It's a long way from raw materials through the mixture to the finished stone. Many plant components are involved in this process. Only if the system components are matched, can one be assured of a smooth process and economical operation of the block making plant.
The manufacturing of autoclaved aerated concrete products demands high standards for mixing and dosing of the aggregates, the control of the fermentation process and the control of each production step. Masa's aerated concrete installations are proven advanced technology processes, designed according to customers specific requirements. This approach allows complete solutions to ensure highly efficient, optimised processes resulting in consistent final product quality.
It's a long way from raw materials through the mixture to the finished sand lime bricks. Many plant components are involved in this process. Only if the system components are matched, can one be assured of a smooth process and economical operation of the sand lime brick production plant.
It's a long way from raw materials over mixture to the finished (Kerb)stone. Masa Kerbstone presses were developed to fulfill among other criteria, the special requirements of the "British Standard" kerbstones. This "British Standard" is still a condition in countries of the Middle East and the UK.
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One of the keys to increasing productivity and quality is continuous training of the machine and maintenance personnel.
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- Sales Department Porta Westfalica
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From VARIO BLOCK to VARIO PANEL
AAC products with steel reinforcementThe manufacturing concept for the production of aerated concrete blocks (VARIO BLOCK) can be extended for the production of reinforced elements (VARIO PANEL).
What are reinforced AAC products?
When aerated concrete wall, roof or ceiling elements are manufactured, additional steel reinforcements have to be inserted into the products. This also applies to room-high separating wall elements and lintels that are placed above doors and windows. The general term for this kind of products is "reinforced AAC products".
Reinforced AAC products (selection)
Plant extension in just a few steps
When the various steps of extension have already been considered in the basic planning of an AAC plant, the VARIO PANEL concept can easily be integrated into existing plants. The required modifications and the implementation of the additional plant components can mostly be carried out while normal production is going on. This saves time and money.
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Step 1 - Preparation area for steel reinforcement cages
Preparation
A preparation area for steel reinforcement cages is established. This section comprises a straightening and cutting machine that is used to cut steel wires to individual lengths. Then a welding machine particularly designed for AAC plants produces various types of reinforcement grids. In a last step, these grids are converted to individual reinforcement cages.
As AAC is an open-porous building material, the reinforcement materials have to be protected with an anti-corrosive coating.
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Step 2 - Preparation area for reinforcement frames
Intermediate buffer for reinforcing frames
The working area for manual loading of the reinforcement frames with steel cages is established. At this point of the production process, it is particularly important that the steel cages are precisely fixed to the holding needles. With the help of a frame system with adjustable holding beams for needles, the reinforcement items are precisely positioned for each individual mould.
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Step 3 - Loading and unloading unit
Loading and unloading unit
A loading and unloading unit is installed. This component places the prepared reinforcement frame onto the casting mould and the reinforcement cages into the still flowable aerated concrete compound thus. This procedure immediately follows the filling of the mould in the mixing plant. Centering elements at the frame and at the mould guarantee a precise positioning of the steel cages and thus precise products. During the fermentation process, the frames remain on the moulds to secure the positions of the reinforcement cages.
When the fermentation process is completed, the same loading and unloading unit removes the frame including holding beams and needles from the mould. The steel reinforcement items remain in the aerated concrete cake that is ready for cutting now.
The existing transport unit transfers the cake to the cutting line.
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Step 4 - Cutting line
Cutting line
The existing cutting line of the VARIO BLOCK line is flexibly adjustable, therefore, modifications are not necessary. It is possible to manufacture various types of reinforced products without any problems.
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Step 5 - Autoclaves
Loading of autoclaves
To give the products their final consistency, they are hardened in autoclaves under steam pressure. For the hardening cycle, it has to be considered whether products with or without reinforcement are processed. Compared to normal block production, particularly the pressure increase and the pressure decrease speed levels have to be reduced. This means an extension of the complete hardening process by approx. two to four hours. As the steps of the autoclaving process can individually be adjusted in the Masa autoclave control system, the transition to reinforced products of best possible quality is quick and easy. For an economical integration of the manufacture of reinforced products into the production process, a quantity of at least one autoclave loading of reinforced products is reasonable.
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Step 6 - Packaging area
When the hardening process is completed, the products are ready for use and are transported to the packaging area. For the reinforced products, a separate packaging line is installed. The existing block transfer device can be used to place the products on a special chain conveyor. Packaging is carried out individually and depends on the products and local requirements.
Talk to us!
You are interested in the VARIO PANEL concept and would like to upgrade your plant? We will be pleased to advise you!