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Useful Information - Frequently Asked Questions (FAQ)

 
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  • ALC
    Aerated Lightweight Concrete. A natural (water) cured lightweight concrete.

  • AAC
    Autoclaved Aerated Concrete. A lightweight concrete cured in pressurized steam. Requires following additional equipment other than ALC equipment.
    • Boiler - To generate the steam
    • Autoclave - A pressure vessel where we keep blocks for curing.

  • CLC
    Cellular Lightweight Concrete. Also known as Foam Concrete.

Tip
  • Manufacturing process of ALC and AAC is similar up to the cutting stage, Difference is with the curing process.
  • ALC plant can be upgraded to AAC by adding Boiler and Autoclave.
For details please click below links

  • Water curing is done simply by sprinkling water on a stack of blocks and keeping it wet to gain the strength naturally. It is not required to keep submerged in a water tank like few other concrete products.

  • In general practice keeping blocks wet for 7 days (more is better) is sufficient. It needs to leave as it is allowing blocks to dry for 3-4 days before shipment. So the total holding period is minimum for 10-12 Days.

Application of both AAC and ALC blocks is the same. To build a wall manufacturing process (curing) is different.

  • During autoclave production, blocks gain strength under high pressure about 12Kg and temperature of about 185°C. This requires expensive equipment and large production areas.
  • In non-autoclaved production, aerated concrete gains strength in natural conditions.
Click here for detailed comparison of AAC and ALC block

  • The cost varies depending on the desired performance, line automation and installation of additional elements.

  • Our sales team will tell you about the details and cost of a specific option, in the process of communication.

Main ingredients (raw materials) for production of aerated concrete (both AAC and ALC)

  • Water
  • Ordinary portland cement
  • Quick lime
  • Gypsum (POP)
  • fillers (fly ash/fine sand)
  • Aluminum powder
  • Additives (these chemicals are used to stabilize / boost the quality of final product)
Most of the raw materials such as fly ash, cement and lime are available locally in many regions or it can be obtained from nearby available sources.
It's important to choose raw material wisely. Quality and quantity of raw material reflects the quality of blocks.
Good raw materials give better product quality.

  • Fly ash/pond ash is available from thermal power plants (fly ash is silica rich product, which is industrial waste generated by burning pulverized coal).

  • The ash generated from wood or agriculture waste burning is not suitable for production of aerated concrete.

Cost of production totally depends on the cost of raw material and its quality. Cheaper raw materials will result in lower production cost. As per market, where raw materials are costly and production cost is high, there market rates for finished goods are also on a higher side.

To calculate the exact production cost at your place, you need to consider many factors, such as raw material properties and its cost, Line capacity, labor cost etc. You can find out detailed information at the consultation with our sales team.

There's huge demand for Aerated Blocks, whether it is natural cured or steam cured. The end user doesn't bother about our manufacturing process. He needs quality blocks. And quality solely depends on raw material and workmanship. Mixer will mix the raw material we put in. but its ratio depends on many factors like raw material properties and weather conditions. And so the output is. And cutting machines will cut the cake in required sizes. But block handling, stacking/storing is to be done carefully.

It's just like cooking. Quality and consistency matters.

AAC blocks can be seen everywhere.

Reason behind this:

There are many large capacity plants such as 500 M³/Day - 1000 M ³/Day are available nearby. The production volume of AAC is very high compared to ALC. So one can see everywhere AAC Blocks.

For ALC, Majority of plants have Smaller production volumes with average 10-20 M ³ /Day production capacity.

So if any manufacturer gets a good order, he supplies blocks to the same client for many days. Due to this reason ALC blocks are not seen at dealers and shops like AAC blocks.

And one more thing, Visually there's NO DIFFERENCE between AAC and ALC Blocks. So on a construction site if ALC blocks are seen, anybody can be mistaken as these are AAC Blocks. As on site also, many people are not aware about natural and steam curing.

It depends on production capacity and automation, here are examples

  • ACB Mini line can be fit in a total area of 5000 Sq Ft
  • ACB Pro Line requires Minimum area of 10000 Sq Ft.
  • AAC Line Require Minimum area of 20000 Sq Ft.

All production lines require 3 Phase electricity.


  • ACB Mini line require electricity from 7HP
  • ACB Pro line require electricity from 10HP to 40HP
  • AAC line require electricity from 50HP to 100HP

It all depends on automation and installed accessories.

You can find out detailed information at the consultation with our sales team.

One should consider two main requirements to be fulfilled from the boiler

  • Working pressure - In the autoclave, the working pressure required for curing is 12Kg. So the boiler should be capable of generating steam with more than 12 Kg pressure.
  • Steam output - Generated steam output is measured in TPH (Ton/Hour). It is determined by the volume of autoclave and number of autoclaves. More production needs more TPH.

To upgrade the system from ALC to AAC these additional two equipment are required majorly.


  • Boiler - is used to generate the high pressure steam, which is used for curing. Fuel used for boiler is either firewood, coal or briquettes
  • Cost of a boiler depends on design type, output steam capacity, working pressure and installed accessories such as chimney, ducting, APH, WPH, PRV station, water softener and length of steam pipeline.
  • Autoclave - is a pressure vessel. Mold trolleys carrying a cake of blocks are kept inside an autoclave with pressurized steam for approximately 12 hours.

Cost of up-gradation from ALC to AAC for 17 M ³ per day capacity is approximately Rs. 60 Lac depending on installed accessories

Each line has its own automation level. Generally to operate the machines for production manpower required from 2-5 people for small lines and 4-10 people for medium sized lines. It depends on the skill and workability of people.

Yes, we train your employees. Firstly, we provide you with documentation, instructions and videos, which describe and show the production process in detail. Secondly, we show how to operate and maintain the equipment at the time of commissioning.

Our equipment is so clear and convenient that installation supervision is not required for most of the small and medium lines. We provide all documentation for assembly. Commissioning works are included in the cost of equipment. You pay only for the traveling of the technologist and his accommodation. Our expert trains your employees and starts production.

We create high-quality equipment that has been working for many years. Receiving feedback from customers, we modernize production lines, so our equipment is the best in the market.


The price is determined by the quality of the goods and the level of service.

Equipment can be purchased on bank loan. We help with the documents for a bank that is ready to provide you with funds.

We have a fixed price for all components, we do not provide discounts. But we surely help to choose the best option for you by avoiding unnecessary elements and reducing the initial cost. If there are seasonal price reductions/offers, then our sales team will inform you about them in the process of communication.

Delivery cost depends on the distance between our factory and your site, and the volume of the purchased equipment.

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