100,000 m3/Year AAC Block Plant Manufacturer
The 100,000 mยณ/Year AAC Block Plant is a medium-scale production line for manufacturing Autoclaved Aerated Concrete (AAC) blocks with an annual output of 100,000 cubic meters. It is suitable for building material manufacturers and investors looking to enter the green construction material market.โ
This plant is designed and installed according to the customerโs specific needs, such as local raw material supply, site conditions and market demand. It mainly consists of key equipment including ball mill, mixing machine, cutting machine, autoclave, overhead crane, and some other related auxiliary equipment like raw material storage silos and finished product packaging machines.โ
These AAC Block Plants can be used for processing AAC blocks of various specifications, as well as extended to produce AAC panels, AAC insulation products, etc., which are widely applied in industrial and civil building projects.
- Capacity: 100,000m3/year (Output can be customized)
- Type: fully automatic
- Construction Period: 3-9months
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How Much Does A 100,000 m3/Year AAC Block Plant Cost?
The total price of 100,000 m3/Year AAC Block Plant ranges from $1,000,000 to $2,200,000, depending on the degree of automation, region, and raw material processing methods.
Core equipment (ball-mill, slurry mixer, casting & foaming unit, tilt-cutter, 2ร31 m autoclaves, boiler): $800,000 โ $1,200,000
Installation, commissioning, and on-site technical training: $150,000 โ $220,000.
Auxiliary systems (dust-collectors, wastewater recovery lines, steam piping, silos): $120,000 โ $180,000
Spare-parts package + first-month raw-material inventory: $80,000 โ $120,000
We provide phased-payment schedules, modular upgrades, and localized cost-engineering to secure the best ROI for every client.
Main Parameters of 100,000 m3/Year AAC Block Plant
| Parameter | Details |
| Production Capacity | 100,000 mยณ/year Daily output: 333-400 mยณ (8-hour shift) |
| Equipment | – Ball Mill: e.g., ฮฆ1.5ร5.7m with 130 kW power – Mixing Machine: 4.2 mยณ capacity (fixed or movable) – Cutting Machine: 4.2ร1.2ร0.6m one – time six – sided cutting – Autoclave: 6 units, ฯ2ร21m – Overhead Crane: 5T double-hook + single-hook |
| Raw Materials | – Silicon materials (sand/fly ash): 65-70% – Calcium materials (lime/cement): 25-30% – Gypsum: 3-5% – Aluminum powder (foaming agent): 400-500 g/mยณ |
| Block Specifications | – Density: 400 – 700 kg/mยณ – Size: Standard 600ร200ร(75/100/200/240) mm, customizable |
| Factory Area | – Total area: 10,000 – 30,000 mยฒ (approx.) – Workshop area: 2,000 – 3,000 mยฒ |
| Power Consumption | 500-800 kW |
| Steam-related | – Steam boiler: 8t/h 1.6mpa – Autoclave steam time: 8h – Steam pressure: 1.3 – 1.6 mpa – Temperature: 190ยฐC |
| Production Process Time | – Material mixing time: 4 – 6 minutes – Slurry in curing room harden time: 1-2 hours – AAC green block cake cutting time: 4 – 5 minutes |
| Labor Requirement | Approximately 20 – 30 workers |
| Certification | CE, ISO (varies by manufacturer) |
| Customization | Available according to customer needs (layout, output adjustment, etc.) |
100,000 m3/Year AAC Block Plant Process
Raw material process โ Batching and Mixing โ Pouring โ Static pre-curing โ Cutting โ Autoclaving Curing โ Finished product Processing
1. Raw Material Processing: Sand is crushed and ground to the desired fineness. Cement, lime, and gypsum are stored in silos, and aluminum powder is mixed with water to form an aluminum slurry.
2. Batching and Mixing: The various raw materials are weighed according to precise proportions and then thoroughly mixed in a mixer to form a uniform slurry.
3. Pouring: The mixed slurry is poured into steel molds. The size and shape of the molds can be designed to meet the desired block specifications.
4. Static Pre-curing: The molds containing the slurry are transported to a pre-curing area where the slurry gradually hardens under suitable temperature and humidity conditions to achieve initial strength. This process typically takes several hours.
5. Cutting: After the slurry is pre-cured, it is cut into the desired size and shape using high-precision cutting equipment like steel wire or blades.
6. Autoclave Curing: Blocks are placed in an autoclave and cured for several hours at temperatures of 175-200ยฐC and pressures of 10-15 bar, significantly enhancing the blocks’ strength and durability.
7. Finished Product Processing: After autoclave curing, the blocks are removed from the autoclave and transported to a storage area. After inspection and packaging, they are ready for shipment.
Advantages of 100,000 m3/Year AAC Block Plant
This medium-scale plant (between small and large operations) balances productivity, cost, and risk. It is perfect for entrepreneurs and businesses new to AAC production or looking to expand steadily.
Targeted Output: With a daily production of 800โ1,200 mยณ (based on 8-hour shifts), it meets the needs of regional construction markets without overcapacity.
Low Investment Risk: Compared to large-scale plants (over 300,000 mยณ/year), initial costs are lower, and the simplified production flow reduces operational complexity. It is ideal for mitigating risks.
Easy Quality Control: Fewer production links mean tighter oversight. Youโll consistently produce high-quality AAC blocks that meet global standards, building trust with clients.
Eco-Friendly & Cost-Effective: AAC blocks use recycled materials like fly ash or silica sand, cutting raw material costs while aligning with green building trends (a major selling point in Europe, North America, and Southeast Asia).
Raw Materials of AAC block
- Cement (Portland Cement): Acts as a primary binder, providing strength and durability to the blocks. Typically, 43 or 53-grade OPC is used.
- Fly Ash or Sand: Serves as the main siliceous material. Fly ash, a byproduct of coal-fired power plants, is an eco-friendly alternative to sand, providing the necessary silica content.
- Lime: A key calcareous material that reacts with other components to form the binding matrix and contributes to the chemical reactions during production.
- Gypsum: Added in small quantities to regulate the setting time and improve the workability of the mix.
- Aluminum Powder or Paste: Functions as a foaming agent. It reacts with lime and water to produce hydrogen gas, creating the characteristic porous, lightweight structure.
- Water: Essential for the hydration of cement and lime, and to facilitate the chemical reactions necessary for the setting and hardening of the blocks.
These materials are carefully proportioned and mixed to form a slurry, which is then cast, pre-cured, cut, and finally autoclaved to produce the finished AAC blocks.
Main Equipment in 100,000 m3/Year AAC Block Plant
1. Jaw Crusher
Function: Crushes large lumps of raw materials such as limestone and gypsum into 50-150 mm pieces, facilitating subsequent fine grinding. It is a key piece of equipment for raw material pretreatment.
Structure: A fixed jaw plate and a movable jaw plate form a deep-chamber crushing chamber lined with impact-resistant, replaceable high-manganese steel tooth plates.
Capacity Range: Common models range from 100 to 500 t/h. The motor and main unit are integrated on a steel frame base, occupying only 4-6 mยฒ of floor space.
2. Ball Mill
Function: Grinds crushed lime, sand, or fly ash into a fine powder with a mesh size of 80-400 (0.2-0.045 mm) to enhance reactivity.
Structure: Horizontal cylinder+wear-resistant liner+steel ball media. It driven by a motor, reducer, and large gear.
Key Parameters: Cylinder diameter 1.2-2.4 m, ball load 5-30 t, power 55-800 kW.
3. Batching System
Function: Accurately weighs cement, lime, fly ash, aluminum powder, and water according to the recipe, with an error of โค ยฑ0.5%. Equipped with multiple silos, metering, and conveying equipment.
Module components: Electronic scale, screw feeder, pneumatic butterfly valve, PLC touch screen; one-touch recipe call, batching completed within 30 seconds.
4. Mixing & Casting Machine
Function: Rapidly mixes weighed dry materials with water and aluminum powder into a fluid slurry, which is then poured into a mold for foaming.
Features: Twin-shaft forced mixing completes one batch in 60-90 seconds; hydraulically tilts 90ยฐ for drip-free pouring.
Key Parameters: Effective volume 2-4 mยณ, motor power 37-55 kW, removable mixing blades, wear life โฅ 30,000 cycles.
5. Tilting Cutter
Function: Cuts pre-cured billets into desired specifications with an accuracy of ยฑ1 mm. Offcuts are recycled online.
Structure: Three sets of longitudinal, transverse, and horizontal steel wire frames; servo motors synchronize lifting and lowering, automatically compensating for wire wear.
Capacity: Cutting cycle โค 5 minutes/die; can cut 75-300 mm thickness, 600 mm standard length, or 1200 mm slabs.
6. Autoclave
Function: High-temperature, high-pressure steam curing allows the green body to complete the hydrothermal synthesis reaction within 8 hours, increasing its strength by 5-8 times.
Specifications: ฮฆ2.68ร32 m or ฮฆ2.85ร38 m; design pressure 1.6 MPa, operating temperature 200ยฐC; equipped with safety interlock and automatic blowdown.
Configuration: Each medium-sized line is equipped with 4-8 units, which can be connected in series or parallel. Energy-saving models include a waste heat recovery interface.
7. PLC Control Room
Function: Serves as the control center for the entire production line, offering features such as recipe management, parameter adjustment, process monitoring, energy consumption analysis, fault alarms, and remote app viewing.
Hardware: Reserved OPC UA interface for integration with the factory’s MES/ERP system.
8. Waste Gas Heat Recovery System
Principle: Autoclave exhaust gas at 160ยฐC is preheated to 90ยฐC via a heat exchanger, saving 8โ12% of natural gas annually.
Configuration: Plate heat exchanger+circulation pump+automatic temperature control valve.
What Makes Our AAC Blocks Stand Out?
Our 100,000 mยณ/year AAC blocks plant produces AAC blocks with properties that set them apart in the global market:
- Lightweight & Porous: Reduces building load, lowers transportation costs, and speeds up construction.
- Excellent Insulation: Cuts energy use for heating/coolingโcritical for markets like the EU and North America.
- High Strength & Seismic Resistance: Safe for high-rise and earthquake-prone regions (e.g., Southeast Asia, Central Asia).
- Fire & Soundproof: Meets strict safety standards in commercial and residential buildings worldwide.
- Easy Processability: Can be cut, drilled, or shaped on-site, saving time for contractors.
Why Partner With Us?
–Global Expertise, Local Support
1. Proven Track Record & Certifications
- 20+ Years of Experience: Supported by R&D with Chinaโs Northeast Architectural Design Institute, our team has designed over 100 AAC plants globallyโcovering Russia, Kazakhstan, Peru, France, the Philippines, and more.
- ISO & EU Compliance: All equipment meets international quality standards. As a member of the China Aerated Concrete Association, we ensure reliability for markets with strict rules.
- Contract-Abiding & Trustworthy: Recognized by Chinaโs industrial authorities for keeping our promises.
2. Cutting-Edge Equipment & Workshops
We have 8 specialized workshops (blanking, welding, machining, etc.) equipped with world-class machinery:
- Swedish plasma cutting machines and laser cutters for precise parts.
- 2,000-ton hydraulic presses and 800-ton CNC bending machines for metal processing.
- Japanese welding robots for strong, stable equipment structures.
- Every component-from 250ร400 jaw crushers (lime crushing) to D250 bucket elevators-goes through strict testing to ensure long-term performance.
3. End-to-End Services for Global Clients
We support you at every stage, no matter where you are:โ
- Customized Plans: We tailor the plant layout to your local space, resources, and market needs.โ
- Technical Consulting: Our team advises on raw material sourcing, process optimization, and meeting local building codes.โ
- After-Sales Support: We offer installation guidance, staff training, and maintenance to keep your plant running smoothly.โ
- Secure Delivery: Professional, eco-friendly packaging and global logistics ensure safe equipment arrivalโweโve shipped to over 100 countries.
Other Hot-Sale AAC Blocks Plant
| Annual Production | Price (USD) | Core Configuration |
|---|---|---|
| 100,000 mยณ | 1.5โ1.9 M | Air-turning cutting, 3ร31 m autoclaves |
| 150,000 mยณ | 2.1โ2.6 M | Robotic palletizing, 4ร31 m autoclaves |
| 200,000 mยณ | 2.8โ3.5 M | Six-sided cutting, 4ร37 m autoclaves |
| 300,000 mยณ | 4.0โ4.8 M | Dual cutting lines, 6ร37 m autoclaves |
| 400,000 mยณ | 5.5โ6.5 M | Fully automatic air-turning, 8ร37 m and above autoclaves |
