AAC was first developed in mid 1923 in Sweden. It is also known as Autoclaved Cellular Concrete (ACC) or Autoclaved Lightweight Concrete (ALC). Production process of AAC is fairly simple. It has become one of the most used building materials in Europe and is rapidly growing in many other countries around the world. It is made with a mixture of fly ash, lime, cement, gypsum, an aeration agent and water. Aeration process, imparts it as a cellular light weight structure. AAC products are precast in various sizes and provides structural resistance, insulation, and fire resistance.

There are 4 plant variants that we offer which varies on the basis of the mold (cake) size, namely Variant A, B, C, & D. The per day production capacity of the plant variant depends upon the number of autoclaves in use. All of the 4 variants have the provision of maximum 6 autoclaves.

24 HOUR PLANT CYCLE :

The time required for Stage 2 : Dosing & Mixing of cement, lime with fly ash slurry along with aluminum powder & other chemicals before discharging it into the mold box takes about 8.5 minutes.

Therefore the plant can produce :

24 Hours = 1440 Min

1440 / 8.5 Min = 168 Molds / Day

After casting the mold the time required for the rising & pre-curing of the mold takes about 2 hours before it proceeds to the demolding & cutting stage & further for Autoclaving process.

The time required for Stage 5 : Autoclaving is about 12 Hours after precuring. Therefore 1 Autoclave can process 2 cycle per day i.e. in 24 Hours

1 Autoclave can steam 11 Molds / Cycle in variant A i.e. 22 molds in 24 hours & 14 Molds/Cycle in variant B,C,& D i.e. 28 molds in 24 Hours.

VARIANT A

DETAILS OF VARIANT-A (FLY ASH BASED) :

MAXIMUM EXPANDABLE CAPACITY	150 M3
POWER INSTALLATION REQUIRED	100 KW
LAND REQUIREMENT	1.5 - 2 ACRES
SHED AREA	1000 TO 1500 M2
BOILER	1 TON 15 KG/CM2
AUTOCLAVE	1.6M DIA X 15 M LONG (THICKNESS 12MM)
MOLD (CAKE FINISHED)	1.2 X 1.2 X 0.8 M (1.152 M3 PER MOLD)
NO. OF MOLDS PER AUTOCLAVE	11 NOS (PER AUTOCLAVE)
AUTOCLAVE YIELD / 12 HOUR CYCLE	12.5 M3 / 12 HOUR CYCLE (25 M3 / DAY)

PLANT CAPACITY :

No. Of Autoclave In Use	Per Day Production (M3)
1 – (22 molds/day)	25
2 – (44 molds/day)	50
3 – (66 molds/day)	75
4 – (88 molds/day)	100
5 – (110 molds/day)	125
6 – (132 molds/day)	150

1 Autoclave – 22 Molds/Day | 1 Mold Volume – 1.152 M3

NO. OF AUTOCLAVE IN USE :

SR.NO	BLOCK SIZE (MM)	BLOCK PER M3	1 - 25	2 - 50	3 - 75	4 - 100	5 - 125	6 - 150
1	600X200X100	83.33	2,083	4,166	6,249	8,333	10,416	12,499
2	600X200X150	55.55	1,388	2,777	4,166	5,555	6,943	8,332
3	600X200X200	41.66	1,041	2,083	3,124	4,166	5,207	6,249
4	600X200X225	37.03	925	1,851	2,777	3,703	4,628	5,554
5	600X200X250	33.33	833	1,666	2,499	3,333	4,166	4,999
6	600X200X300	27.77	694	1,388	2,082	2,777	3,471	4,165

VARIANT B

DETAILS OF VARIANT-B (FLY ASH BASED)

MAXIMUM EXPANDABLE CAPACITY	240 M3
POWER INSTALLATION REQUIRED	200 KW
LAND REQUIREMENT	2 – 2.5 ACRES
SHED AREA	1700 TO 2000 M2
BOILER	3 TON 15 KG/CM2
AUTOCLAVE	2.1 M DIA X 15.6 M LONG (THICKNESS 12MM)
MOLD (CAKE FINISHED)	2.0 X 1.2 X 0.6 M (1.44 M3 PER MOLD)
NO. OF MOLDS PER AUTOCLAVE	14 NOS (PER AUTOCLAVE)
AUTOCLAVE YIELD / 12 HOUR CYCLE	20 M3 / 12 HOUR CYCLE (40 M3 / DAY)

PLANT CAPACITY

1 Autoclave - 28 Molds/Day	1 Mold Volume – 1.44 M3
No. Of Autoclave In Use	Per Day Production (M3)
1 – (28 molds/day)	40
2 – (56 molds/day)	80
3 – (84 molds/day)	120
4 – (112 molds/day)	160
5 – (140 molds/day)	200
6 – (168 molds/day)	240

SR.NO	BLOCK SIZE (MM)	BLOCK PER M3	NO. OF AUTOCLAVE IN USE
			1–40	2–80	3–120	4–160	5–200	6–240
1	600X200X100	83.33	3,333	6,666	9,999	13,332	16,666	19,999
2	600X200X150	55.55	2,222	4,444	6,666	8,888	11,110	13,332
3	600X200X200	41.66	1,666	3,332	4,999	6,665	8,332	9,998
4	600X200X225	37.03	1,481	2,962	4,443	5,924	7,406	8,887
5	600X200X250	33.33	1,333	2,666	3,999	5,332	6,666	7,999
6	600X200X300	27.77	1,110	2,221	3,332	4,443	5,554	6,664

VARIANT C

DETAILS OF VARIANT-C (FLY ASH BASED)

MAXIMUM EXPANDABLE CAPACITY	315 M3
POWER INSTALLATION REQUIRED	250 KW
LAND REQUIREMENT	3 – 3.5 ACRES
SHED AREA	2500 TO 2700 M2
BOILER	3.5 TON 15 KG/CM2
AUTOCLAVE	2.1 M DIA. X 19.5 M LONG (THICKNESS 16 MM)
MOLD (CAKE FINISHED)	2.5 X 1.2 X 0.6 M (1.875 M3 PER MOLD)
NO. OF MOLDS PER AUTOCLAVE	14 NOS (PER AUTOCLAVE)
AUTOCLAVE YIELD / 12 HOUR CYCLE	26.25 M3 / 12 HOUR CYCLE (52.5 M3/DAY)

PLANT CAPACITY

1 Autoclave - 28 Molds/Day	1 Mold Volume – 1.875 M3	No. Of Autoclave In Use	Per Day Production (M3)
1 - (28 molds/day)			52
2 - (56 molds/day)			105
3 - (84 molds/day)			157
4 - (112 molds/day)			210
5 - (140 molds/day)			262
6 - (168 molds/day)			315

SR.NO	BLOCK SIZE (MM)	BLOCK PER M3	NO. OF AUTOCLAVE IN USE
1	600X200X100	83.33	4,333	8,749	13,082	17,499	21,832	26,248
2	600X200X150	55.55	2,888	5,832	8,721	11,665	14,554	17,498
3	600X200X200	41.66	2,166	4,374	6,540	8,748	10,914	13,122
4	600X200X225	37.03	1,925	3,888	5,813	7,776	9,701	11,664
5	600X200X250	33.33	1,733	3,499	5,232	6,999	8,732	10,498
6	600X200X300	27.77	1,444	2,915	4,359	5,831	7,275	8,747

VARIANT D

DETAILS OF VARIANT-D (FLY ASH BASED)

MAXIMUM EXPANDABLE CAPACITY	504 M3
POWER INSTALLATION REQUIRED	450 KW
LAND REQUIREMENT	3.5 – 4.5 ACRES
SHED AREA	3000 TO 3200 M2
BOILER	6 TON 15 KG/CM2
AUTOCLAVE	2 M DIA. X 32 M LONG (THICKNESS 16 MM)
MOLD (CAKE FINISHED)	4.2 X 1.2 X 0.6 M (3.0 M3 PER MOLD)
NO. OF MOLDS PER AUTOCLAVE	14 NOS (PER AUTOCLAVE)
AUTOCLAVE YIELD / 12 HOUR CYCLE	42 M3 / 12 HOUR CYCLE (84 M3 / DAY)

PLANT CAPACITY

1 Autoclave - 28 Molds/Day	1 Mold Volume – 3.0 M3	No. Of Autoclave In Use	Per Day Production (M3)
1 - (28 molds/day)			84
2 - (56 molds/day)			168
3 - (84 molds/day)			252
4 - (112 molds/day)			336
5 - (140 molds/day)			420
6 - (168 molds/day)			504

SR.NO	BLOCK SIZE (MM)	BLOCK PER M3	NO. OF AUTOCLAVE IN USE
1	600X200X100	83.33	6,999	13,999	20,999	27,998	34,998	41,998
2	600X200X150	55.55	4,666	9,332	13,998	18,664	23,331	27,997
3	600X200X200	41.66	3,499	6,998	10,498	13,997	17,497	20,996
4	600X200X225	37.03	3,110	6,221	9,331	12,442	15,552	18,663
5	600X200X250	33.33	2,799	5,599	8,399	11,198	13,998	16,798
6	600X200X300	27.77	2,332	4,665	6,998	9,330	11,663	13,996