AAC Blocks Manufacturing Process – Dosing and Mixing

AAC Blocks Manufacturing Process

Step 2 – Dosing and Mixing

After raw material preparation, next step of AAC blocks manufacturing process is dosing and mixing. Process of dosing and mixing defines the quality of final products. Maintaining ratio of all ingredients as per the selected recipe is critical to ensure consistent quality of production. This is accomplished by using various control systems to measure and release the required quantity of various raw materials.

AAC blocks manufacturing - Slurry, water, lime powder, cement and gypsum poured as per set dosage

Slurry, water, lime powder, cement and gypsum being poured as per set dosage during AAC blocks manufacturing.

A dosing and mixing unit is used to form the correct mix to produce Autoclaved Aerated Concrete (AAC) blocks. Fly ash/sand slurry is pumped into a separate container. Once the desired weight is poured in, pumping is stopped. Similarly lime powder, cement and gypsum are poured into individual containers using screw conveyors. Once required amount of each ingredient is filled into their individual containers control system releases all ingredients into mixing drum. Mixing drum is like a giant bowl with a stirrer rotating inside to ensure proper mixing of ingredients. Steam might also be fed to the unit to maintain temperature in range of 40-42oC. A smaller bowl type structure used for feeding Aluminium powder is also attached as a part of mixing unit. Once the mixture has been churned for set time, it is ready to be poured into molds using dosing unit. Dosing unit releases this mixture as per set quantities into molds for foaming. Dosing and mixing process is carried out continuously because if there is a long gap between charging and discharging of ingredients, residual mixture might start hardening and choke up the entire unit.

AAC blocks manufacturing - Cement, lime powder and gypsum sent from silo to mixing tank using screw conveyor

Cement, lime powder and gypsum is sent from silo to mixing tank using screw conveyor during AAC blocks manufacturing

For AAC blocks manufacturing, entire dosing and mixing operation is completely automated and requires minimum human intervention. This entire operation is monitored using control systems integrated with computer and CCTV cameras. As with any industrial operation, there is provision for human intervention and emergency actions integrated inside the control system.

AAC blocks manufacturing - Control panel and CCTV cameras help monitor and control entire production process

Control panel and CCTV cameras help monitor and control AAC blocks manufacturing process

AAC Blocks Manufacturing Process (…contd….)

AAC Blocks Manufacturing Process: Step 1 – Raw Material Preparation

AAC Blocks Manufacturing Process: Step 2 – Dosing and Mixing

AAC Blocks Manufacturing Process: Step 3 – Casting, Rising and Pre-curing

AAC Blocks Manufacturing Process: Step 4 – Demoulding and Cutting

Leave a Reply

Your email address will not be published. Required fields are marked *

  1. Dear Sir,
    Sir,i want to learn a recipe of aac block according to density of fly ash and scrap slurry…pls

    Thanks
    Amit Pratap Singh

    • Dear Amit,

      Thank you for your response on my website. Kindly note that recipe is specific to raw materials available. Moreover it is not something that can be shared just like that as it requires time, effort and money to arrive at suitable recipe and its iterations. In case you are willing to pay for the same, do give me a call.

      Regards,

      Vishal Kansagra
      (+91) 76986 17371