Autoclaved aerated concrete (AAC) blocks have become a highly popular building material. Comprising 80% air, AAC blocks are lightweight, fire resistant, have thermal insulation properties and offer strength. To produce these remarkable aircrete blocks efficiently, a specialized AAC block making machine is required. Recent advances in AAC block machine technology are enabling manufacturers to maximize productivity and profits. In this blog, we’ll explore the innovations in modern AAC block making machines.
How AAC Block Machines Work
AAC production relies on mixing fine aggregates, lime, cement, water and aluminum powder to create a flowable slurry. The aluminum powder reacts with calcium hydroxide and forms hydrogen bubbles, resulting in the aerated slurry. The slurry is poured into molds and then cut into blocks before being autoclaved under heat and pressure. This causes the mixture to rise like bread dough and solidify into strong AAC blocks.
AAC block machines are fully automated to mix the raw materials, pour the slurry into molds, cut blocks and stack them onto pallets ready for curing. The process from mixing to finished blocks takes under 5 minutes. Advanced AAC plants can produce up to 150 cubic meters of blocks per hour.
Innovations In AAC Block Making Technology
To maximize AAC production, the latest block making machines feature cutting-edge innovations including:
- Servo-Driven Pallet Feeder: This allows continuous automated feeding and stacking of AAC blocks. Precise servo motor control eliminates jitter and vibration for higher pallet capacity.
- Intelligent Mold Cutting: Laser sensor technology enables the mold cutting apparatus to accurately cut blocks with precision and repeatability. The blade depth is computer controlled.
- Advanced Mixing Technology: High shear wet mixers with flow simulation software mix the slurry homogeneously. Strong powerful hydraulic cylinders provide vibration-free molds.
- SCADA Controls: The entire plant is controlled by SCADA (supervisory control and data acquisition) automation. This allows remote monitoring, data analysis and predictive maintenance.
- Teleservice Support: Modern AAC equipment offers teleservice functionality. The service team can remotely monitor and diagnose the plant for enhanced technical support.
- Larger Capacities: Bigger molds and mixing cylinders allow single plants to achieve higher outputs of up to 600 cubic meters per day. Jumbo block making machines maximize productivity.
- Variable Block Sizes: Flexible mold setups can produce different block types, heights and dimensions without changeover delays. Some plants can make up to 15 block variations.
- Improved Serviceability: New block making machines are designed for quick maintenance and repairs. Wear parts are standardized and easily replaced to minimize downtime.
Benefits of Advanced AAC Block Making Machines
- Higher Throughput: Produce greater volumes of AAC blocks to meet rising market demand more profitably. Larger equipment capacities maximize output.
- Better Product Consistency: Precision controls and intelligent sensors improve block dimensional accuracy and air content consistency batch after batch.
- Lower Operating Costs: Optimized processes, reduced downtime and teleservice support lower the overall operating costs. Automation reduces labor costs.
- Quicker Installation: Prewired and pretested machines allow faster setup. Some plants can be operational within a month of delivery.
- Greater Uptime: Reliable components and smart diagnostics allow preventive maintenance. The production of AAC blocks can continue uninterrupted.
With rapid urbanization across the globe, AAC blocks are the ideal building material. The latest AAC block making machines enable manufacturers to reap the benefits of surging market demand. Investing in advanced technology results in higher productivity, consistent quality, lower costs and quicker returns on investment.