Comprehensive AAC/ALC Production Workflow

Comprehensive AAC/ALC Production Workflow

The production of AAC/ALC is a science-driven industrial process that converts raw minerals into high-performance, lightweight building materials through precision engineering.

1. Material Dosing & High-Shear Mixing

The process begins with the precise weighing and dosing of raw materials: fly ash or silica sand, lime, cement, gypsum, and aluminum paste.

• Kaber Advantage: Our advanced aluminum paste ensure consistent slurry rheology and homogeneous pore distribution.

2. Pre-curing Dynamics & Reinforcement Integration (ALC Specialized)

This transition phase is critical for pore formation and structural setting.

• The Science: Aluminum paste reacts with the alkaline slurry to generate hydrogen gas, forming the internal pore architecture.

• ALC Panel Reinforcement Cycle:

  • Steel Mesh Preparation: Before casting, the anti-corrosion treated steel mesh cage is prepared.

  • Steel Rod Insertion : Precise guide rods (steel pins/braids) are inserted into the mold to secure the reinforcement mesh in its exact geometric position, ensuring it remains centered during the slurry expansion phase.

  • Stabilization: Kaber’s specialized stabilizers are essential here to ensure perfect slurry encapsulation around the mesh without causing voids.

  • Rod Extraction : Once the green cake reaches the optimal "plastic-to-solid" consistency but prior to final hardening, the guide rods are mechanically extracted (pulled out) from the cake, leaving the steel mesh perfectly embedded and aligned within the structure.

3. Precision Cutting

• AAC Blocks: The cake is cut into standard dimensions, prioritizing surface smoothness.

• ALC Panels: The cutting system is precision-configured to navigate around the internal steel reinforcement cage, ensuring the load-bearing integrity remains intact.

4. Autoclaving (Hydrothermal Curing)

Products are subjected to high-pressure steam (approx. 12 bars at 190°C). This hydrothermal reaction forms a durable, crystalline tobermorite structure, granting the product its compressive strength and insulation properties.

5. Post-Production: Quality Assurance

• ALC Panels: Final finishing and structural integrity checks are performed to verify reinforcement compliance.

• AAC Blocks: QC focuses on compressive strength and dimensional tolerance.