AAC for the World

New Equipment for Ukrainian Areated Concrete Industry

Fig. 1 Installation of the bind-ing agent silos laterally next to the mixing tower installed in the factory building.

Fig. 2 The silica containing sand is milled in a wet ball mill to a sand slurry. Quality con-trol, carried out continuously, guarantees processing of raw materials in the best way.

Fig. 3 The mixing sequences are optimized by the Masa-Henke mixing control system. The mix designs can be stored and reactivated at the push of a button. For an improvement of the mixture, mixing times and quantities can be adapted by the operator at any time. The filing of the batches allows tracing and analyzing.

Fig. 4 Filled molds in the fermentation area: The low building height in the fermentation area improves the thermal balance and reduces the energy consumption during the fermentation process, and saves costs in the construction stage. The plant concept is designed to use the exhaust steam to heat the fermentation area in the cooler seasons.

Fig. 5 and 6 The cutting line is divided into three parts and ensures optimum accuracy of the products. In the first two stations the block is cut to length and width and depend
ing on the product range the tongue and groove are manu
factured too.

Fig. 5 and 6
The cutting line is divided into three parts and ensures optimum accuracy of the products. In the first two stations the block is cut to length and width and depending on the product range the tongue and groove are manufactured too.

Fig. 7 The cross saw with integrated recessed grip mill is a good investment in the future, since also the market in Ukraine may change. The recessed grips facilitate the transport of the blocks on the construction site and can have a positive effect on the construction process.

Fig. 8 The loading and unloading crane of the autoclave: The loading and unloading crane is responsible for an efficient transport of the cakes. It can transport up to three cakes at a time. Loading and unloading of the autoclaves within the required time pattern is carried out in combination with the fully-automated curing car pulling device.

Fig. 9 The waiting area in front of the autoclaves has a low ceiling height like the fermentation area. As a result, the temperature of the cake remains high in this area with a positive effect on the hardening process and thus also on the product quality.

Fig. 10 Curing car with three green cakes positioned vertically side by side. In one autoclave, 18 green cakes can be hardened per cycle simultaneously.

Fig. 11 Curing area with the autoclaves.

Fig. 12 Process diagram of the steam control system: Due to the steam control system the hardening process can run fully automatically. Thus, the vacuum, pressure increasing, pressure holding and pressure decreasing phases are precisely controlled and adjusted. Using the steam control system of Masa-Henke saves costs and energy.

Fig. 13 The finished product passing through the packaging line.

Fig. 14 The first cake produced in the factory and the factory manager, Hasan Baser, together with the project team.

 The UDK Gazbeton company opens its new fully-automated autoclaved aerated concrete factory in Ukraine. The up-to-date and complete machinery and equipment was supplied, installed and commissioned by Masa-Henke Maschinenfabrik GmbH.

It all started with an idea. UDK Gazbeton based in Dnepopetrovsk - Ukraine intended to supply the local market with autoclaved aerated concrete with significantly improved properties in terms of building physics and workability than available by the existing old production plants. At the same time, the idea should meet the highest economical and ecological demands - even in future.

Since the location of the future autoclaved aerated concrete factory had already been chosen and the financial resources had been provided, it was now about searching the right partner for a reliable realization of...