Ecotrend (Cambodia) New Building Materials Development Co., Ltd. is a Chinese-invested enterprise established in the Kingdom of Cambodia, specializing in the development, manufacture and export of eco-friendly, energy-efficient new building materials--- autoclaved aerated concrete (autoclaved lightweight concrete) products (known as AAC or ALC products).
Ecotrend is located at Sihanouk Ville Special Economic Zone, Cambodia. The company occupies land area of about 25000 square meters; and total investment of more than 14 million dollars.
The technical performance and quality standard of ECOTREND’s block meet the requirements of the national autoclaved aerated concrete block GB11968-2006 standard. It is suitable for civil and industrial buildings in areas with seismic fortification intensity less than 7 degrees, which are made of non bearing wall materials by dry thin layer masonry technology; it is suitable for heat preservation and energy saving buildings, which are widely used in residential buildings, office buildings, hospitals, hotels, schools and other civil, public and industrial buildings.
ECOTREND plate is a kind of rust-proof three-dimensional steel mesh frame built on ECOTREND’s advanced production process technology with built-in patented technology, which is made of quartz sand, lime, cement and gas-generating materials. It is formed by high temperature, high pressure and steam curing. Porous lightweight board is a new type of green building wall innovation material.
Most autoclaved aerated concrete blocks are mainly made of cement, lime, silica sand, etc. Some ingredients, such as fly ash, are added. The concrete needs to add steel mesh. Then according to the different products, the addition ratio of materials and ingredients are different.
AAC products are mainly made of silica sand (fly ash and other siliceous materials), cement, lime, and gypsum as the primary raw materials, and aluminum slurry as the foaming agent. AAC products are cured under high temperature (180℃~200℃) and high pressure (10~12 standard atmospheres) after the process of batching, mixing, pouring, pre-curing, cutting, etc. As China famous AAC panels & blocks manufacturer, we introduce the manufactur procedure of AAC products in this article.
1）Raw materials inspection
The raw materials used in the production of aerated concrete are firstly transported into the factory by various vehicles and stored in the warehouse or yard. Then siliceous materials such as sand, fly ash, etc., are ground finely; among them, there are several different handling methods according to the raw material requirements and process characteristics. It can be either dry ground into powder and then made into slurry by mixing with water; or directly input into a ball mill with water to make a slurry by wet grinding; it can also be mixed with a part of lime, phosphogypsum, etc. After crushing lime, it is finely ground by a ball mill and stored in a powder lime silo. Cement is directly punched into a cement warehouse by a cement tanker. Aluminum powder is purchased regularly every month according to plan and stored in a cool and dry warehouse. The raw material stockpile mainly ensures the continuity of production and the stability of raw materials, achieves a reasonable ratio of raw materials from different sources and of different quality, etc., to meet the process requirements and produce qualified products. Among the main raw material silica sand requirements, SiO2 is greater than 85%, 0.08 square hole sieve residual after fineness ≤ 15%. The criteria for lime are that the ablation speed should be between 8 and 15min, the ablation temperature should be ≥ 70 ℃), etc.
This process is the preparation process of the mixing process, which is to make the raw materials into materials that meet the requirements of the process. It provides convenience and possibility for the subsequent mixing process and enables various raw and auxiliary materials to give full play to their physical and chemical functions. The first process link directly affects whether the whole production process can be carried out smoothly and whether the product quality can meet the requirements.
2) Production of reinforcing steel mesh (only required by panel)
Steel processing treatment is a unique process for producing aerated concrete panels. Steel bars are welded to the mesh with an automatic steel welding machine and assembled into a double-layer reinforcing mesh, followed by rust removal, straightening, cutting, welding, paint preparation, paint impregnation, and drying. The rebar mesh assembly process assembles the anticorrosion-treated rebar mesh into the mold according to the size specifications and relative positions required by the process. It makes it fixed for pouring and the formation of the slurry gassing.
According to the process order, the pouring process is to put the raw materials, which are already prepared in the first process, into the pouring car. Then, after mixing by the pouring machine, make a mixed slurry that meets the requirements of time, temperature, and consistency specified in the production process, pour the mixed slurry into the mold and then form the billet the pretreatment process. After all kinds of materials are put into the pouring truck, a series of initial chemical reactions will occur through the pouring mixer, which keeps mixing to make each material thoroughly mixed. The mixing process is an essential process for aerated concrete to form an excellent porous structure. It constitutes the core link of the aerated concrete production process and the feeding process.
If you are making panels, you must put the completed double-layer reinforcement mesh into the mold frame in this process.
The main intention of the pretreatment process is to promote the completion of the mixture of the slurry to continue to complete the gas expansion thickening, the completion of the billet in the mold long high hardening so that the aerated concrete blanks achieve a specific cutting strength, convenient cutting process. The hardening of aerated concrete blanks mainly relies on the heat given off by the chemical reaction of the materials with hydration ability inside the aerated concrete blanks to promote. Still, the external ambient temperature should not be neglected and needs to be kept at a constant temperature. The pretreatment process generally does not have many operations. We attach great importance to the influence of ambient temperature and have ambient temperature regulation facilities.
The cutting process is to divide and process the appearance of aerated concrete embryos to meet the requirements of aerated concrete product appearance and size. The cutting process reflects the characteristics of mass mechanized production of aerated concrete. By cutting with special cutting machines, the apparent size of aerated concrete products can be made flexible and varied, meeting various user needs, customizing multiple sizes, length cutting, and cross-cutting according to different requirements. The working condition of the cutting machine directly determines the appearance quality and certain inner quality of aerated concrete products. It directly affects the production efficiency of the whole aerated block production line. Therefore, we must pay high attention to the cutting process in the production process of aerated products.
6) Autoclaved curing
The high-temperature curing process is a steam curing process of aerated concrete blanks in a high temperature, high-pressure environment. The production of autoclaved aerated concrete must undergo sufficient time under the proper temperature and pressure of saturated steam, curing for the billet to complete a series of physical and chemical changes to produce the adequate strength and turn into the qualified product we need. Steam curing requires high temperature (above 180℃), high pressure (above 10 standard atmospheres), high humidity, and confined space. Under such high temperature, high humidity, and confined environmental conditions, the aerated concrete billet will undergo sufficient internal hydration reaction to produce the required hydrates such as tropomorphite to form the required compressive strength. The steam-raising operation should be handled properly; otherwise, some problems will occur, and more scrap will occur in severe cases, affecting the finished product rate.
7) Finished product inspection
Finished product inspection is the last process in the production process of aerated concrete products, which guarantees to provide qualified products to the market and the regular operation of the next production cycle. The factory is equipped with a professional laboratory, which will conduct batch release tests for finished products, including specifications, hardness, dimensions, etc. before they are released to the market.
8) Packaging and transportation
After the inspection of aerated concrete products is completed, the standard packaging methods are pallet packaging, PE packaging, corner protection, etc. The factory is equipped with special packing and transportation machines, which can integrate packing and transporting to the warehouse. The products will be transported according to the density and size of the corresponding containers to ensure products are delivered to buyers intact.
AAC products require less energy in the production process, low consumption of raw materials, recycled and widely used, making them more environmentally friendly and accepted by the market. Especially AAC panels, as one of the prefabricated building materials, will become a new trend in the construction industry and be recognized by consumers.
Currently, Ecotrend AAC products are becoming one of the most popular green prefabricated building materials. AAC building systems have been successfully developed and implemented for over 65 years, and they have been used in a wide range of residential and commercial applications. It is a composite material consisting of fine quartz sand (fly ash, river sand, and other siliceous materials that can be used instead), cement, lime, and gypsum. The significant difference between AAC blocks and AAC panels is that AAC panels have bi-directional welded steel mesh inside; apparently, the two layers of welded steel mesh enhance the compressive strength of AAC panels on top of the original.
How AAC blocks and panels, interior and exterior walls, roofs, and floors, should be installed respectively is detailed in the following links. This article provides recommendations and guidance only; the installing contractor should determine the specific operation.
● Installing AAC Block
● Installing Vertical Wall Panels
● The Installation Process of Ecotrend AAC External Wall Panel System
● The Installation Process of Ecotrend AAC Internal Wall Panel System
● The Installation Diagram of Ecotrend AAC Floor and Roof
● The Fastest Way to Build a Nice and Solid Fence with Ecotrend AAC Panel
AAC performs well as thermal and sound insulation because of its aerated structure and distinctive thermal insulation and thermal mass. AAC is relatively easy to work with since it can be cut and shaped with hand tools or even woodworking tools. Its magic comes from airtightness, pest resistance, longevity, ease of use, instability, speed, and won't even need to mention fire resistance—all of this in one material.
● 4 most critical reasons to choose AAC beyond conventional advantages
The most significant difference between aerated concrete products and autoclaved aerated concrete products can be known from the name whether there is a process of autoclaving. Due to the lack of necessary maintenance technology for non-autoclaved aerated concrete products, many performance parameters of aerated concrete blocks cannot reach Chinese national standards, such as dry density, heat preservation, compressive strength, etc. We can find the differences in the absence of professional experimental equipment by observing the appearance and weight.
● The Difference between Autoclaved Aerated Concrete and Non-autoclaved Aerated Concrete
AAC block vs Red bricks: What's the difference
Bricks are an integral part of the wall. The strength and durability of the wall and the building as a whole depend on brick. Red brick is the oldest and most commonly used brick. The popularity of red brick can be attributed to its accessibility, durability, low cost, convenience, and feasibility.
However, due to population growth, the demand for red bricks is also increasing. Fertile land needs to be sacrificed. In addition, the scarcity of skilled labor and the increased cost of kiln fuel make red bricks more costly. This is why it is crucial to balance the demand and supply of bricks and look at alternative solutions to bricks. That is why the trend of concrete blocks as an alternative material is gradually emerging.
There are various types of cement blocks on the market. However, the most used is AAC blocks. AAC blocks were one of the significant achievements in construction in the 20th century. Fly ash, a by-product of industry, is used to manufacture AAC blocks, making them eco-friendly materials. The disposal of fly ash is a headache, and such a choice makes its use more beneficial to the environment. It is a revolutionary material that offers a unique combination of high durability and strength, low weight, and excellent ecological "green" features.
So here we give you a brief comparison between AAC block and red brick to help you make the right and informed choice.
AAC block consists mainly of silica sand/fly ash, cement, lime, and aluminum paste. It is a honeycomb concrete forming material that has been widely used for exterior/interior walls of residential and commercial buildings, such as villas, apartments, schools, factories, shopping malls, hospitals, etc. It is also a perfect choice as a prefabricated building material.
Red brick is mainly made of lime clay, sand, lime, and iron oxide. It is one of the oldest and most common building materials. Due to its low cost, durability, and easy availability, red brick still enjoys a high reputation in the construction field.
1）The production process of AAC blocks.
As mentioned above, the production process of AAC blocks goes through 8 processes: incoming material inspection, production of reinforcing mesh (rustproof treatment of reinforcing mesh), mixing (pouring and inserting reinforcing mesh), pretreatment, cutting, autoclave maintenance, finished product inspection, packaging, and transportation.
2）Red brick production process.
There are many steps in traditional brickwork - gathering the materials needed for mortar, sand, cement, and water. They were transporting cement and sand to the mixing place—screening of sand before mixing into the mortar. Pre-wet the bricks before using them on site. Mix all materials according to required specifications. Supervise during bricklaying. They are curing of brickwork after completion.
1) AAC blocks are lightweight material; the density of AAC is 1/3 of clay bricks, reducing the base cost by 15-20%.
2) AAC blocks are about 4 times the size of bricks, with fewer joints, less mortar, and twice as much labor as clay bricks so that they can be installed faster.
3) The thermal conductivity of AAC is 1/4 of clay bricks, which helps keep the room warm in winter and cool in summer, and can save up to 30% of energy consumption for air conditioning.
4) AAC blocks are lighter in weight and more environmentally friendly. The primary clay material of red bricks comes from natural soil, so the production process consumes the top fertile soil and emits more CO2, causing damage to nature.
5) AAC block has better fireproof and sound insulation performance. 100mm thick wall has 4 hours fireproof rating and is recognized as European A1 non-combustible product; 100mm thick wall with double-sided putty can reduce 40.8 decibels of noise.
6) Lightweight and excellent integrity enable AAC blocks to absorb strong impacts, thus reducing inertia forces during earthquakes. In contrast, red bricks cannot be used for load-bearing structures in high seismic zones.
7) AAC blocks are eco-friendly, while traditional red bricks are not. Due to less use of cement, steel, and concrete, AAC blocks emit less heat in the atmosphere, while on the other hand, red brick emits more heat in the atmosphere.
8) On AAC blocks, the dead load on the structure is low, thus reducing cement, steel, and water consumption. Whereas with laterite blocks, the dead load on the structure is heavy.
9) AAC blocks have less material waste, while traditional red clay bricks have more material waste.
10) AAC blocks have higher thermal and acoustic insulation properties, while red clay bricks have lower thermal and acoustic insulation properties.
AAC blocks are an innovative alternative to traditional building materials. They have unique advantages over traditional red bricks, such as lightweight, fire resistance, sound insulation, heat insulation, and earthquake resistance.
Have you ever bought the AAC products? Do you really understand AAC products? Generally speaking, AAC stands for autoclaved aerated concrete; and AAC also can be divided into two main products according to different raw materials, one is called autoclaved sand aerated concrete and the other is called autoclaved ash aerated concrete.
● Autoclaved Sand Aerated Concrete or Autoclaved Ash Aerated Concrete?
This article will give you the complete answer if there are questions about wall grooving, wall hanging, installation of door and window frames, paint, and ceramic tile practices.
● Frequency asked questions about Autoclaved Lightweight concrete wall