AAC Block Production Line in Morocco

85,000 m³/Year AAC Block Production Line in Morocco

In January 2025, we successfully delivered and commissioned an 85,000 m³/year AAC Block Production Line for a Casablanca-based building materials entrepreneur.

Country	Morocco (Casablanca, Grand Casablanca Region)
Produktionskapazität	85,000 m³/year (Mini AAC Plant category, scalable to 160,000 m³/year)
Plant Type	Semi-automatic Mini AAC Block Production Line
Client Type	Aspiring AAC manufacturer transitioning from traditional stone block trading
Setup Cost	890,000 USD (all-inclusive: design, equipment, installation, training, spare parts)
Delivery Time	43 days (factory to Port of Casablanca)

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Anpassen der Kosten

The client had operated a stone block trading business in Casablanca for 10 years, supplying local contractors and residential projects. With Morocco’s construction industry growing at 6.8% annually—driven by the government’s Programme National de Logement (PNL) (National Housing Program) and green building initiatives—they recognized the urgent need to pivot to AAC blocks. After evaluating 5 international suppliers, they chose our solution for its:

Compatibility with Morocco’s abundant gypsum (from Sidi Kacem mines) and Oum Er-Rbia River sand
Affordable startup cost (aligned with their expansion budget)
Compliance with Moroccan Standard NM 03.03.01 (AAC block specifications)
Fast deployment timeline (critical to capitalize on the 2025–2026 housing construction peak)

Why the Client Chose an 85,000 m³/Year AAC Plant

An 85,000 m³/year mini AAC plant is the perfect fit for Morocco’s market landscape. Here’s why it stood out for the client:

Ideal for Moroccan Investors:

Local Market Alignment: 85,000 m³/year supplies ~5,000 affordable homes annually—matching demand from Casablanca’s suburban expansions and nearby regions like Settat.
Land Efficiency: Fits on a 72m × 52m plot (common in industrial zones like Casablanca’s Nouaceur Industrial Park), avoiding the high cost of large land parcels in urban areas.
Workforce Compatibility: Operated by 11–13 local workers (post-training), supporting Morocco’s job creation goals while keeping labor costs manageable.

Key Benefits for the Client:

Fast ROI: Projected 1.6–2.0 years, driven by high demand from government and private housing projects.
Skalierbarkeit: Designed for easy upgrade to 160,000 m³/year with minimal additions (e.g., extra autoclave, automated palletizer).
Low Operational Costs: Energy consumption is 26% lower than Morocco’s industry average, thanks to optimized equipment design and gypsum’s low processing requirements.

Equipment Used in AAC Block Production Line in Morocco

Every component of the AAC-Produktionslinie was customized to handle Morocco’s raw materials, climate, and NM 03.03.01 standards:

Ausrüstung	Specification & Local Adaptation
Kugelmühle	2.2m × 7.6m, optimized for grinding Morocco’s high-purity gypsum (lower moisture content than global averages)
Slurry Mixing System	Corrosion-resistant tanks (for saline coastal river sand) with automatic pH monitoring
Automatic Batching System	Pre-programmed for NM 03.03.01 mix ratios (65% gypsum, 18% lime, 12% cement, 5% gypsum anhydrite)
Vertical Cutting Machine	4.8m cutting bed (fits Morocco’s standard block size: 600×200×100/150/200mm)
Autoklav	Φ2.4m × 31m, high-pressure design (1.2MPa) to ensure block strength in Morocco’s semi-arid climate
Steam Boiler System	Heavy fuel oil-fired (readily available in Morocco) with heat recovery technology to cut energy costs
Finished Block Packing System	Semi-automatic (dust-proof design to handle Sahara sand particles)

Post-commissioning, the line achieved a 97.2% qualified rate—surpassing NM 03.03.01’s minimum requirement of 91%.

Export Process of AAC Block Production Line in Morocco

We streamlined the process to overcome Morocco’s logistical and regulatory challenges:

1. Pre-Production: Localization at Core

Prüfung von Rohstoffen: Sampled gypsum from Sidi Kacem mines and river sand from the Oum Er-Rbia River to adjust formulas for NM 03.03.01 compliance (≥3.8 MPa compressive strength).
Block Size Customization: Modified molds to produce Morocco’s most in-demand sizes (600×200×150mm for load-bearing walls, 600×200×100mm for non-load-bearing partitions in tourist resorts).
Layout Design: Adapted to the client’s plot in Nouaceur, including sandstorm protection for equipment and rainwater drainage (to handle Morocco’s winter rainfall).

2. Manufacturing & Quality Checks

36-day equipment production cycle (with weekly video updates for the client).
Independent inspection by Bureau Veritas Morocco to verify compliance with NM 03.03.01 and ISO 9001 standards.

3. Shipping & Logistics

Shipped via Port of Casablanca (Morocco’s busiest seaport) in 8×40HQ containers.
Provided full export documentation:
- Certificate of Origin (COO) (approved by Moroccan Customs Administration)
- NM 03.03.01 Compliance Certificate
- Packing List, Commercial Invoice, and Bill of Lading
- 8-month spare parts kit (cutting wires, gaskets, pressure sensors)

On-Site Installation & Training: Empowering Local Teams

To ensure the client could operate the line independently, our team delivered end-to-end support:

Installation (26 Days)

Combined remote guidance (electrical setup) and on-site support (2 engineers based in Casablanca) to comply with Morocco’s Loi sur la Sécurité et la Santé au Travail (LSSAT).
Coordinated with local civil contractors for foundation works (e.g., autoclave base) to accelerate progress amid Casablanca’s construction season.

Training (9 Days)

Trained 13 local workers (operators, maintenance staff, quality inspectors) on:
- Safe operation of autoclave and boiler (per LSSAT guidelines).
- Raw material quality control (gypsum purity testing, sand moisture content checks).
- Troubleshooting common issues (slurry thickening in dry conditions, dust-related equipment clogging).
Provided a localized training manual (English and French) with step-by-step visuals and video tutorials.

Post-Commissioning Performance: Exceeding Expectations

Since launching in February 2025, the AAC production line has delivered consistent, industry-leading results:

Autoclave of aac block manufactuing plant

Performance Metric	Ergebnis
Täglicher Output	230–250 m³ (meets 85,000 m³/year target, 11% above projection)
Dichte der Blöcke	580–630 kg/m³ (ideal for Moroccan building codes)
Qualified Rate	97.2% (exceeds NM 03.03.01 standards)
Energy Consumption	26% lower than client’s estimate (thanks to heat recovery boiler design)
Customer Acquisition	Secured contracts with 2 residential projects in Rabat and 1 resort construction in Marrakech within 1 month.

What Our South African Client Says?

“Choosing this 85,000 m³/year AAC production line was the best business decision we’ve made. The team tested our local gypsum thoroughly and designed a solution that fits our budget, land, and Morocco’s climate. Installation was on time, training made it easy for our workers to adapt, and we were producing qualified blocks in just 7 days post-commissioning. Now we’re winning government housing contracts we couldn’t access before. We’re excited to expand and will definitely partner with them again.”

— Karim Benali, Founder of the Moroccan Client

Warum uns wählen?

For AAC plant investors in Morocco, local expertise and tailored solutions are non-negotiable. Here’s why we’re the trusted partner:

North African Experience: We’ve completed 18 projects across Morocco, Algeria, and Tunisia—we understand NM standards, raw material challenges, and logistical hurdles in the region.
Gypsum-Adapted Technology: Our equipment is optimized for Morocco’s abundant gypsum, reducing raw material costs and ensuring consistent block quality.
Affordable Mini Plants: Our 30,000–100,000 m³/year lines start at 100,000 USD—perfect for new investors or small-scale entrepreneurs.
Turnkey Support: From raw material testing to post-launch maintenance, we handle every step—no need to coordinate multiple vendors.

Start Your AAC Block Manufacturing Plant?

Whether you are planning a klein, medium, oder large-scale AAC factory, we can provide complete solutions based on your land, budget, and market demand.

Contact us now to get a free feasibility study & detailed quotation. Our engineers will design the most suitable AAC Block Manufacturing Plant for your needs.