Autoclave Process

autoclaveprocess

Why are more Masons and Architects choosing Autoclave Block?

More resistant to water damage

  • Autoclave’s drying and curing results in a tougher, stronger block less effected and more impermeable to moisture.


Consistency in Colour

  • Exacting control in the Autoclave process results in uniformity from cycle to cycle.
  • No efflorescence as limes and salts unite with silicates to form new structures free of leaching or efflorescence


Lighter means easier to work with

  • Dried well below standard residual moisture content means less water resulting in a lighter block.
  • Save 1,000 of lbs. in lifting and carrying our lighter block, as much as 4,000 lbs. on only 1,000 block.


Stronger then conventional block

  • Complete curing, within 8 hours, at full strength, whereas other conventional blocks making process’s take 28 days to cure to full strength.
  • Army Corps of Engineers recognize Autoclave as superior blocks above other processes.


Shrinkage is virtually non-existant

  • Save money with less wall reinforcement, few joint controls
  • Tests prove 50% less shrinkage than non-Autoclave process
  • Less volume change even when they get wet


Avoid call backs

  • Stronger, tougher block with less shrinkage and change in volume means, when installed properly, far less shifting and movement, resulting in mortar cracking virtually eliminated

The Design

The first step in design is the size and shape of the block. There are a variety of shapes, however the basic block is 40cm long and 20cm high with 10cm, 15cm, 20cm, 25cm and 30cm widths. The second step in design is the material of which it is made.

There are two main categories:

Regular Concrete
Which is a mixture of Portland cement, silica flour, sand, gravel and limestone screenings. (Limestone, sand and gravel aggregates)

Slag
Which is byproduct of steel and is lighter than concrete in fact it is 2/3 weight of regular concrete. No limestone is used. Although slightly more expensive than concrete, it absorbs sound better and has greater fire resistance than regular concrete

The Process

There are five easy steps; Mixing, Moulding, Pre-Curing, Final Curing, Storage or Delivery

Mixing/Automated Batching
The cement, silica flour and aggregates are measured and mixed in the prescribed amounts with water then fed down to moulding machines.

Moulding
The hopper feeds this mixture down to the block machines. It is then formed and pressed under extreme pressure in the block moulds into what is known as wet or green blocks. All cutting, e.g. scored blocks, or forming is done at this time. These blocks are made on a steel pallet which are then loaded onto steel racks to be moved into the Autoclave for precuring.

Pre-Curing
This stage allows blocks to set properly as hydration occurs making blocks stronger over a 2-3 hour period. This is done inside the plant in an Autoclave which is pre-heated to a constant temperate with the Autoclave door open, time and temperature are monitored to ensure proper curing.

Curing
This stage takes place within an Autoclave, which is 33m long and 2.5m in diameter. Here the blocks are put under intensive heat (177c) and steam pressure (1000kpa) for approximately 4-6 hours. Upon removal from the Autoclave, the blocks are cured and ready for installation.

Storage/Delivery
Following full curing the blocks are then removed and loaded onto a pallet loading machine which evenly stacks the set amount of blocks and then rolls each pallet on to an outdoor shipping area to be picked up by forklift and placed in designated storage areas or placed on flatbed trucks for delivery.

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