Our detailed cutting edge manufacturing process follows the strictest norms to bring the very best to the customer.
AAC block is produced out of a porous cake moulded from a mix of quartz sand or Pulverized Fly Ash (PFA), lime, cement, gypsum, water and aluminium powder. It is then cut into either blocks or panels, and placed in an autoclave chamber for 10-12 hours. During this steam pressure hardening process, when the temperature reaches 190Â° Celsius (374Â° Fahrenheit) and the pressure reaches 8 to 12 bars, quartz sand/ PFA reacts with calcium hydroxide to form calcium silica hydrate, which accounts for AAC’s high strength and other unique properties. After the autoclaving process, the material is ready for immediate use on the construction site.
The steps of AAC Block manufacturing process:
1. RAW MATERIAL PREPARATION AND MIXING
The raw materials i.e. fly ash, lime, cement, gypsum, water and aluminum powder is well mixed and then converted into porous cake.
2. PANEL REINFORCEMENT PREPARATION
Steel coils are straightened, cut and spot-welded into mats, where crossbars provide anchorage to the longitudinal reinforcements. After dipping the welded mats in a homogenized anti-corrosion mix for rust protection, they are dried and assembled into cages and set accurately in the moulds before the slurry is poured in.
The cake is cut by high precision cutting machines. Cutting is done by cutting knives and by pneumatically tensioned cutting wires.
4. GREEN SEPARATION
One of the USPs of KON_CRETE blocks is the green separation process it undergoes. Further, this green separation substantially improves the autoclaving process as steam can penetrate into the cake more effectively.
In the autoclaves the cakes are cured for approximately 10 -12 hours at a temperature of 190°C with saturated steam at a pressure of 12 bars. The fully automatic autoclave control system ensures a safe and optimal autoclaving process, allowing for steam transfer and energy reutilization in combination with the condensate heat recovery system.
KON_CRETE blocks are then well packed into high quality plastic material and then ready for dispatch.