GCC-German Connex Consult connects the experience in Technology with Marketing.

For decades of activity with commitment to provide satisfactory work in engineering services in the areas of Chemical,

Petrochemical and Construction Industry for internationally known companies, such as:

Bayer AG, Leverkusen, Dormagen, Germany

INEOS GmbH, Köln-Vorringen, Germany

Shell Deutschland Oil GmbH, Wesseling, Germany

Basell Polyolefine GmbH, Wesseling, Germany

Dynamit Nobell, Leverkusen, Germany

KHD Humboldt Wedag GmbH, Köln, Germany

Martinswerk, Bergheim, Germany

To expanding our activities, we see the Marketing Service in the industry sector, as one of the main tasks of our

company.

We are specialized in marketing of machines and complete production lines of construction product.

For decades, GCC-German Connex Consult is working closely with partners and internationally known manufacturers

in construction industry with high technological know-how and each is an expert in his field.

GCC-German Connex Consult is a leading distributor of machinery and production lines in the building materials

industry. Our activities cover the region of Europe, Africa and the Middle East.

With the second seat of our company GCC-German Connex Consult Sarl in Tunisia, we are in direct contact with

customers.

With our professional network that is established for years in Arab and African countries, we have the best chance to

promote our high quality products in the best conditions.

We offer machines and complete production lines in various sectors such as:

Autoclaved aerated concrete plant - AAC-plant

Sand-lime brick plant

Block machines plant for solid and hollow blocks, pavers, and curbstones.

Concrete Batching Plant

Nano panel plant (Prefabrication of the walls for social housing)

Technical consulting and marketing services

50676 Cologne - Germany

Tel.: +49-221-9230620

Fax: +49-221-9230621

Mobil: +49-163-428 64 14

E-Mail: aa@gccinter.com

http://www.gccinter.com

2010 Manouba, Tunisie

Cement plant

Mining, quarry and gypsum industry.

Handling and Storage technology.

Packaging technology.

Automation technology.

Autoclaved Aerated Concrete plant (AAC- Plant).

Turnkey systems from a single source.

The production of cellular concrete demand high standards for the preparation and dosage of raw materials,

fermentation process monitoring and control of all stages of production.

Economic systems concepts will be programmed according to individual needs of our customers.

List of components of AAC-plant

1 Raw material delivery system

2 Sand mill

3 Slurry silos with integrated stirring device

4 Dosing systems of raw material

5 Mixer

6 Casting tower with the control room

7 Casting mould with car

8 Mould manipulator

9 Transfer platform and fermentation area

10 Cutting line Horizontal, Vertical and Profiling

Currently we offer a very significant opportunity in the field of modern construction; it is the autoclaved aerated

concrete plant (AAC- Plant).

11 Autoclaves with Steam generator

12 Loading and unloading crane

13 Separating machine

14 Packaging crane

15 Compacting device

16 Strapping station

17 Transport system of finished products

The AAC is the most advantageous for all other building materials.

Here, some advantages of autoclaved aerated concrete (AAC-Plant):

Through its physical nature, it is four times faster to build with than other construction products.

Excellent thermal insulation.

Temperature in balance almost constant.

Remarkable sound insulation.

High dimensional accuracy.

Extremely lightweight.

High Resistance to compression between

2,5 – 7,0 N / mm.

High fire Resistance, non-combustible – min. 4 hours, up

to 6 hours.

High efficiency; It can be cut, sawn, drilled, nailed, and

milled like wood.

Lightweight - Lower transportation costs.

Recycling - Lower production costs.

Resistance to termites and insects.

Resistance to the earthquake, comparable to ordinary

bricks.

AAC block production line with annual capacity of 150 000 m3

Capacity description:

Main raw material: Silica Sand

Cutting machine size: 4.2 meter

Mould net size (after cutting): 4.2 x 1.2 x 0.6 m

Autoclave: Φ 2 x 31.5 m, 6 set

Mould Quantity 26 pcs, steam trolley 63 pcs, mould pallet 152 pcs

Boiler: 6 Ton/hour, 16 bar pressure.

Land requirement: total factory 20 000 m2, workshop about 6000 m2

Water consumption: 250 Ton/day

Gas consumption: 6250 m3/day

Electricity consumption: about 6000 kw/day

In order to obtain 150 000 m3 AAC block per year, so within 300 working days per year, we should produce 500 m3

AAC block per day.

Per mould size 4.2 x 1.2 x 0.6 = 3 m3, in order to obtain 500 m3 per day, we should pouring and cut per day

500 m3 ÷ 3 m3 = 167 moulds. Total working time should be within 22 hours per day (except autoclave section).

Factory building

The building required for cellular concrete factory as following:

The necessary building for the aerated concrete plant as following:

Length: 140 m Width: 46 m Height: 9 m

Built area: 140 m X 46 m = 6440 m²

The width can be divided into two parts to facilitate the construction: 46 m : 2 = 23 m

Raw materials

The finial formula will be designed by Supplier’s engineers according client materials

For Example 550kg/m3 AAC block, we need the raw material list as following, just for reference:

No. Name Ratio Unit Kg/m3

1 Sand 65-70% Kg 380

2 Lime 12-15% Kg

80

3 Cement 10-14% Kg

75

4 Gypsum 2-3% Kg

15

5 Lubrication oil Kg

1,5

6 Aluminum 0.7% Kg

0,42

7 Water Kg

450

8 Gas M3 10 - 12

9 Power KWH 12 - 15

Raw material requirements

The specified requirements of the raw materials are ideal value. Even if raw materials deviate from these values, it is

still possible to produce good Aerated concrete.

The final data, the plan and any additional machines must be clarified on a case by case basis.

Sand

Super Grad First Grad Qualified product

SiO2 ≥ 85% 75% 65%

CI- 0.02% 0.03% 0.03%

Mica ≤ 0.5% 0.5% 1%

SO3 ≤ 1% 1% 2%

clay ≤ 3% 5% 8%

K2O+Na2O ≤ 1.5% 3% 5%

Cement: the strength of AAC product mainly depends on cement which provides calcium materials. The cement suits

to the AAC product depending on its type and label. Ordinary Portland Cement 42.5 should be first choice.

Cement

SiO2 Al2O3 Fe2O3 CaO MgO C3S C2S C3A C4AF

21-23 5-7 3-5 64-48 4-5 44-59 18-30 5-12 10-18

Lime: one of the main raw materials of AAC; the main effect is to provide efficient calcium oxide with cooperation of

cement making calcium oxide react with SiO2、Al2O3 in hot water then to produce calcium silicate hydrate.

Therefore, lime is also the main resource of strength. Effective calcium oxide of lime should not less than 65%; over

80% is perfect and should accord with JC/T621-1996.

Lime

Item

Grade

Super Grade First Grade Qualified product

A(CaO+MgO) Quality Fraction % ≥ 90 75 65

MgO Quality Fraction % < 2 5 8

SiO2 Quality Fraction % < 2 5 8

CO2 Quality Fraction % < 2 5 7

Digestion speed ,min < 8 - 15

Digestion temperature , ℃

> 60 - 90

Undigested residue quality fraction ,% < 5 10 15

Fineness (0.080 square hole sieve left

amount) %

< 10 15 20

Gypsum is the foaming regulator in AAC which dispels quicklime and postpones slurry’s densification.

Gypsum

CaSO4 > 70%

MgO < 2%

Chloride < 0.05%

Preferably ground residue 90μm < 10-15%

Aluminum paste and powder

There must be foaming materials working as foaming agent making air holes to form porous structure.

Aluminum

Type and recommendation for supply depend on raw materials and mix formula

Metal Content Approx. > = 90 % Powder

Physical characteristics of AAC block

B04 grade: average density 400 – 425 kg/m3, pressure 2.0 - 2.5 Mpa

B05 grade: average density 500 – 525 kg/m3, pressure 2.5 - 3.5 Mpa

B06 grade: average density 600 – 625 kg/m3, pressure 3.5 - 5 Mpa

Workers arrangement

(Only for reference, depend on local condition)

Type Production section Shift Workers per shift Total workers

Production

Workshop

Material dealing section 2 2 4

Measure and pouring section 2 2 4

Curing section 2 1 2

Cutting section 2 3 6

Autoclave section 3 1 3

Packing section 2 3 - 4 6 - 8

Assist

Workshop

Power 2 1 2

Steam (boiler house) 3 1 3

Machine maintain worker 2 1 2

Labor 2 1 2

Others

Salesman 1 2 2

Manager 2 2 - 3 4 - 6

Accountant 2 1 2

Total 42 - 46

AAC block size

Length 600 mm

Breadth 100 mm, 120 mm, 125 mm, 150 mm, 200 mm, 250 mm, 300 mm

Height 200 mm, 240 mm, 250 mm, 300 mm, 400 mm

Aerated concrete production procedure.

Raw material storage

Sand, cement, lime, gypsum, aluminum paste should be stored separately in the materials

stock yard, transport them to workshop when use them.

Silica sand is transported from the storage silos to be ground into fine sand slurry dispersed in a wet ball

mill, and then stored in the sand slurry Silo with agitator and density measurement

It is important to constantly and continuously keep the specified density and adjusted either manually or

automatically

Distributor of raw material

Silos for Raw material storage.

Sand Slurry Silo with Agitator and

Density Measuring.

Sand mill

Dosing and mixing

The sludge of sand, the return sludge, lime, cement, gypsum, aluminum agent and water are determined

automatically in accordance with the prescription of respective product in the mixer.

Scales for raw materials.

Mixer of raw materials.

Casting mould in casting position

under the mixer.

Filling of a casting mould.

Water treatment

Silos for cement and

limestone.

Distribution unit of agent

alumium.

Pouring:

Pouring mixer, each time pouring will control within 5 minutes, max 5.5 minutes.

Now we use Germany AAC-concept design, the pouring time could control within 5 minutes.

5 minutes x 167 mould = 835 minutes ≈ 14 hours ≤ 22 hours.

Pre-curing, fermentation:

Usually the pre-curing time will be 3 hours in one cycle, per day we can have 7 cycle times pre-curing (within 22

hours), so 167 mould ÷ 7 cycle = 24 mould per cycle.

The minimum we need is 24 moulds to working in pre-curing room per cycle, because moulds need to return, oil

painting and maintenance, so we add extra 2 moulds (total 26 moulds) to guarantee the production.

In order to guarantee the pre-curing time and efficiency, the pre-curing room is designed in ferry cart two side by two

lines, in order to send or take out each of mould.

A certain amount of mass from the mixer will be paid into an oiled mold consisting of two parts and extremely tight

seal. In this mould, the cellular concrete cake ferments approx.

2.5 – 3 hours in a 50 – 55 °C heated fermentation chamber, in order to cure at temperatures well defined.

The mould has been specifically designed for the switching operation is then performed. It consists of a torsion-free

structure with tapered sidewalls and being removable from the top. This will remove the cake from the mould smoothly

and flawlessly. The bottom of the mould and the walls always join accurately, so as to form a perfect unity.

The mold shrinkage of the bottom of the forms - also called stripping - and subsequent transport is performed by

means of a gantry system. The green cake is the subject of very few manipulations - gently - so that damage such as

cracks that are later seen elsewhere after autoclaving does not arise.

Mould full with green cake of aerated concrete

will be transported to the fermentation chamber

and remains 2,5 hours to harden at well-defined

temperatures.

Demoulding: After 2.5 hours of hardening, the

mold will be removed from the top of green cake

of cellular concrete and remains on the transfer

car which will be transported to the cutting line.

Cutting line

The level cutting machine will be 2 pieces, 1 piece for male – female groove and knife cutting, second piece for wire

cutting. Total Cutting time will control within 5 minutes

The cutting process begins once the demoulding is completed. Cutting line consists of the following components:

Cap extractor

Horizontal cut.

Vertical cut.

Profile cutting.

Cutting waste which falls into the

ditch and which will be reintroduced

in the production process.

Grip hole cutting.

Cutting line: After the demoulding the green cake of cellular concrete will be cut laterally horizontally

and vertically.

Primary section: here, is carried out a right angle cutting of the cake, which is in a horizontal position.

Recliner station: the cellular concrete cake is tilted through 90° so as to meet the vertical on the cutting board.

Horizontal cut: steel wire, positioned shifted and stretched pneumatically, have an input and output angle 0 - 60 ° it

is possible to adjust continuously. This avoids that the material is torn at the outlet of the cutting wire.

Vertical cut: here the sides of the cake will be positioned vertically cut, and tongue and groove will be inserted.

Taut lines, arranged in the desired format, move in the opposite direction by oscillating. They move through the cake

from above. If necessary, it is here possible to activate a pocket milling device. A suction hood sucks the top layer of

the cake by the vacuum system. Then this layer falls into the cutting gap and is again fed back into the production

process by means of a scraper conveyor. Then the sides of the cake of the head are corrected by means of a groove

cutter.

Curing in the autoclave

^^

After cutting, the green cake will

be transported on the transfer

car to the autoclaves.

Steam generator which delivers

the steam to the autoclaves.

Placing the green cake on the

hardening car and drive it into the

autoclave.

After 12 hours of curing time, the cured cake leaves the autoclave.

Piping which transports the

steam from the steam generator

to the autoclaves.

Steam Autoclave:

a): 1 autoclave one time loading capacity: 3 m3 x 14 cakes = 42 m3

b): 1 autoclave steam time will be within 12 hour (usually 10 - 11hours).

It can cycle two times per day, one autoclave one day production: 42 m3 x 2 times = 84 m3

c): 6 pieces autoclave 1 day production, 84 x 6 = 504 m3 ＞500 m3

A standard autoclave is designed for a pressure of 12 bar and 190 °C. With 31,5 m in length and 2 m in diameter, it

carries 6 hardening cars with three pallets of the autoclave each car, in whole there are 18 cakes which find their

places in the autoclave.

Steam generator:

6 Ton/hour, with 16 bar pressure. Each m3 block will use 150 kg steam (water),

so 500 m3 x 150 kg = 75 Ton boiler steam.

So average, 6 Ton/hour boiler x 12.5 hours = 75 ton boiler steam, full capacity

Heat recovery:

The curing of the material in the autoclave is the primary stage of the process consuming the steam. Usually several

autoclaves are operated at different times, and a steam accumulator used for the partial recovery of heat.

Heat recovery is to use the condensate and also to the optimum reuse of the steam that is produced for autoclaving.

Upon closing of the autoclave, the steam will be temporarily stored on the one hand for use in autoclaving and

secondly to the building heating system and the preheating of the feed water.

Through a heat exchanger, heat can be regained condensate for use in the feed water preheating or to preheat the

fermentation chambers or to heat buildings.

Unloading the white cake with

crane and transfer to the

separator.

After Hardering, the blocks of white cake are separated from each

other by the separator.

After curing in the autoclave cured cake out of the autoclave with a transport portal system will be

transported to the separator for separating stones of the cake from each other.

Tilting Manipulator.

3D Separation Unit.

Packaging line.

Unloading and storage.

Marking System.

Aerated concrete is applied successfully in the residential and industrial construction for:

External and internal Partitions

Bearing Walls and not bearing walls

Firewall

Wall elements for the structure of the skeleton

Examples of building with AAC-Plant.

In Bremerhaven Germany. In Kirchheim Germany.

In Bremen Germany.

In Rostock Gemany.

We offer an AAC-Plant with a turnkey service; from technical advice, supply, Construction Management until after

service.

Upon request, we will be pleased to send you our best offers.

Our competence and reliability are your advantage. All from one hand - from consulting and project planning to final

assembly, commissioning and furthermore:

Short ways.

Less interfaces.

Execution time reduced to a minimum.

Only one contact.

Customized automation and Engineering solutions.

Integration of existing systems in new concepts.

High system availability through robust construction.

Easy maintenance, reliable customer service.

Short-term available of original spare parts.

We will be pleased to receive your inquiries.