A Dream Comes True

Fully automatic AAC factory in Abu Dhabi

Fig. 1 Signing of the contract: Delivering a AAC plant with a daily capacity of 1,200 m³. Mr. Khalaf Al Mazurei, Bena and Mr. Jörg Hülsiggensen, Masa-Henke.

Fig. 2 Formal laying of the foundation stone and official presentation of the project on the basis of a 3D-model.

Fig. 3 Installation of the mixing tower.

Fig. 4 Installation of the bonding agent silo.

Fig. 5 Stirring device of the sand slurry

Fig. 6 After several months of planning, the building works can start. Masa-Henke staff was already on site and constantly available to support the customer and his contractor during the foundation works.

Fig. 7 The mixing sequence is optimized by the Masa-Henke mixing control system. The recipes can be stored and reactivated. For an improvement of the mixture, mixing times and quantities can be adapted by the operator anytime. The filing of the batches enables an analysis.

Fig. 8 The reduced ceiling height in this area increases the thermal balance, reduces the energy consumption during the fermentation process, and saves building costs. The plant concept is designed to use the exhaust steam to heat the fermentation area in the cooler seasons.

Fig. 9 Mold under the turning and demolding crane: The mold design with 4 fixed walls guarantees a safe transport and gentle demolding of the cake.

Fig. 10 Cutting line: The cross saw with integrated recessed grip mill is a good investment in the future because the markets along the Arabian Gulf change.

Fig. 11 The recessed grips facilitate the transport of the blocks on the building sites and can have a positive effect on the building sequence.

Fig. 12 Hardening car with three green cakes standing upright. In one autoclave, 18 green cakes can be hardened at the same time.

Fig. 13 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 schedule is carried out in combination with the fully automatic hardening car pulling device.

Fig. 14 Process diagram for the steam control system: Due to the self-developed steam control system, the hardening process can run fully automatically. The vacuum, pressure increasing, pressure holding and pressure decreasing phases are precisely controlled and adjusted. Using this means saving costs and energy.

Fig. 15 Packaging line for blocks.

Fig. 16 Packaging line for blocks.

Fig. 17 Reinforced element with a width of 7.5 cm.

Fig. 18 The first packages run off the conveyor. They are kept in a storage yard until they are sold. The fully automatic packaging line with automatic pallet feed for AAC blocks of all sizes and reinforced elements is unique in the United Arab Emirates.

Fig. 19 The dream of the manufacture of reinforced elements has come true. The first cakes with reinforcing elements are ready for sale; they meet all requirements of the local building authorities. After a few weeks only, these products have already become bestsellers.

Fig. 20 The first cake has been produced.

Bena, a member of the Offset Group, open their fully automatic AAC factory in the United Arab Emirates.

It all started with an idea. Mr. Abdul Rahman Rashid, the Bena General Manager, wanted to supply the local market with building materials with improved structural-physical qualities and better workability. At the same time, his idea was to meet the highest demands on economy, ecology and sustainability.

Because of the outstanding advantages of the building material „aerated concrete“, the basic decision to set up an AAC factory was made quickly.

But Mr. Abdul Rahman Rashid was even more ambitious. He wanted to produce reinforced AAC elements as well – to reduce the construction periods of his...