Autoclaved Aerated Concrete (AAC) blocks have become a preferred choice in modern construction due to their lightweight, strength, and thermal efficiency. Buildmate, a leading manufacturer of AAC blocks, follows a streamlined process to ensure high-quality production. Here is a detailed step-by-step look at Buildmate’s AAC blocks manufacturing process.
1. Raw Material Preparation
The manufacturing process begins with the selection and preparation of raw materials. Buildmate uses high-quality ingredients, including fly ash (or sand), cement, lime, gypsum, and aluminum powder. These materials are stored in designated silos and carefully measured to maintain consistency in the final product.
2. Mixing and Slurry Formation
Once the raw materials are measured, they are transferred to the mixing unit. In this step, fly ash (or sand) is mixed with water to form a slurry. The mixture is then blended with cement, lime, and gypsum to create a homogeneous paste. Aluminum powder is added as a foaming agent, which reacts with the other components to produce hydrogen gas, causing the mixture to expand and form a lightweight structure.
3. Molding and Pre-Curing
The prepared slurry is poured into large molds. As the chemical reaction occurs, the mixture begins to expand and rise, similar to the rising of bread dough. This process takes approximately 2-3 hours, during which the material partially solidifies into a “green cake.”
4. Cutting Process
Once the green cake reaches the desired consistency, it is removed from the mold and transferred to the cutting unit. Buildmate employs precision cutting technology to ensure uniform block sizes. The green cake is cut into standard or customized dimensions using horizontal, vertical, and cross-cutting wires. This process ensures accurate block sizes with smooth edges.
5. Autoclaving (High-Pressure Steam Curing)
After cutting, the AAC blocks undergo autoclaving, a crucial process for achieving strength and durability. The cut blocks are placed inside a high-pressure autoclave chamber, where they are exposed to steam at temperatures of around 180-200°C and pressures of 12-14 bar for 8-12 hours. This autoclaving process results in the formation of crystalline structures, making the AAC blocks strong, lightweight, and thermally efficient.
6. Quality Control and Testing
Quality assurance is a vital part of Buildmate’s manufacturing process. After autoclaving, the AAC blocks undergo rigorous quality control tests, including:
- Compressive Strength Test: Ensuring the blocks meet structural integrity standards.
- Density Check: Confirming lightweight properties for easy handling.
- Thermal Conductivity Test: Assessing energy efficiency.
- Dimensional Accuracy Test: Guaranteeing uniform sizes and smooth surfaces.
7. Packing and Dispatch
Once the blocks pass all quality tests, they are carefully stacked, packed, and prepared for dispatch. Buildmate ensures that the blocks are properly wrapped to prevent damage during transportation. The final products are then shipped to various construction sites, where they contribute to sustainable and efficient building projects.
Conclusion
Buildmate’s AAC blocks manufacturing process is a well-engineered and precise method designed to deliver high-quality, sustainable, and durable building materials. From raw material preparation to autoclaving and quality testing, every step is executed with precision to ensure superior performance.
If you are looking for a reliable AAC Blocks Manufacturing Plant in Hyderabad, Buildmate stands as the trusted name in the industry, offering cutting-edge solutions for modern construction needs.
