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We put concrete into shape

Autoclaved Aerated Concrete (AAC)

HESS Group - Successful for more


than 5 decades
HESS AAC Systems B.V. (previously Stork
Bouwtechniek) possesses specific knowhow on the building of machines and
plants for the autoclaved aerated concrete
and sand-lime brick industry.
About thirty years ago HESS AAC became
active on the AAC market, concentrating mainly
on manufacturing, installing and maintaining
the production machinery for the world market
leaders in AAC. During this relationship HESS
built several production lines for key customers
in Europe.
Today HESS is known worldwide for its excellent
craftsmanship, engineering know-how and
high quality of the products and services it
supplies. The machinery is robust and equipped
with first class components, at a very competitive price level.

HESS
G

HESS AAC Systems B.V.


P.O. Box 321, 7550 AH Hengelo (Ov.),
The Netherlands
Phone:
Fax:
E-Mail:
Internet:

+ 31 (0)74 240 70 00
+ 31 (0)74 240 70 86
info@hess-aac.com
www.hess-aac.com

HESS
AAC SYSTEMS

HESS

Autoclaved Aerated Concrete (AAC)

The Autoclaved Aerated Concrete (AAC) material


was developed in 1924 in Sweden. It has become one
of the most used building materials in Europe and is
rapidly growing in many other countries around the
world.
Autoclaved Aerated Concrete, also known as Aircrete, is
a lightweight, load-bearing, high-insulating, durable building
product, which is produced in a wide range of sizes and
strengths.
AAC offers incredible opportunities to increase building
quality and at the same time reduce costs at the construction
site.
AAC is produced out of a mix of quartz sand and/or
pulverised fly ash (PFA), lime, cement, gypsum/anhydrite,
water and aluminium and is hardened by steam-curing in
autoclaves. As a result of its excellent properties, AAC is
used in many building constructions, for example in residential homes, commercial and industrial buildings, schools,
hospitals, hotels and many other applications.

Autoclaved aerated concrete is actually hydrated calcium


silicate. The calcium is obtained from quick lime, hydrated
lime and cement. The gypsum is used as a katalyst and
for optimizing the properties of AAC.
The silica is obtained from silica sand, fly ash (PFA), crushed
silica rock and/or stone. It is possible to obtain silica as
a by-product from other processes, e.g. foundry sand or
burgee from glass grinding, provided the levels of alkalis
or other impurities, are not too high.

AAC SYSTEMS

Advantages of AAC
large variety of sizes: AAC can be produced in a large
variety of sizes, from standard blocks to large reinforced
panels;
excellent thermal insulation: AAC has a very low
thermal conductivity and therefore a very high thermal
energy efficiency is achieved. This results in savings
on heating and cooling costs;
extremely lightweight: AAC weighs approximately
50% less than other comparable building products;
high compressive strength: AAC is a solid product,
therefore making it highly load bearing. The entire
surface area is used in structural calculations;
high dimensional accuracy: As a result of its
dimensional accuracy, AAC is extremely easy to install,
as no thick set mortar is required;

great acoustic insulation: The porous structure of


AAC provides a high acoustic insulation;
high fire resistance: AAC has an extremely high fire
rating of at least 4 hours and more;
termite resistance: AAC can not be damaged by
termites or insects;
high workability: As a result of the excellent size/weight
ratio, constructing with AAC is very rapid. Even though
AAC is a solid building material, it can be cut, sawn,
drilled, nailed and milled like wood, making it an
extremely workable product.

HESS

Autoclaved Aerated Concrete (AAC)

AAC SYSTEMS

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ball mill for milling sand


slurry tanks
silos for lime, cement and gypsum
dosing and mixing
casting
position for reinforcement insertion
rising/pre-curing
position for extraction of reinforcement holding pins
tilting the cake with tilting crane
mould oiling
vertical cut and profiling

horizontal cut
cross cut and handgrip milling
back-tilting of the cake onto a cooking frame
bed waste removal
stacking and buffering of green cakes
autoclaving
buffering and destacking of hardened cakes
unloading from cooking frames
separating
packaging of final product

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The HESS philosophy is to provide our customers with
a pro-duction system designed as a solution for the
specific needs of the market in terms of capacity and
product range.
The HESS Keen-Crete systems can offer this high degree
of flexibility in plant design, based on know-how and
experience in both tilt-cake and flat-cake systems. Performance
is guaranteed through the use of proven standard machine
modules and components.
Following plant concepts are generally available:
KBT-S version:
capacity range from 450 - 900 m per day
KBT version:
capacity range from 900 - 1550 m per day

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HESS

Autoclaved Aerated Concrete (AAC)

AAC SYSTEMS

Raw material preparation


A ball mill finely wet-grinds the quartz sand with water to a
sand slurry, which is then mixed with lime, cement, gypsum
and aluminium powder/paste.

Casting and rising/pre-curing


The mix is poured into moulds. In the rising area
the cake pre-cures for ca. 2 3 hours and is then
ready for cutting.

Tilting
The tilting crane tilts the mould by 90. The crane
unlocks the mould and removes the mould body,
so that the cake remains on one mould
side/platform for cutting. This tilting system has
proven to be the safest method for tilting the cake
into the vertical cutting position, as the cake is
tilted onto the same side that it rose on.

Cutting
The cake in cut by high precision cutting machines. Cutting is done by pneumatically tensioned
cutting wires.
the pre-cutter and vertical cutter cut the block
length and panel width. In this station the
profiling (tongue and groove) can be cut into
the cake with profiling knives;
the horizontal cutter cuts the block and panel
thickness;
the cross cutter cuts the block height and the
panel length. Optionally hand-grips can be
milled into the cake in the green stage.

HESS

Autoclaved Aerated Concrete (AAC)

AAC SYSTEMS

Back-tilting and bed removal


In most tilt cake systems the cake is autoclaved
in the vertical position. The HESS KBT-S and
KBT systems have combined the advantages
of the tilt-cake and flat-cake system.
After the cutting is completed, the cake is tilted
back by 90 onto a cooking frame. In the HESS
system no part of the mould or platform used for
cutting go into the autoclaves. After the cake has
been tilted back into the horizontal orientation,
the bottom/bed waste will be removed before
autoclaving. Autoclaving the cake on the cooking
frames allows efficient autoclave loading and most
importantly, will prevent most of the sticking of
the layers, which is a typical disadvantage for the
traditional tilt-cake systems.
HESS SYSTEMS PRODUCE NO
PROCESS RELATED WASTE

Unloading and packaging


After the autoclaving is completed the cakes are destacked
and the cakes are unloaded from the cooking frames.
Depending on product specification and raw material
quality, it might be necessary to separate the layers.

Autoclaving
The cakes on the cooking frames get stacked three high
and are then fed into the autoclave, where they are cured
for 10-12 hours at a temperature of 190C with saturated
steam at a pressure of 12 bar.

The finished products are packed according to


the market requirements. Usually this is on
wooden pallets and covered in foil.

HESS

Autoclaved Aerated Concrete (AAC)

AAC SYSTEMS

Development Design Fabrication


HESS machinery is designed on modern 3-D CAD
systems. In the production only materials and
components of the highest standards are used.
Continuous in-house control ensures this high
quality standard.
Machine components are made out of certified steel
types and manufactured with the help of CNC controlled
welding-, milling- and drilling machinery. This results in
machinery and systems with accurate dimensions and
a high quality standard.

HESS can offer you a financially and technically attractive solution to


upgrade your existing Hebel-type cutting machine.
In order to increase the quality of the product as well as
the reliability of the plant, without investing in a complete
new cutting machine, the modification of the Hebel technology based cutting machine is possible.
new cutting table with moving bridges
new set of needles with rectangular design
replacement of the cross cutting shafts
vertical wire tensioning system
top crust removal system

horizontal cutting system for lintel cutting

Even after the installation and commissioning


of your plant, HESS customers benefit from
the first-class know how of our engineers.

counter pusher with pusher package


bottom and top profiling system
new control system
new hydraulic system
Highlights
short installation time
proven technology
the existing logistics and production do not
require major changes due to these modifications

Experienced and trained service engineers can assist


in resolving problems by access to the machinery
via remote diagnosis.
Also regular service inspections on site can be offered
to ensure that the productivity and product quality
remain at a constantly high level.
Storage facilities worldwide with original spare and
wearing parts guarantee availability and ensure
continuous production of your systems.

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