A 120,000 m³/year AAC block making line is a medium-scale automated AAC manufacturing plant designed to produce approximately 330–360 m³ of AAC blocks per day (one shift). It is ideal for countries where AAC demand is growing, including Southeast Asia, the Middle East, Africa, and South America.
Suitable for:
- Construction material factories expanding capacity
- Real estate developers with their own block plants
- Investors supplying regional or state-level markets
- Companies upgrading from a 50,000–80,000 m³ plant
Typical daily output: 330–360 m³/day (one shift); Up to 600–650 m³/day (two shifts)
Typical land size required: 10,000–15,000 m²
Automation level: Semi-automatic or fully automatic depending on budget.
A 120,000 m³/year AAC line offers the best balance between investment cost and profitability, usually achieving ROI within 18–30 months.
Price Range of a 120,000 m³/Year AAC Block Making Line
The total investment depends on automation level, raw material type, and plant layout. Below is the general price structure:
Equipment Cost Range: USD 1,200,000 – 1,800,000 (including mixers, molds, cutting machine, autoclaves, batching system, etc.)
Land & Civil Construction: USD 150,000 to USD 450,000.
Installation & Training: USD 60,000 – 120,000
Total Estimated Plant Setup Cost: USD 1,400,000 – 2,300,000
Comparison with other plant sizes:
| Plant Size | Yearly Capacity | Typical Setup Cost | Best For |
|---|---|---|---|
| Mini AAC Plant | 30,000–100,000 m³ | USD 100,000–1,000,000 | New investors, small markets |
| Medium AAC Plant | 100,000–200,000 m³ | USD 1,200,000–2,300,000 | Growing demand, regional supply |
| Large AAC Plant | 200,000–600,000+ m³ | USD 2,000,000–3,000,000 | National markets, high volume |
The 120,000 m3/Year AAC Block Making Line sits at the sweet spot between cost and profitability.
Advantages of a 120,000 m3/Year AAC Block Making Line
Investors choose the 120,000 m³ configuration because it provides high output, stable quality, and cost efficiency. Key advantages include:
1. Optimal Cost–Output Balance
Compared with small 30,000–80,000 m³ plants, the 120,000 m³ line benefits from:
- lower production cost per cubic meter
- higher automation level
- better labor efficiency
- stronger competitiveness in local markets
For many investors, this is the capacity that maximizes profit without risking over-production.
2. High Block Strength & Stable Quality
Our production line achieves:
- 3.5–5.0 MPa compressive strength
- uniform density (500–650 kg/m³)
- accurate block dimensions
- excellent curing consistency due to advanced autoclave control
High-quality blocks improve market acceptance and resale value.
3. Energy-Efficient Autoclave System
A key feature of our 120,000 m³ plant is the low-energy curing system:
- optimized steam distribution
- faster heat transfer
- lower fuel consumption
- stable pressure holding (1.2–1.3 MPa)
This reduces operating cost significantly.
4. Flexible Raw Material Options
Common local materials include:
- river sand
- crushed sand
- fly ash
- cement
- lime
- gypsum
- aluminum powder
Adaptable formulation allows operation in diverse regions such as Malaysia, Indonesia, Kenya, Saudi Arabia, and Mexico.
5. Fully Modular & Expandable Design
The line can later be expanded to 150,000–200,000 m³/year by adding:
- extra molds
- additional autoclaves
- robotic cutting upgrades
This protects your long-term investment.
120,000 m3/Year AAC Block Making Line Process
Raw material process → Batching and Mixing → Pouring → Static pre-curing → Cutting → Autoclaving Curing → 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 175-200°C 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.
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 120,000 m3/Year AAC Block Making Line
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 m² 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 ≤ ±0.5%. 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 90° for drip-free pouring.
Key Parameters: Effective volume 2-4 m³, motor power 37-55 kW, removable mixing blades, wear life ≥ 30,000 cycles.
5. Tilting Cutter
Function: Cuts pre-cured billets into desired specifications with an accuracy of ±1 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 ≤ 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: Φ2.68×32 m or Φ2.85×38 m; design pressure 1.6 MPa, operating temperature 200°C; 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 160°C is preheated to 90°C via a heat exchanger, saving 8–12% of natural gas annually.
Configuration: Plate heat exchanger+circulation pump+automatic temperature control valve.
Technical Parameters of 120,000 m³ AAC Production Line
| Item | Specification |
|---|---|
| Annual Output | 120,000 m³ |
| Daily Output | 330–360 m³/day |
| Autoclave Pressure | 1.2–1.3 MPa |
| Steam Temperature | 185–195°C |
| Density Range | 500–650 kg/m³ |
| Compressive Strength | 3.5–5.0 MPa |
| Molds Required | 16–24 sets |
| Plant Area | 10,000–15,000 m² |
| Power Requirement | 450–620 kW |
| Workforce | 30–45 workers (depending on automation) |
What Is An AAC Block？
Autoclaved aerated concrete (AAC) blocks are a lightweight, porous, high-strength new building material.
The unique internal pore structure provides lightweight, high strength, thermal insulation, fire resistance, and sound insulation.
It is an ideal choice for achieving energy-saving and structural safety in buildings.
Application of AAC Block
Civil Buildings: Used in internal and external walls, floor slabs, roof slabs, etc. of residential buildings to reduce building weight and improve seismic performance.
Commercial Buildings: Suitable for non-load-bearing walls of shopping malls, hotels, office buildings, etc., with good thermal insulation and sound insulation effects to enhance building comfort.
Industrial Buildings: Served as wall and partition materials for factories and warehouses, meeting the special requirements of industrial production for building materials.
Special Buildings: Widely applied in hospitals, schools, gymnasiums and other places due to their excellent fire resistance and environmental protection properties.
120,000 m³ AAC Block Plant Exported to Malaysia
Location: Johor, Malaysia
Customer Type: Building materials company
Capacity: 120,000 m³/year
Automation Level: Semi-automatic + automatic cutting line
Investment: USD 1.65 million (equipment only)
Land Size: 12,000 m²
Raw Materials: River sand + cement + lime + gypsum
“The equipment quality is excellent. Your team solved every technical issue quickly. Our AAC blocks sell out faster than we can produce them. We are planning to expand to 200,000 m³ next year.”
Why Choose Us as Your AAC Block Plant Supplier?
Investors choose us because we deliver quality, reliability, and complete technical support.
1. 20+ Years of AAC Engineering Experience
We have installed AAC plants in:
- Southeast Asia
- Middle East
- Africa
- Eastern Europe
- Latin America
Our technical team has handled 30,000 m³ to 600,000 m³ AAC lines worldwide.
2. Complete Turnkey Service
We provide:
- Project consulting
- Layout design
- Raw material testing
- Equipment manufacturing
- Global shipping
- Installation & commissioning
- Formula optimization
- Long-term technical support
3. Advanced Cutting Technology
Smooth cutting, low waste, and precise dimensions give your blocks strong market competitiveness.
4. Strong Autoclave Manufacturing Capability
Our autoclaves feature:
- seamless welding
- high-pressure tests
- optimized steam circulation
Ensuring long lifetime (15–20 years).
5. Lower Operating Costs
Efficient machinery allows you to reduce:
- energy consumption
- labor cost
- material waste
- maintenance cost
6. Fast ROI & High Profitability
Typical payback period: 18–30 months
Profit margin per m³: USD 12–22 (varies by region)
Services We Offer
- Project Planning & Design
Provide overall planning and detailed design schemes for AAC block plants based on client needs and actual conditions, including process design, equipment layout, and civil engineering design. - Equipment Supply & Installation
Supply full sets of AAC production line equipment, and undertake installation and commissioning to ensure normal operation, meeting designed capacity and product quality standards. - Technical Training
Offer professional training for operators, technicians, and managers covering production processes, equipment operation, maintenance, and quality management. - After-Sales Service
Establish a sound after-sales system providing daily maintenance guidance, fault troubleshooting, and spare parts supply to ensure continuous stable production. - Technical Support & Upgrades
Provide ongoing technical support and offer equipment upgrading/technical transformation solutions based on client needs and industry trends to improve efficiency and quality. - EPC General Contracting
One-stop EPC services from design, equipment procurement, civil construction, installation, and training to trial production for a hassle-free experience.
Other Hot-sale Block Manufacturing Plant
| Annual Production | Price (USD) | Core Configuration |
|---|---|---|
| 100,000 m³ | 1.5–1.9 M | Air-turning cutting, 3×31 m autoclaves |
| 150,000 m³ | 2.1–2.6 M | Robotic palletizing, 4×31 m autoclaves |
| 200,000 m³ | 2.8–3.5 M | Six-sided cutting, 4×37 m autoclaves |
| 300,000 m³ | 4.0–4.8 M | Dual cutting lines, 6×37 m autoclaves |
| 400,000 m³ | 5.5–6.5 M | Fully automatic air-turning, 8×37 m and above autoclaves |
