ALC/NAAC Block Production Process


Production of Lightweight Aerated Concrete Blocks density from 600 to 800 kg/M3 Density

Main Components (Raw Materials) and Quantity per Cubic Meter

  • Water - 200 - 280 Ltrs
  • Ordinary Portland cement (OPC 53 Grade) – 180-280KG
  • fillers (Fly ash/Fine Sand) – 350 – 550KG
  • Aluminum powder – 500Gms
  • Additives – Quantity depends on raw material properties

  • Water
    Water for concrete mixture shall of any suitable drinking water. It is preferable to water from surface sources, unsalted, soft or medium hardness. It is also preferred to provide the required amount of water heated to a temperature of 40-50 º C for best results.

  • Portland Cement
    virtually all of Ordinary Portland cement (OPC 53 Grade) suitable for the production of aerated lightweight concrete. Cement should be Fresh, Lumps free. Preferred to use good standard brands. 

  • Fillers
    As part of concrete mix Fly ash / Fine Silica Sand / Dolomite can be used as filler.
    Fly ash / Pond Ash is from Thermal Power Plants (Fly ash is Silica rich product, which is industrial waste obtained from thermal power plant). Also fine silica sand, Dolomite (Limestone dust) can be used as filler.

  • Foaming Agent
    Small quantity of Pure Aluminum Powder is used for Foaming of concrete.

  • Additives
    Just like other concretes, Additives such as Activators / Accelerators are used to improve and stabilize the quality of final product.

    Process of production

  • Measured quantity of water is poured in Mixer.

  • Measured quantity of Fly ash (Filler) is added in mixer. Mix for 1-2Min

  • Desired quantity of Cement is mixed with fly ash (Filler) slurry. Mix for 1-2Min

  • Additives are poured in mixer.

  • Aluminum Powder premixed with small quantity of water is added in Mixer. Mix for 15-30Seconds.

  • Prepared concrete slurry is poured in Molds.

  • After filling mold, mixer moves towards next mold for filling again ( for Stationary Lines )
    After filling, mold moves towards mixer for next filling ( for Conveyor Lines )

  • In filled mold, Concrete slurry rises (just like Bread) and volume increases up to desired height in 15-20 Minutes.

  • In 3-5 Hrs. raised concrete gets its initial strength and mold panels are removed for cutting process.

  • Then this concrete “cake” is sliced in required sizes Horizontally and then Vertically with cutting machines (or Manually with the help of Slotted Cutting Guide Frame).

  • After cutting the sliced Concrete blocks are left overnight for initial hardening process.
    (Or it can be kept in Heat chamber for 5-6Hrs in 50-60 Degree Celsius temperature for accelerated Curing)

  • Next day hardened Blocks are removed and shifted to curing area for water curing.

  • Curing is done by simply spraying water on stack of blocks, just twice a Day minimum for Seven Days.

  • After curing Blocks are ready for shipping…








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