troubleshooting solution within 1 hour. We provide assistance within hours (e.g., parameter adjustments, component repair guidance). We recommend local parts suppliers (e.g., motors, belts, cutting wire, and other common components) and provide component specification lists to help customers quickly source replacement parts and minimize downtime. We also provide ongoing technical documentation updates (e.g., raw material ratio optimization solutions and equipment maintenance tips) to help customers adjust production parameters based on local raw material prices and market demand, thereby improving operational efficiency.
Core Value of the Solution
This solution is precisely designed for annual production capacity of 50,000 cubic meters. It not only meets the investment budget of small and medium-sized AAC block factories (equipment investment is approximately 8-10 million yuan), but also reduces the risk and cost of factory construction through local raw materials, modular equipment, and remote service. As a dedicated AAC block machine manufacturer, we have experience in over 10 overseas projects (e.g., in Southeast Asia, the Middle East, and Africa). We can quickly respond to the compliance requirements, climate characteristics, and resource availability of different countries, helping customers quickly enter the aerated concrete industry. Achieving sustainable profitability in overseas markets.
If you need to adjust production capacity (e.g., expand to 100,000 cubic meters/year), customize special-sized AAC bricks, or inquire about AAC block prices (local market conditions) or local raw material procurement channels, please feel free to contact us. We will optimize customized solutions for you and help you gain an advantage in the local construction market.
