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LPG Line for aerated concrete block production

 

LPG Line is meant for aerated concrete block production.
The line contains:

1. Cement storage silo (drawings for manufacturing).
Used to load and store bulk cement. In case the cement is packed into big bags or single use soft containers, the line can be additionally equipped with a discharger.

2. Cement screw conveyor.
The conveyor transfers cement from the silo to the weigher. It is equipped with a gear motor and a helical screw.

3. Sand bunker* (drawings for manufacturing).
Used for sand feeding. The sand is fed into the silo by a front-end loader.

4. Vibrating screen*.
Designed for sand sifting. Allows foreign particles to be sifted out from sand to obtain the required sandy size.

5. Belt-type conveyor.
After being sifted by the vibrating screen, the sand is transferred by a belt-type conveyor to a weigher. The conveyor is equipped with a gear motor and a ribbed belt.

6. Mixing section.
Includes the following:
- scaffold with operator's platform;
- dry weighers (for cement and sand*);
- autoclaved aerated concrete mixer;
- water batcher with booster pump;
- compressor (500 l/min);
- switchboard.

Weighers are equipped with strain gauges for precise weighing. Components are unloaded from the weighers to the mixer by means of pneumatic disc valves. The water batcher facilitates quick filling of the mixer with required amount of water. The compressor supplies compressed air to enable operations of disc valves. The switchboard is located at the operator's platform. Operator controls all loading and dosing processes as well as operation of the autoclaved aerated concrete mixer.

7. Moulds FM-0.85 cu.m.
The mould comprises a foundation with wheels and detachable sides. Dimensions of the monolith produced with the mould: 2396*607*598mm. The monolith cutting provides 24 blocks of 598*295*198mm or 48 blocks of 598*295*98mm. Blocks with other sizes are also available. The number of moulds depends on the line capacity.

7.1 Reversible foundations of moulds FM-0.85 cu.m.
Used to ensure continuous mould filling. The curing of autoclaved aerated concrete lasts for 4–6 hours, then the monolith is transferred with the mould foundation to the cutting area. The mould's sides are mounted to the reversible foundation and the mould is filled again. The number of reversible foundations depends on the line capacity.

8. Curing and heat treatment chambers (drawings for manufacturing).
The curing chamber (+ 30-40оС) ensures plastic strength of autoclaved aerated concrete before cutting into blocks. The heat treatment chamber (+ 60-70оС) is used to make the blocks stronger after cutting.

9. Transfer cart.
Designed to transfer moulds to the mixing area and to transfer the mould foundation with cut monolith from the cutting area to the heat treatment chamber.

10. Rails.
Used to move moulds and the transfer cart.

11. Automatic cutting system ARK-003.
A monolith is horizontally and vertically sawn by a single band with the help of a rotational unit. ARK-003 is completely automatic that allows one operator to control the entire system.

12. Electromechanical pusher.

*Note: sand humidity should not exceed 5 %, otherwise a drying unit is recommended.



Process description:
Warm water** (+30-40оС) is fed to the autoclaved aerated concrete mixer by means of booster pump and water batcher. Cement from either silo or discharger is fed to the weigher by the screw conveyor. The sand from the loading hopper is transferred to the vibrating screen where it is sifted and then transferred to the weigher by the belt-type conveyor. After weighing, the cement and sand are loaded to the autoclaved aerated concrete mixer (fly-ash or other mineral aggregates can be used instead of sand). When the water and the input products are loaded, the mixer prepares sand-cement mortar for 3 minutes.

After that, the operator loads a gas-forming admix to the autoclaved aerated concrete mixer and mixes the mortar for 1 additional minute. Then, the mixer is turned off and the autoclaved aerated concrete mixture is loaded to the mould, which is installed under the mixer. The mould filled with the autoclaved aerated concrete is transferred to the curing chamber by means of the electromechanical plunger. The autoclaved aerated concrete is cured for 4–6 hours at +30-40оС, increases in volume, and gains plastic strength, which is enough for cutting the monolith into blocks. After the time spent in the curing chamber, the mould is transferred to the cutting area where its sides are detached. The monolith is cut into blocks. To do this, a layer is removed from two sides of the monolith as well as from the top and the bottom. The next stage is to make the blocks stronger after cutting. For this purpose the mould foundation with blocks is transferred to the heat treatment chamber by means of the transfer cart. Being treated with the temperature of +60-70оС, the blocks gain the required strength. After that, the blocks are placed on pallets, packed with stretch wrap, and strapped with bundling strap..

**Note: the Customer shall provide warm water heated to +30-40оС. 

  • LPG-20 line
  • LPG-30 line
  • LPG-40 line
Aerated concrete block production line LPG-20 cu.m using sand as a filler.













Mixing section. Dimensional sheme.

No.

Description

Q-ty

Price, rubles.

Total, rubles.

Section for storing, handling and feeding raw material

1

Cement screw conveyor (L – 6 m, gear motor (Italy), N – 4 kW)

1

175 000

175 000

2

Vibrating screen VG-1(N - 3 kW, capacity of 1 tonne per hour)

1

95 000

95 000

3

Belt conveyor for sand L-6 m, gear motor 2.2 kW (Italy), chevron conveyor belt (Czech Republic)

1

235 000

235 000

Mixing section

1

Utility bridge

1

595 000

595 000

2

Electronic control system

1

Scope of supply:

Switchboard with weight batching

1

Electronic water gauge DV-1700

1

Booster pump ADK-20

1

3

Cement weight batcher

1

Scope of supply:

Strain gauge transducer

3

Butterfly valve with pneumatic drive (WAM, Italy)

1

Electrical vibrator EV-320 (N – 0.2 kW)

1

4

Sand weight batcher

1

Scope of supply:

Strain gauge transducer

3

Butterfly valve with pneumatic drive (WAM, Italy)

1

Electrical vibrator EV-320 (N – 0.2 kW)

1

5

Aerated concrete mixer GB-0.85 (N – 11 kW, V – 0,85 cu.m).

1

225 000

225 000

6

Compressor 50G1048 (260 l per min, 8-10 atm)

1

32 000

32 000

7

Cable kit

1

-

-


Section of Aerated concrete monolith cutting
 

1

Automatic cutting system АРК-003 for vertical and horizontal cutting of monoliths (N – 13 kW)

1

1 450 000

1 450 000

Scope of supply:

Railings (L – 5.6 m)

1

Traveling carriage with cutting module

1

Cable support rack

2

Bridthe to move the mold

2

Remote control (supplied with cable)

1

Saws set

1

Spare parts, tools, devices

1

2

Mould for aerated concrete monolith

FM-0.85 cu.m (V – 0,85 cu.m, monolith dimensions - 396*598*607mm).

24

35 000

840 000


Mould transfer system
 

1

Transfer cart

2

25 000

50 000


  TOTAL:

3 697 000

List of the equipment to be manufactured by the Customer:
  • Curing (+30-40оС) and heat treatment (+60-70оС) chambers
  • Cement silo (drawings are provided)
  • Sand loading hopper (drawings are provided)
  • Railings to ensure movement of moulds and transfer cart (drawings are provided)

Additional requirements:
  • The temperature of the water used for production of autoclaved aerated concrete should be +30-40оС
  • The area of production facility should not be less than 400 sq.m
  • The ceiling height (at the mixing area) should not be less than 6 m
  • Ambient temperature should not be less than +15оС
  • Power line not less than 35 kW
  • The number of employees — 5

Advantages of the LPG Line
  • Automated loading and dosing of input products ensures high performance, allows unmanned operation, and minimises man-hours.
  • Automatic cutting system produces blocks of precise geometry that correspond to the 1st GOST category.
  • Unique state-of-the-art technologies are based on our 15-years experience and provide autoclaved aerated concrete with stable performance.
  • Technology adjustment and equipment pre-commissioning preformed by our experts ensure fast commissioning of the line and training of the Customer's personnel.
  • High quality materials and accessories from leading European manufacturers (WAM, SITI, CAMOZZI) guarantee high reliability of all line components.
  • Further technical and technological support from our company.
  • Fast rate of return.
  • Fast warranty and post-warranty maintenance.
  • Complete package of technical and technological documentation (manufacturing instructions, job description, safety instructions, selection of relevant GOST standards).

Aerated concrete block production line LPG-30 cu.m using sand as a filler.













Mixing section. Dimensional sheme.

No.

Description

Q-ty

Price, rubles.

Total, rubles.

Section for storing, handling and feeding raw material

1

Cement screw conveyor (L – 6 m, gear motor (Italy), N – 4 kW)

1

175 000

175 000

2

Vibrating screen VG-1(N - 3 kW, capacity of 1 tonne per hour)

1

95 000

95 000

3

Belt conveyor for sand L-6 m, gear motor 2.2 kW (Italy), chevron conveyor belt (Czech Republic)

1

235 000

235 000

Mixing section

1

Utility bridge

1

595 000

595 000

2

Electronic control system

1

Scope of supply:

Switchboard with weight batching

1

Electronic water gauge DV-1700

1

Booster pump ADK-20

1

3

Cement weight batcher

1

Scope of supply:

Strain gauge transducer

3

Butterfly valve with pneumatic drive (WAM, Italy)

1

Electrical vibrator EV-320 (N – 0.2 kW)

1

4

Sand weight batcher

1

Scope of supply:

Strain gauge transducer

3

Butterfly valve with pneumatic drive (WAM, Italy)

1

Electrical vibrator EV-320 (N – 0.2 kW)

1

5

Aerated concrete mixer GB-0.85 (N – 11 kW, V – 0,85 cu.m).

1

225 000

225 000

6

Compressor 50G1048 (260 l per min, 8-10 atm)

1

32 000

32 000

7

Cable kit

1

-

-


Section of Aerated concrete monolith cutting
 

1

Automatic cutting system АРК-003 for vertical and horizontal cutting of monoliths (N – 13 kW)

1

1 450 000

1 450 000

Scope of supply:

Railings (L – 5.6 m)

1

Traveling carriage with cutting module

1

Cable support rack

2

Bridthe to move the mold

2

Remote control (supplied with cable)

1

Saws set

1

Spare parts, tools, devices

1

2

Mould for aerated concrete monolith

FM-0.85 cu.m (V – 0,85 cu.m, monolith dimensions - 396*598*607mm).

35

35 000

1 225 000


Mould transfer system
 

1

Transfer cart

2

25 000

50 000


  TOTAL:

4 082 000

List of the equipment to be manufactured by the Customer:
  • Curing (+30-40оС) and heat treatment (+60-70оС) chambers
  • Cement silo (drawings are provided)
  • Sand loading hopper (drawings are provided)
  • Railings to ensure movement of moulds and transfer cart (drawings are provided)

Additional requirements:
  • The temperature of the water used for production of autoclaved aerated concrete should be +30-40оС
  • The area of production facility should not be less than 500 sq.m
  • The ceiling height (at the mixing area) should not be less than 6 m
  • Ambient temperature should not be less than +15оС
  • Power line not less than 35 kW
  • The number of employees — 6

Advantages of the LPG Line
  • Automated loading and dosing of input products ensures high performance, allows unmanned operation, and minimises man-hours.
  • Automatic cutting system produces blocks of precise geometry that correspond to the 1st GOST category.
  • Unique state-of-the-art technologies are based on our 15-years experience and provide autoclaved aerated concrete with stable performance.
  • Technology adjustment and equipment pre-commissioning preformed by our experts ensure fast commissioning of the line and training of the Customer's personnel.
  • High quality materials and accessories from leading European manufacturers (WAM, SITI, CAMOZZI) guarantee high reliability of all line components.
  • Further technical and technological support from our company.
  • Fast rate of return.
  • Fast warranty and post-warranty maintenance.
  • Complete package of technical and technological documentation (manufacturing instructions, job description, safety instructions, selection of relevant GOST standards).

Aerated concrete block production line LPG-40 cu.m using sand as a filler.













Mixing section. Dimensional sheme.

No.

Description

Q-ty

Price, rubles.

Total, rubles.

Section for storing, handling and feeding raw material

1

Cement screw conveyor (L – 6 m, gear motor (Italy), N – 4 kW)

1

175 000

175 000

2

Vibrating screen VG-1(N - 3 kW, capacity of 1 tonne per hour)

1

95 000

95 000

3

Belt conveyor for sand L-6 m, gear motor 2.2 kW (Italy), chevron conveyor belt (Czech Republic)

1

235 000

235 000

Mixing section

1

Utility bridge

1

595 000

595 000

2

Electronic control system

1

Scope of supply:

Switchboard with weight batching

1

Electronic water gauge DV-1700

1

Booster pump ADK-20

1

3

Cement weight batcher

1

Scope of supply:

Strain gauge transducer

3

Butterfly valve with pneumatic drive (WAM, Italy)

1

Electrical vibrator EV-320 (N – 0.2 kW)

1

4

Sand weight batcher

1

Scope of supply:

Strain gauge transducer

3

Butterfly valve with pneumatic drive (WAM, Italy)

1

Electrical vibrator EV-320 (N – 0.2 kW)

1

5

Aerated concrete mixer GB-0.85 (N – 11 kW, V – 0,85 cu.m).

1

225 000

225 000

6

Compressor 50G1048 (260 l per min, 8-10 atm)

1

32 000

32 000

7

Cable kit

1

-

-


Section of Aerated concrete monolith cutting
 

1

Automatic cutting system АРК-003 for vertical and horizontal cutting of monoliths (N – 13 kW)

1

1 450 000

1 450 000

Scope of supply:

Railings (L – 5.6 m)

1

Traveling carriage with cutting module

1

Cable support rack

2

Bridthe to move the mold

2

Remote control (supplied with cable)

1

Saws set

1

Spare parts, tools, devices

1

2

Mould for aerated concrete monolith

FM-0.85 cu.m (V – 0,85 cu.m, monolith dimensions - 396*598*607mm).

47

35 000

1 645 000


Mould transfer system
 

1

Transfer cart

2

25 000

50 000


  TOTAL:

4 502 000

List of the equipment to be manufactured by the Customer:
  • Curing (+30-40оС) and heat treatment (+60-70оС) chambers
  • Cement silo (drawings are provided)
  • Sand loading hopper (drawings are provided)
  • Railings to ensure movement of moulds and transfer cart (drawings are provided)

Additional requirements:
  • The temperature of the water used for production of autoclaved aerated concrete should be +30-40оС
  • The area of production facility should not be less than 600 sq.m
  • The ceiling height (at the mixing area) should not be less than 6 m
  • Ambient temperature should not be less than +15оС
  • Power line not less than 35 kW
  • The number of employees — 6

Advantages of the LPG Line
  • Automated loading and dosing of input products ensures high performance, allows unmanned operation, and minimises man-hours.
  • Automatic cutting system produces blocks of precise geometry that correspond to the 1st GOST category.
  • Unique state-of-the-art technologies are based on our 15-years experience and provide autoclaved aerated concrete with stable performance.
  • Technology adjustment and equipment pre-commissioning preformed by our experts ensure fast commissioning of the line and training of the Customer's personnel.
  • High quality materials and accessories from leading European manufacturers (WAM, SITI, CAMOZZI) guarantee high reliability of all line components.
  • Further technical and technological support from our company.
  • Fast rate of return.
  • Fast warranty and post-warranty maintenance.
  • Complete package of technical and technological documentation (manufacturing instructions, job description, safety instructions, selection of relevant GOST standards).