AAC Block (Hebel) Production Line and Factory Setup

An AAC (Autoclaved Aerated Concrete) block production line is a complete industrial system designed to mix, cast, pre-cure, cut and autoclave lightweight concrete blocks under controlled process conditions. The line produces AAC blocks for construction.

From an industrial perspective, AAC manufacturing is important because it combines precise dosing of silica sand, lime, cement and aluminium powder, controlled expansion, accurate cutting and high-pressure steam curing to achieve consistent density, strength and dimensional accuracy. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary materials typically include silica sand, lime, cement, gypsum, aluminium powder and water. The core machinery set consists of feeders, crushers, vertical mixers, pre-curing systems, wire cutting machines, industrial autoclaves (above 174.5 °C) and cooling conveyors.

The Industrial Department supports investors who want to establish a new AAC plant as well as existing operators who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey AAC plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The AAC line is engineered as an integrated process system covering raw-material preparation, mixing, casting, pre-curing, wire cutting, autoclaving, cooling and packaging. Design capacity is determined during the engineering phase and can typically range from 50000 to 500000 m³ per year.

Main machinery groups include mixers, casting systems, cutting machines, autoclaves and handling equipment. Supporting infrastructure covers electrical power, gas/steam and process water.

Manpower requirements depend on the degree of automation. Quality control covers density, compressive strength and dimensional accuracy.

Technical Specifications

Specification	Description
Product	AAC (Hebel) blocks
Production Capacity	50000–500000 m³/year
Required Area	1000–3000 m²
Electrical Power	380 V three-phase, 150–300 kW
Gas	300–800 m³/h
Water Consumption	20–50 m³/day
Manpower	10–20 persons per shift
Main Machines	Mixer, casting system, wire cutter, autoclave, cooling conveyor

All figures are indicative.

Products

AAC blocks in various densities and sizes for wall and partition applications.

Raw Materials for AAC Factory

Primary materials are silica sand, lime, cement, gypsum, aluminium powder and water.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of cement, lime, sand and packaging required by AAC plants.

Registering an order for raw materials for the factory AAC Block
Sahi Rasa Supply Chain Department

Support is available for projects in Iran, Iraq, Kurdistan Region, Afghanistan and other regional markets.

Manufacturing Process

1. Raw Material Preparation – Sand, lime, cement and aluminium powder are prepared.
2. Mixing – Materials are mixed into a slurry.
3. Casting and Pre-curing – Slurry is cast and allowed to rise and set.
4. Wire Cutting – Green cake is cut into blocks.
5. Autoclaving – Blocks are cured under high-pressure steam (above 174.5 °C).
6. Cooling and Packaging – Blocks are cooled and packed.

Machinery & Equipment

• Mixer – Prepares the slurry. Position: first process stage. Importance: uniformity of mix. Quality impact: incomplete mixing causes density variation. Maintenance: agitators and seals. Sahi Rasa support covers design, installation, repair and spare parts.
• Casting and Pre-curing System – Forms the green cake. Position: after mixing. Importance: expansion and strength development. Quality impact: incorrect timing affects cutting quality. Maintenance: moulds and handling systems.
• Wire Cutter – Cuts the cake into blocks. Position: after pre-curing. Importance: dimensional accuracy. Quality impact: inaccurate cutting causes waste. Maintenance: wires and drives.
• Autoclave – Cures under high-pressure steam. Position: core stage. Importance: final strength and stability. Quality impact: incorrect pressure or time affects quality. Maintenance: pressure vessels, valves and controls.

Factory Layout & Building Requirements

Typical areas include raw-material storage, mixing and casting, cutting, autoclave hall, cooling and packaging, quality control, utilities and staff facilities. Exact area is determined during engineering.

Utilities

• Electricity: 380 V three-phase, 150–300 kW
• Gas/Steam: 300–800 m³/h equivalent
• Water: 20–50 m³/day

Turnkey Factory Setup

An investor can start from an empty site. The project can be accompanied through feasibility, engineering, design, machinery, installation, commissioning, training and commercial production.

EPC & PMC

Projects can be executed under EPC or PMC approaches within defined contracts.

Machinery Repair

Existing AAC lines can request inspection, repair and spare-parts support for mixers, cutters and autoclaves.

Machinery Overhaul & Refurbishment

Older equipment can be overhauled and control systems upgraded.

Capacity Expansion

Capacity can be increased by adding autoclaves or cutting capacity.

Industrial Automation

PLC control of mixing, cutting and autoclave cycles is typical.

Supply Chain

The Supply Chain Department supports cement, lime, sand and packaging supply.

Packaging

Blocks are stacked and protected according to market requirements.

Branding & Product Development

Support for product development and technical documentation is available when required.

Market & Country Sections

Services are available in Iran, Iraq, Kurdistan Region, Afghanistan and other listed regional markets.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment
Factory Design	Layout and process design
Machinery Design / Manufacturing	Equipment specification and supply
Procurement	Sourcing of machinery and materials
Installation & Commissioning	Start-up and testing
Automation	PLC and process control
Raw Material Supply	Via Supply Chain Department
Repair / Overhaul	Restoration of existing equipment
Capacity Expansion	Throughput increases
Staff Training	Operational training

Why Sahi Rasa

Integrated process engineering, machinery, installation and training provide a clear path from concept to operating production line.

From Empty Land to Production

Typical sequence from feasibility through commercial production.

Who Should Contact Sahi Rasa?

• Investors planning a new AAC block plant
• Existing owners needing repair, overhaul or expansion
• Industrial buyers requiring machinery or materials

Final CTA

Contact the Industrial Department for factory setup, machinery, repair, overhaul or raw-material coordination.

Registering an order for raw materials for the factory AAC Block

FAQ

1. What capacity can be designed?
   Typically 50000–500000 m³/year.
2. Which main machines are required?
   Mixer, casting system, wire cutter, autoclave and cooling conveyor.
3. How much space is needed?
   Approximately 1000–3000 m².
4. Can existing lines be repaired?
   Yes.
5. Are turnkey projects available?
   Yes under defined contracts.
6. Are services available in Iraq and Afghanistan?
   Yes.
7. Can materials be supplied?
   Yes via the Supply Chain Department.
8. Is installation included?
   It can be included according to the package.
9. What about automation?
   PLC and process control can be provided.
10. How is capacity expanded?
    By adding autoclaves or cutting capacity.