Our Process

An automated precision.

Our Process
Raw Materials

Autoclaved aerated concrete is manufactured with the main raw materials of quicklime, cement and siliceous sand. The sand must be finely ground. A proportion of the sand may be replaced with quick ash.

Mixing the Raw Materials

The ingredients are mixed using a set ratio and then water is added and a mortar mix is created. A small amount of aluminium powder is then mixed into the resulting suspension.

Moulding and Curing

The mortar is poured into a tub (mould), where the metallic, fine particled aluminium develops hydrogen gas in the alkaline mortar mixture. Many small gas bubbles are created, which expand the gradually stiffening mixture. After 15 – 50 minutes, the final volume is achieved and blocks between 3 and 8 metres long, up to 1,5 metres wide and 50 – 80 cm high are produced.

Cutting and Autoclaving

These “doughy” blocks are cut into the required building element sizes with wire. After 8 – 12 hours the aerated concrete attains its final properties via curing in special autoclaves (high-pressure steam boilers) at temperatures of 180 – 200 deg C in steam under saturated vapour pressure of 10 – 12 Bar. The autoclaved aerated concrete corresponds chemically to the mineral tobermorite, which can be found in natural environments. The production takes place in a sealed cycle and this no pollutants to water, air or ground are released. Via the curing with steam, the autoclaved aerated concrete avoids a great deal of potential energy waste.

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