AAC Block (Hebel) Production Line and Factory Setup

An AAC (Autoclaved Aerated Concrete) block production line is an integrated industrial system designed to mix silica sand, lime, cement, gypsum and aluminum powder, cast into molds, pre-cure, wire-cut into blocks, autoclave under high-pressure steam and cool the finished lightweight blocks. The line produces high-quality AAC blocks for construction.

From an industrial perspective, AAC manufacturing is important because it combines precise mixing, controlled expansion (aluminum powder reaction), accurate wire cutting and high-pressure autoclaving (above 174.5 °C) to form calcium silicate hydrate (tobermorite) that provides strength and lightness. Typical capacity ranges from 50 000 to 500 000 m³/year.

Primary raw materials typically include cement, lime, silica sand, gypsum, aluminum powder and water. Core machinery consists of vibrating feeders, jaw crushers, vertical mixers, pre-dryers, industrial autoclaves (high-pressure steam), cooling conveyors and wire-cutting machines.

The Industrial Department supports investors establishing a new AAC block factory as well as existing plant owners requiring repair, overhaul, capacity expansion or automation of current lines. Projects can start from an empty site or from an operating facility that needs 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 block production 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 50 000 to 500 000 m³/year depending on final product mix and market requirements.

Product types include AAC blocks of various sizes and densities. The overall process flow follows a defined sequence: raw-material preparation, vertical mixing, casting into oiled molds, pre-drying/expansion, wire cutting, autoclaving under high-pressure steam (above 174.5 °C), cooling and packaging.

Main machinery groups include vibrating feeders, jaw crushers, vertical mixers, pre-dryers, autoclaves, cooling conveyors and wire-cutting machines. Supporting infrastructure covers electrical power, gas and process water.

Manpower requirements depend on the degree of automation. Quality control covers density, strength, dimensional accuracy and packaging integrity. Finished blocks are stored under protected conditions before distribution.

Technical Specifications

The following technical data represent typical ranges for an industrial AAC block production line. Final values are defined during basic and detailed engineering and may vary according to selected technology, level of automation, product portfolio and factory layout. For precise project-specific figures, contact the Industrial Department.

Specification	Description
Product	AAC (Autoclaved Aerated Concrete) blocks
Production Capacity	50 000–500 000 m³/year (depending on project capacity and selected equipment sizing)
Required Area	1000–3000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 150–300 kW (depending on equipment selection and automation level)
Gas	300–800 m³/h
Water Consumption	20–50 m³/day
Manpower	10–20 persons per shift (depending on automation level)
Main Machines	Vibrating feeder, jaw crusher, vertical mixer, pre-dryer, industrial autoclave (above 174.5 °C), cooling conveyor, wire-cutting machine

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial AAC block production line can manufacture AAC blocks of various sizes and densities according to market requirements.

Raw Materials for AAC Block Factory

Raw material selection and quality control are critical for density, strength and dimensional accuracy. The main materials used are described below.

Main Raw Materials

Cement, lime, silica sand, gypsum, aluminum powder – Form the AAC body and generate the aeration reaction.

Secondary / Optional Materials

Water, additives and packaging materials

Storage and handling conditions must be controlled to preserve material quality and prevent moisture variation.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by AAC block factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

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

Raw-material supply chain support can be examined for industrial projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

The industrial AAC process follows a defined sequence of unit operations.

Raw-Material Preparation – Silica sand, lime, cement, gypsum and aluminum powder are prepared and proportioned.
Mixing – Materials are mixed in a vertical mixer to form a uniform slurry.
Casting – Slurry is poured into oiled molds.
Pre-Curing / Expansion – Molds enter a pre-dryer for aeration and volume increase.
Wire Cutting – Semi-hardened blocks are cut to size by a wire-cutting machine.
Autoclaving – Blocks are cured in an industrial autoclave under high-pressure steam (above 174.5 °C) to form tobermorite.
Cooling and Packaging – Blocks are cooled on a conveyor and packaged.

Machinery & Equipment

Each main machine performs a specific function. Support is available for design, manufacturing or procurement, customization, installation, commissioning, repair, overhaul, refurbishment, automation and spare-parts supply according to the agreed project scope.

Vibrating Feeder and Jaw Crusher – Feed and crush raw materials. Position: first stage. Importance: consistent feed and particle size. Maintenance: screens, jaws and drives. Sahi Rasa support covers design and spare parts.
Vertical Mixer – Homogenizes slurry. Position: after preparation. Quality impact: mixing uniformity. Maintenance: agitators and seals.
Pre-Dryer – Allows expansion and pre-hardening. Position: after casting. Quality impact: controlled expansion. Maintenance: heaters and conveyors.
Wire-Cutting Machine – Cuts blocks to size. Core machine for dimensional accuracy. Position: after pre-curing. Quality impact: cut accuracy. Maintenance: wires, frames and drives. Sahi Rasa provides specialized cutting support and overhaul.
Industrial Autoclave – Cures blocks under high-pressure steam (above 174.5 °C). Core machine for strength development. Position: after cutting. Quality impact: temperature and pressure profile determine final properties. Maintenance: pressure vessels, seals and temperature controls. Sahi Rasa provides specialized autoclave support and overhaul.
Cooling Conveyor – Cools finished blocks. Position: after autoclaving. Quality impact: controlled cooling. Maintenance: belts and drives.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, mixing and casting hall, pre-curing and cutting area, autoclave section, cooling and packaging, finished-goods warehouse, quality-control laboratory, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect process flow, high-pressure zoning and dust control. Exact area allocation is determined during the engineering phase according to capacity and product range.

Utilities

Electricity: 380 V three-phase, typically 150–300 kW
Gas: 300–800 m³/h
Water: 20–50 m³/day
Steam generation for autoclaves
HVAC and drainage according to local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC (Engineering, Procurement, Construction) or PMC (Project Management Consultancy) approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing AAC factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for mixers, cutters, autoclaves and conveyors.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn wires and seals, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (autoclave, cutter) or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and pressure monitoring, automatic dosing, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for AAC projects.

Packaging

Protective packaging, secondary packaging, labeling, coding and palletizing are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, industrial design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for AAC block projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new AAC block factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up an AAC block (Hebel) production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory AAC Block

FAQ

What is the typical cost of setting up an AAC block factory?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Vibrating feeder, jaw crusher, vertical mixer, pre-dryer, industrial autoclave, cooling conveyor and wire-cutting machine.
What production capacity can be designed?
Typical capacity ranges from 50 000 to 500 000 m³/year, determined during the engineering phase.
How much space is needed?
Typical process area ranges from approximately 1000 to 3000 m², subject to final layout.
What are the main raw materials?
Cement, lime, silica sand, gypsum, aluminum powder, water, additives and packaging materials.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.