Proposal

Autoclaved Aerated Concrete (AAC)

Industry factory

Syamsurizal Dimjati
19 September 2012

PLANT WITH BRIGHT PROFIT

Much-needed construction materials, replacement materials clay brick

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Table of Contents
Autoclaved Aerated Concrete .............................................................................. 3
The light weight means that R-values for AAC .................................................... 4
Advantages .......................................................................................................... 5
Block ................................................................................................................... 6
Sustainability and Energy Considerations .................................................... 7
Calculation ECONOMIC AND BENEFITS...................................................... 8
Capacity and land area ........................................................................ 14
Margin ................................................................................................................ 17
Documentation of Photo .................................................................................... 20

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Autoclaved Aerated Concrete
Although, autoclaved aerated concrete (AAC) systems consist of blocks held together by mortar like concrete
masonry, the two systems are very different. AAC uses new, technologically advanced concrete and mortar to
give builders and buyers a new range of advantages.

Easily Installed
AAC is made with all fine aggregates, nothing more coarse than a grain of sand, cement, and a natural expansion
agent that causes the concrete to rise like bread dough, with countless small air pockets. In fact, this concrete is
80 percent air.

ACC can be molded and cut it into precisely dimensioned units. While block-size is most common, it can also be
cast into reinforced panels for walls, floors, and roofs. Its light weight/cellular properties make it easy to cut,
shave, and shape, accept nails and screws readily, and allow it to be routed to create chases for electrical
conduits and small-diameter plumbing runs. This gives it design and
construction flexibility, and the ability to make easy adjustments in the
field. Due to the similarity to traditional concrete masonry, AAC units
(block) can be easily installed by concrete masons. Sometimes,
carpenters get involved in installation. Depending on the type of finish
selected, they can be directly adhered or mechanically attached to the
face of AAC. View more on the construction of homes with autoclaved
aerated concrete.
Sustainable Benefits. AAC offers both material and performance
aspects from a sustainability perspective.
On the material side, it can contain recycled materials like fly ash and rebar, which may help contribute to credits
in LEED or other green rating systems.
Further, it incorporates such a large quantity of air that it contains less raw material per volume than many other
building products. From a performance perspective, the system leads to tight building envelopes. AAC combines
insulation and structural capability in one material for walls, floors, and roofs. This creates an energy efficient
envelope and protects against unwanted air losses. Physical testing demonstrates heating and cooling savings of
roughly 10 to 20 percent compared to conventional frame construction. In consistently cold climates, the savings
may be somewhat less because this material has lower thermal mass than other types of concrete. Depending on
the location of manufacturing relative to the project site, AAC may also contribute to local materials credits in
some green building rating systems.

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The light weight means that R-values for AAC
Are comparable to conventional frame walls, but they have higher thermal mass, provide air tightness, and as just
noted, are not combustible. That light weight also gives a high sound reduction for privacy, both from outside
noises and from other rooms when used as interior partition walls. Additionally, as a concrete wall system, AAC
resists water, rot, mold, mildew, and insects. It also has excellent fire resistance, with 8 inch-thick AAC achieving
a 4-hour rating (actual performance exceeds that and meets test requirements for up to 8 hours). And because it
is noncombustible, it will not burn or give off toxic fumes. The 2008 New American Home was constructed with
AAC. The ENERGY STAR- rated home also found additional benefits in sound reduction and resistance to
natural disasters.

Concrete Shines in ENERGY STAR Home/Building

Since 2003, The New American Home (TNAH) has been
certified through the ENERGY STAR program. Each of these
homes has featured concrete wall systems, one of the most
energy-efficient building envelopes available.

The home or building, which debuted at 2008 International

Builders' Show in Orlando, Fla., is no exception. It utilizes a
relatively new concrete system and some of the most trusted
concrete technology. The exterior structural walls were built with a
combination of lightweight autoclaved aerated concrete blocks
(AAC), and traditional poured-in-place concrete.

These concrete wall systems helped reduce energy consumption for heating and cooling by about 62 percent
compared to a house of comparable size in the same climate. That level far exceeds the ENERGY STAR
requirement of being at least 15 percent more energy efficient than a typical home. ENERGY STAR is a joint
program of the U.S. Environmental Protection Agency and the U.S. Department of Energy designed to save
money and protect the environment through energy efficient products and practices.

Concrete systems and products provide the home other environmental and comfort benefits. The more than 500
cubic yards of poured concrete throughout the 6,725 square-foot home create a house that is resistant to
termites, fires, wind, hurricanes, floods, and other natural disasters. Together these and other green building
products make the 2008 New American Home the first home to be certified by the National Home Builders
Associations National Green Building Program. Especially important for this home are the excellent
soundproofing qualities of concrete. It's located near the Orlando International Airport. In addition to providing a
comfortable home, concrete products contributed to the homes beauty. The family room fireplace is built from
concrete veneer bricks. The home is topped with concrete roof tiles and finished with a cement-based system.

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Autoclaved Aerated Concrete
Autoclaved aerated concrete, or AAC, is made with fine aggregates, cement, and an expansion agent that causes
the fresh mixture to rise like bread dough. In fact, this type of concrete contains 80% air. In the factory where it is
made, the material is molded and cut into precisely dimensioned units. Cured blocks or panels of AAC are joined
with thin bed mortar. Components can be used for walls, floors, and roofs. The lightweight material offers
excellent sound and thermal insulation, and like all cement-based materials, is strong and fire resistant. In order to
be durable, AAC requires some type of applied finish, such as a polymer-modified stucco, natural or
manufactured stone, or siding.

Advantages
AAC combines insulation and structural capability in one material for walls, floors, and roofs. Its light
weight/cellular properties make it easy to cut, shave, and shape, accept nails and screws readily, and
allow it to be routed to create chases for electrical conduits and small-diameter plumbing runs. This
gives it design and construction flexibility, and the ability to make easy adjustments in the field.

Durability and dimensional stability. A cement-based material, AAC resists water, rot, mold, mildew, and
insects. Units are precisely shaped and conform to tight tolerances.

Fire resistance is excellent, with 8 in. thick AAC achieving a 4-hr rating (actual performance exceeds
that and meets test requirements for up to 8 hr). And because it is noncombustible, it will not burn or
give off toxic fumes.

The light weight means that R-values for AAC are comparable to conventional frame walls, but they
have higher thermal mass, provide air tightness, and as just noted, are not combustible. That light
weight also gives a high sound reduction for privacy, both from outside noises and from other rooms
when used as interior partition walls.

But the material does have some limitations. It is not as widely available as most concrete products, though it can
be shipped anywhere. If it has to be shipped, its light weight is advantageous. Because it is lower strength than
most concrete products or systems, in load-bearing applications, it must typically be reinforced. It also requires a
protective finish since the material is porous and would deteriorate if left exposed.

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Sizes.
Both blocks and panels are available. Blocks are stacked similarly to conventional masonry, but with a thin-bed
mortar, and panels are stood vertically, spanning full-story heights. For structural needs, grouted, reinforced cells
and beams are placed within the wall section. (Concave depressions along vertical edges can create a cylindrical
core between 2 adjacent panels.) For usual applications, a vertical cell is placed at corners, on either side of
openings, and at 6- to 8-ft spacings along a wall. AAC averages about 37 pcf (lbs per cu ft), so blocks can be
placed by hand, but panels, because of their size, usually require a small crane or other piece of equipment.
Installation, Connections, and Finishes.
Due to the similarity to traditional concrete masonry, AAC units (block) can be easily installed by concrete
masons. Sometimes, carpenters get involved in installation. Panels are heavier due to their size and require the
use of a crane for placement. Manufacturers offer training seminars, and its usually adequate to have 1 or 2
knowledgeable installers on small projects. Depending on the type of finish selected, they can be directly adhered
or mechanically attached to the face of AAC.

Block.
First course is laid and leveled. Blocks are stacked together with thin-bed mortar in a running bond with a
minimum of 6-in. overlap.
First course is laid and leveled. Blocks are stacked together with thin-bed mortar in a running bond with
a minimum of 6-in. overlap.
Walls are plumbed, leveled, and squared with a rubber mallet.
Openings and odd angles are cut with a handsaw or bandsaw.
Reinforcement locations are determined, rebar placed, and grouting occurs. Grout must be
mechanically vibrated to consolidate it.
Bond beams are placed at the top of the wall and can be used for heavy-duty fixture attachment.
Panels.
Panels are placed one at a time, starting from the corner. Panels are set into a layer of thin-bed mortar
and vertical rebar is attached to dowels extending up from the floor before the adjacent panel is placed.
A continuous bond beam is created at the top, either with plywood and AAC material or with bond beam
block.
Openings can be precut or field cut.

Connections.
Roof frame/framing is connected to a conventional top plate or hurricane
straps embedded in the bond beam.
Floor framing is attached with standard ledgers anchored to the side of
the AAC assembly adjacent to a bond beam.
AAC floor systems bear directly on top of AAC walls.
Larger structural steel members are set on weld plates or bolt plates set into the bond beam.

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Finishes.
Stucco-type finishes are made specifically for AAC. These polymer-modified plasters seal against water
intrusion yet allow moisture vapor for breathability.
Conventional siding materials are mechanically attached to the wall face. Furring strips should be
employed if back ventilation of the siding material is desirable.
Masonry veneers can be directly adhered to the wall face or can be built as cavity walls. Direct-applied
veneers are typically lightweight materials like manufactured stone.

Sustainability and Energy Considerations.

AAC offers both material and performance aspects from a sustainability perspective. On the material side, it can
contain recycled materials like fly ash and rebar, which may help contribute to credits in LEED or other green
rating systems. Further, it incorporates such a large quantity of air that it contains less raw material per volume
than many other building products.

From a performance perspective, the system leads to tight building envelopes. This creates an energy efficient
envelope and protects against unwanted air losses. Physical testing demonstrates heating and cooling savings of
roughly 10% to 20% compared to conventional frame construction. In consistently cold climates, the savings may
be somewhat less because this material has lower thermal mass than other types of concrete. Depending on the
location of manufacturing relative to the project site, AAC may also contribute to local materials credits in some
green building rating systems.

Manufacturing and Physical Properties

First, several ingredients are blended into a slurry: cement, lime, water, finely ground sand, and often, fly ash. An
expansion agent like aluminum powder is added and the fluid mixture is cast into a large billet. As the slurry
reacts with the expansion agent to generate air bubbles, the mixture expands. After its initial set, the resulting
cake is wire cut into precisely sized blocks or panels and then baked (autoclaved). The heat helps the material
to cure faster so that blocks and panels maintain their dimensions. Reinforcement is placed within panels prior to
curing.

This manufacturing process produces a lightweight,

noncombustible material with the following properties:
Density: 20 to 50 pcf (lb per cu ft)this is light enough
to float in water.
Compressive strength: 300 to 900 psi.
Allowable shear stress: 8 to 22 psi.
Thermal resistance: 0.8 to 1.25 per in. of thickness.
Sound transmission class (STC): 40 for 4 in. thickness;
45 for 8 in. thickness.

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 Perhitungan EKONOMI DAN MANFAAT
Produksi Bata Beton Aerasi 50.000m3 sampai dengan 300.000m3 Setiap tahun ( AAC )
Autoclaved Aerated Concrete

1. INTRODUCTION
I. Bata beton aerasi (bata ringan) adalah bahan buidling ringan dan berpori. Hal ini ringan,
menjaga suhu, tidak DIBAKAR serta keuntungan lainnya. dapat dibuat menjadi berbagai jenis
batu bata (misalnya: 600 250 250, 600 200 200. 600 150 bangunan industri 200.
600 100 100), AAC dapat digunakan dan umum pada bangunan. AAC lebih populer di
dunia. di masa depan, AAC akan benar-benar menggantikan bata tanah liat.

2. PROSES AAC DALAM DIAGRAM

I.
PASIR KAPUR PLASTER SEMEN Alumuniu BOILER
m

CRUSH CRUSH

CALCULAT CALCULAT enterSILO CALCULAT STEAM

E E E

GRIND

enterSILO

CALCULAT CALCULAT CALCULAT MIXING

E E E

MIXING

POURING

CURING

CUTTING

STEAMING Page | 8
3. Konsepsi umum Beton Aerasi
I. Kerapatan beton yang umum biasanya 1600-2400kg/m3, tapi beton Areated adalah
500kg/m3, 600kg/m3, 700kg/m3. Tidak memiliki biji-bijian besar, penggunaan bahan silikon
utama (misalnya: abu batubara, pasir, debu batu dan lain-lain), melalui pembuatan materi
kecil (Untuk pasir misalnya), dapat digunakan secara langsung jika memiliki gelar cukup kecil
(untuk abu batubara misalnya). Materi Kalsium Mixing, kapur, semen, air ke slop khusus,
kemudian tambahkan debu aluminium dan aditif. Membuat debu aluminium dan slop khusus
memiliki Kimia yang senyawa. kemudian menghasilkan hidrogen untuk membuat slop konkret
untuk memperluas atau membengkak,. busa. Selanjutnya, menempatkan mereka ke ruang
curing untuk concreting, memotong, mengukus/dipanaskan, Penguapan. terakhir, Selanjutnya
akan ada cahaya bata. tingkat berpori 70-80%. (diukur menurut foto baris)

II. RUMUSAN UMUM DARI BATA RINGAN / AAC

i. Bahan silikon (Fly Ash / pasir) 68-73%
ii. Kapur 20-25%
iii. Semen 6-15%
iv. Plester 3-5%
v. Aluminium debu 0,08%

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 III. PROSES PEMBUATAN AAC

Sebelum memeriksa memperkenalkan, silahkan buka "AAC garis gambar teknologi proses kerja" dan "AAC garis
kerja menunjukkan 3D", ada memiliki dua dokumen terpisah yang akan diperiksa.

1. Pertama beban loader pasir bahan ke dalam "hopper material" (dalam gambar 3D mark Tidak ada (1)),
pasir melalui sabuk conveyer masuk ke "mesin ball mill" (a) Untuk menghancurkan ke bubur bubuk.
dalam proses menghancurkan, air akan menambah ke dalam mesin pengolah bola dalam waktu yang
sama. jadi akhirnya mesin ball mill akan menghasilkan bubur pasir.

2. Setelah bubur pasir keluar dari mesin ball mill masuk ke dalam lubang beton, bubur akan dikirim
menjadi dua "pengolahan bubur mixer "(b) melalui" pompa lumpur ".

3. Ketika perlu untuk membersihkan lumpur, bubur dibebaskan dari "mixer pengolahan bubur" dan masuk
ke dalam pit bubur yang di bawah "mixer pengolahan bubur". Ada lagi, memiliki "pompa lumpur"
mengambil bubur pasir masuk ke dalam "ukuran bubur skala" otomatis, Pada saat yang sama, kapur,
semen, gipsum akan menambahkan ke "skala semen ukuran kapur gypsum" otomatis satu per satu,
Setelah pasir, kapur, semen, gipsum ukuran selesai, mereka akan menambahkan ke "mixer bubur
menuangkan" otomatis, dalam waktu yang sama, aluminium akan menambahkan ke "mixer bubur

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 menuangkan" secara manual setelah mengukur skala manual. ketika semua bahan pencampuran di
"mixer pengolahan bubur", setelah 4-6 menit pencampuran, semua bahan akan dituangkan ke "Mould
box". Dalam proses materi batching, kecuali aluminium adalah dengan menambahkan secara manual,
proses kerja lainnya secara otomatis dilakukan oleh sistem PLC di ruang kontrol.

4. Setelah itu bubur akan dituangkan ke dalam kotak cetakan, "konversi frekuensi menuangkan
melambat" akan mengambil cetakan masuk dalam Curing area ruang otomatis, semua kotak cetakan
akan menambahkan ke ruang Curing untuk Curing secara otomatis melalui sistem PLC di ruang
kontrol.

5. Ketika kotak cetakan bergerak di ruang Curing, semua proses kotak cetakan bergerak secara otomatis,
di bawah kotak cetakan, ada akan memiliki roller otomatis untuk mendukung bergerak dan dikendalikan
oleh sistem PLC di ruang kontrol,.

6. Setelah 1,5-2 jam pra-curing di daerah Curing, kotak cetakan dengan blok busa akan pindah ke "derek
pembalikan" Posisi, crane reversal akan mengangkat dan melakukan pekerjaan cetakan, menempatkan
blok dengan palet pada "cutting translasi cart ", maka akan tingkat pemotongan dan proses
pemotongan vertikal, proses pemotongan akan dikendalikan dalam ruang kontrol otomatis.

7. Setelah pemotongan, blok akan transportasi ke palung uap troli "transportasi blok crane", crane akan
dikontrol oleh perangkat kontrol nirkabel, juga ada memiliki perangkat kawat kontrol untuk bolak
cadang.

8. Setelah selesai menyiapkan 6 troli (12 blok), Lalu akan dimasukkan ke dalam autoklaf melalui mesin
"mesin kerek".

9. Dalam autoclave, untuk pasir, maka akan membutuhkan sekitar 10-11 jam untuk uap, pertama kita
perlu 1,5 jam untuk melepaskan udara dingin dari autoklaf dan 1 jam untuk menambah tekanan
mencapai 0,6 Mpa perlahan, kemudian gunakan 0,5 jam untuk mencapai 1,0-1,3 Mpa cepat. pada 1,0-
1,3 Map periode, kita perlu terus sekitar 5-6 jam uap, setelah itu kita akan membutuhkan 1,5-2 jam
untuk melepaskan tekanan dan uap. total setelah sekitar 10-11 jam, blok bisa mengambil dan
mengangkut di daerah Penyimpanan.

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 10. Palet kosong
dengan troli akan dikirim kembali ke
derek reversal dan mengatur ke dalam
cetakan baru untuk lingkaran untuk
digunakan. troli akan diangkut dan
mempersiapkan masuk ke wilayah
autoclave menggunakan lingkaran.

4. KAPASITAS DAN LUAS LAHAN

I. Untuk jalur AAC, menurut kapasitas: ada memiliki Produksi per tahun 50.000m3, 10.0000m3,
150.000m3, 200.000m3, 300.000m3 menurut 330 hari untuk menghitung kapasitas per tahun,
mereka berarti per hari menghasilkan 160m3, 310m3, 460m3,. 610m3, 910m3.

II. Untuk persyaratan Areal,

i. Biasanya untuk 50.000m3 dan 100.000m3 per tahun, kita perlu 2000m2 Luas
wilayah, dan Total lahan setidaknya 8.000m2, lebih besar lebih baik.

ii. Biasanya untuk jalur AAC 150.000m3, kita perlu Luas wilayah 2.500m2, total lahan
setidaknya 10.000m2 lebih besar lebih baik.

iii. Biasanya untuk 200.000m3 - 300.000m3 Produksi AAC, kita perlu Luas wilayah
3.000m2, total lahan setidaknya 15.000m2, lebih besar lebih baik.

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5. Komposisi ( Referensi ) per M3 ( Bahan )

Number Item Using Composition

1 Silicon Material (Coal Ash or Sand) 450Kgs - 500Kgs

2 Lime / Kapur 90Kgs
3 Cement 70Kgs
4 Gypsum 5Kgs
5 Alumunium Paste 0.5Kgs
6 Water 300 Litre
7 Electric / Listrik 9 degree
8 Coal 30Kgs

6. Pekerja

Number Position Manpower

1 General Manager 1
2 Produce Director 1
3 Manage Director 1
4 Acountant 1
5 Cashier 1
6 Storage 1
7 Quality Consignee 2

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 7. Operasi pekerja, setiap shift membutuhkan sekitar 10-12 orang, 2-shift membutuhkan 20-24
orang

Number Position Manpower

1 Load material 1
2 PLC Control Room 1
3 Pouring Mixer Inspection 1
4 Reversal Crane Operator 1
5 Finished Block Moving Crane 1
6 Oil Plant 1
7 Maintenace Engineer 1
8 Finished Block Moving Person 3 s/d 5

8. PROFIT ANALYSIS
I. Flyash AAC block plant profit analysis,
i. Laporan analisis dasar pada periode musim ketiga pada tahun 2010, di satu tempat
dan satu Cube meteran blok AAC. hanya untuk referensi, analisis rinci harus sesuai
fakta setempat.
II. Satu kubus meteran (M3) AAC blok menggunakan biaya bahan:

Number Item Harga /Ton Konsumsi/M3(Kgs) Unit Cost /M3

1 Pasir 31,000.00 450.0 13,950.00

2 Semen 1,260,000.00 50.0 63,000.00
3 Kapur 1,250,000.00 120.0 150,000.00
4 Gypsum 1,250,000.00 15.0 18,750.00
5 Alumunium 17,500,000.00 0.5 8,750.00
Total Cost per M3
254,450.00

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 III. Satu kubus meteran (M3) AAC blok menggunakan baiya Lainnya :

Number Item Harga /Ton Konsumsi/M3(Kgs) Unit Cost /M3

1 Burning Coal 907,206.00 30.0 27,216.18

2 Demould oil 4,550.00 1.0 4.55
3 Water Cost 3,050.00 300.0 915.00
4 Electric Cost 1,500.00 6.0 9.00
5 Worker salary 16,650.00 16,650.00
Total Cost per M3
44,794.73

IV. One cube meter AAC block material cost :

254,450.00 + 44,794.73 = Rp. 299,244.73

V. Price Market M3 AAC On Jakarta Indonesian Rp. 1,090,000.00-

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9. KEUNTUNGAN
I. Ringan,
i. Kerapatan beton Areated biasanya 500-700kg/m3, (sesuai kebutuhan pasar yang
diciptakan), sama seperti 1/3 dari batu bata tanah liat dan beton 1/5 yang umum.
Jadi menggunakan bata ringan dapat mengurangi berat Bangunan, dan juga
mengurangi balok atap dan tekan pilar terbaik. maka Anda dapat melihat, itu bisa
menyimpan bahan dan biaya, juga terhadap getaran.

II. Menjaga Suhu,

i. AAC Ini memiliki banyak berpori, koefisien hearting pengiriman adalah 0,9-0.22W /
(mk), sama seperti 1/4 atau 1/5 dari batu bata tanah liat, sehingga bahan terbaik
sekarang ini di dunia.

III. Memiliki banyak jenis bahan, memiliki limbah terendah,

i. Bahan Utama: abu batubara, pasir, bahan limbah tambang, batu batubara, debu
batu dan lainnya silikon bahan Simpan lebih banyak tanah, ketika menghasilkan
10.000 m3 bata ringan, akan menggunakan Abu batubara 4.200 Ton abu, dan
menyimpan abu batubara menggunakan 400m2 Wilayah, Menghindari membakar
3500m2 bata tanah liat.

IV. Standard Produksi AAC

i. The block have conform GB 11968-2006 ,and the machine have passed ISO9001
and CE certificate . And the bricks can undertake 3.5-5 Mpa

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Investment needed of AAC to set up a factory in Indonesian.

Investment opportunities AAC / Hebel is potentially huge, look at all sectors, Indonesia is a
developing country, the need for these products is huge, given the number of craftsmen brick
fuels have decreased, associated excavation permit that has been reduced, the fuel for brick
red earth also has a very small decrease, from the red brick of them that that is hardly used
anymore.

The availability of soft brick or AAC / Hebel is easier for building designers and contractors will
switch to using this product, which means that in terms of marketing lightweight brick in
Indonesia is very large prospectively in a very long period of time.

I hope, that you may want to consider the establishment of this industry in Indonesia, we have
a location not far from the raw materials needed, in the future it will be very nice.

investment needed to build this industry ranges :

US$ 9.2 million, inclusive of industrial land and equipment.
See Our Land Project (click for View Map )

Thanks And Best Regards

Develop by,

HERY SYAMSURIZAL DIMJATI

http://www.hsdmj.com email : rizalbee@hsdmj.com
Mobile : +628176870882 Mobile : +6281322193818
Skype : Rizalbee MSN : kola_syamsu@hotmail.com

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Bottom waste material removing system

PLC control room.

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Top of curing room is concrete floor, the purpose is to welding the reinforcement for AAC block panels.

Steam trolley back

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After cutting, the block crane put the block body on the ferry cart,using ferry cart to move the block body,
its like race to race games, let the work more efficiency.

Side pallets return system

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Another Ferry cart before curing room. Its mainly purpose for the AAC block panel, put out of the steel

Using the machine drag out of the finished blocks.

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 Moving separating machine

Pouring mixer control system, the pouring mixer head can up and down

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THANK YOU

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