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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.
3) Mixing
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.
4) Precuring
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.
5）Cutting
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.
