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

Main ingredends (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 – Approx 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 lukewarm/hot 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 use of a good standard brand. 

  • 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 a 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 may 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.

  • Desired quantity of cement is mixed with fly ash (filler) slurry.

  • Additives (if required) are poured in mixer.

  • Aluminum powder premixed with small quantity of water is added in mixer. Mix for 15-30 seconds.

  • Prepared concrete slurry is then poured in greased molds.

  • After filling the mold, mixer moves towards next mold for filling (for stationary lines).
    After filling the mold, mold moves towards pre curing area and a new mold is moves towards mixer for next fill (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.

  • Next day these blocks are removed from mold base and shifted to curing area for water curing.

  • Curing is done by simply spraying water on stack of blocks, and keeping it wet minimum for seven days.

  • After curing and drying blocks are ready for shipping…

    Note : Raw material quantity is depend on quality of raw material. it may vary from place to place

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