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Autoclaved Aerated Concrete Production Process
Updated at:
2026-03-12 09:40
1. Raw Material Storage and Feeding in the Autoclaved Aerated Concrete Block Production Process
Raw materials such as fly ash and sand are all delivered to the plant by truck. Fly ash, sand, and stone powder are centrally stored in the raw-material yard and loaded into feed hoppers for use. Bagged cement and bulk cement are stored in the cement silos and loaded into feed hoppers when needed. Chemicals and aluminum powder are stored separately in the chemical storage facility and the aluminum-powder storage facility, respectively, and are transported to the production workshop as required.
2. Raw Material Processing in the Autoclaved Aerated Concrete Block Production Process
Fly ash or sand and stone powder is conveyed to the ball mill via an electromagnetic vibrating feeder and a belt conveyor. The finely ground fly ash or sand and stone powder is then pumped by fly ash pumps into slurry tanks for storage. Lime is fed into a jaw crusher through an electromagnetic vibrating feeder and a belt conveyor; the crushed lime is subsequently lifted by a bucket elevator into a lime storage silo, and then conveyed by a screw conveyor into the ball mill. The finely ground material is then transported via screw conveyor and bucket elevator to the powdered-material batching bin. Chemicals are manually measured according to specified proportions to prepare solutions of a certain concentration, which are then stored in storage tanks. Aluminum powder is transported from the aluminum powder warehouse to the production workshop, hoisted by an electric hoist to the second floor of the batching building, and accurately metered into a mixer where water is added to form an aluminum powder suspension.
3. Process of Autoclaved Aerated Concrete Block Equipment: Mixing, Blending, and Pouring of the Aerated Concrete Mix
Lime and cement are sequentially conveyed by screw conveyors from the powder batching silos to automatic weighing scales for cumulative measurement; below the scales, another screw conveyor evenly feeds the materials into the pouring mixer.
Fly ash, sand, stone powder, and waste slurry are fed into metering cylinders for precise measurement. Once all materials have been accurately metered and the molds are in place, the slurry can be mixed. Prior to pouring, the slurry must meet the specified process requirements (approximately 40°C). If the temperature is insufficient, steam can be introduced into the slurry metering tank for heating. Additionally, an aluminum powder suspension should be added 0.5 to 1 minute before the material is poured.
4. Initial Curing and Cutting of Autoclaved Aerated Concrete Blocks in the Production Process
After pouring, the molds are conveyed via a chain conveyor into the initial curing chamber for gas evolution and initial setting, where the ambient temperature is maintained at 50–70°C for 1.5–2 hours (this step may be omitted under favorable geographical conditions). Following initial curing, a vacuum lifting device is used to hoist both the mold frame and the green body together onto a cutting table pre-equipped with kiln bottom plates. The mold frame is then removed, and the cutting machine performs transverse cutting, longitudinal cutting, and end-face milling on the green body. The mold frame is subsequently lifted back onto the mold transport cart for manual cleaning and degreasing, after which it is reloaded onto the mold cart for assembly and preparation for the next pouring cycle. The cut green bodies, together with the kiln bottom plates, are then lifted by an overhead crane onto kiln carts and stacked in two layers, with four supports placed between the layers; several kiln carts are grouped together as a unit.
The edge and corner waste generated during cutting is conveyed by a screw conveyor to a waste slurry mixer located next to the cutting machine, where water is added to form a waste slurry for use during batching.
5. Autoclaving and Finished Product Processes for Aerated Concrete Block Equipment
After the green bodies have been grouped on the pre-kiln parking line, the autoclaved aerated concrete plant opens the door of the autoclave designated for discharge, first using a winch to pull the finished-product kiln car out of the autoclave, and then using the winch to push the kiln car prepared for autoclaving into the autoclave for curing. The finished products on the kiln car are lifted by an overhead bridge crane into the finished-product warehouse, and then transported to the finished-product stackyard by a forklift. The empty kiln car and the autoclave bottom plate are hoisted back to the return line, cleaned, and then pulled by winch to the kiln-car rack for the next cycle.
Simply put, the production process for aerated concrete equipment involves adopting different processing methods based on the type and quality of raw materials as well as the operational characteristics of the main equipment. Typically, fly ash or silica sand is ground with water to form a slurry, to which an appropriate amount of powdered lime, cement, gypsum, and a foaming agent are added. After thorough mixing, the slurry is poured into molds, allowed to undergo static oxygen-induced foaming and curing, then cut into blocks or panels of various specifications. These are subsequently loaded onto curing carts and placed in autoclaves, where they are cured under high-temperature saturated steam conditions, ultimately yielding porous, lightweight aerated concrete products.
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