The ALC block manufacturing process is a sophisticated yet streamlined method for producing high-quality, lightweight construction materials. Essarcon, a pioneer in this industry, leverages advanced technology to ensure precision and efficiency in every step. Here’s a detailed look into the process.
1. Raw Material Selection
The journey begins with selecting high-quality raw materials, which include:
- Ordinary Portland Cement
- Quicklime
- Gypsum
- Fly Ash or Fine Sand
- Aluminum Powder
- Water
Careful selection and proportioning of these materials are critical, as they determine the strength, weight, and thermal properties of the final product.
2. Mixing
In the ALC block manufacturing process, the raw materials are mixed in a specially designed batching system. The addition of aluminum powder creates a chemical reaction, releasing hydrogen gas. This reaction forms tiny, uniform air bubbles, giving ALC blocks their characteristic lightweight and insulating properties.
3. Molding and Pre-curing
The aerated mixture is poured into molds to form large cakes. These molds undergo pre-curing at ambient temperature, allowing the hydrogen bubbles to stabilize within the slurry. This step is essential in the ALC block manufacturing process, as it establishes the blocks’ cellular structure.
4. Cutting
Once pre-cured, the cakes are precisely cut into blocks of the required dimensions using advanced cutting machines. The cutting process ensures minimal waste while achieving consistent sizes, a key factor in efficient construction.
5. Natural Curing
Unlike autoclaved aerated concrete (AAC), the ALC block manufacturing process employs natural curing methods. The blocks gain strength over time under natural conditions, eliminating the need for high-pressure steam curing. This makes the process cost-effective and suitable for smaller production facilities.
Advantages of ALC Blocks
The ALC block manufacturing process results in products that offer:
- Lightweight construction, reducing load on the foundation
- Superior thermal insulation, reducing energy costs
- Soundproofing, enhancing living comfort
- Eco-friendly production, with reduced energy consumption