About Us

Orbit Engifab Projects Pvt. Ltd is a famous manufacturer, exporter of a qualitative assortment of Automatic Fly Ash Bricks Plant, Automatic Block Making Plant and Autoclaved Aerated Concrete Block Plant. Integrated in the year 2004, at Mehsana (Gujarat, India), we have developed an ultramodern infrastructural unit where we manufacture these products in large quantity with assured quality. Managed under the supervision of our mentor, Mr. Rakesh Patel & Mr. Nirav Patel

We are pleased to introduce ourselves as Leading Engineering Company engaged in the manufacturing of Best Quality Small Capacity AAC (Autoclaved aerated concrete) blocks making Plant, Automatic Fly Ash Bricks Plant, Automatic Concrete Blocks Plant, Automatic Material Batching & Feeding Systems, and Fly Ash & Cement Storage Silo etc.

We are offering various capacity AAC (Autoclaved aerated concrete) blocks making Plant. Capacity 30/50/100/200 Cub Blocks per Cubic Meter.

 We are also manufacturing Automatic Fly Ash Bricks Plant in Different Models to meet production requirements of 500 /1000/ 1200 /1800/2500/2800/3500/4000/4500/& 5000 Bricks Per Hour. 

All of the equipments offered by our Company are manufactured under strict quality standards & fitted with the best quality bought outs to let them run for years without any trouble. These equipments are also backed with Best Workmanship & After sales services all over India.

Our Infrastructure

Orbit Engifab Projects Pvt. Ltd. is having its Ultra Modern Manufacturing Facility at Mehsana – Gujarat – India. In its infrastructure, Orbit Intelligent Engineering is having Fabrication Facilities, Machining Facilities, Assembly Shop, Designing & Communication Facilities. Orbit Engifab Projects Pvt. Ltd. is having Well Skilled & Experienced Manufacturing & Service Staff to cater it’s valued Clients Nationwide.
Orbit Engifab Projects Pvt. Ltd. is located 65 km from Ahmadabad Airport, 75 km from Ahmadabad Railway Station & 15 kms from Mehsana Railway Station.

About our Mentors

Orbit Engifab Projects Pvt. Ltd. was found in 2004 by its young, dynamic & well experienced founders, Mr. Nirav Patel & Mr. Rakesh Patel. Both of the Partners are Mechanical Engineers having decades of experience in the field of Construction Equipments Design & Manufacturing.

About AAC Block Plant:

AAC was invented in mid-1923 in Sweden. It is also known as Autoclaved Cellular Concrete (ACC) or Autoclaved Lightweight Concrete (ALC). Production process of AAC is fairly simple. It is made with made with a mixture of fly ash, lime, cement, gypsum, an aeration agent and water. Aeration process, imparts it a cellular light-weight structure. AAC products are precast in various sizes and provide structure, insulation, and fire and mold resistance. AAC products are offered in various shapes and sizes including but not limited to blocks, wall panels, floor and roof panels, and lintels. Use of Autoclaved Aerated Concrete (AAC) blocks in construction industry in India offers interesting proposition for various segments in the society. For a project developer it means faster and lower cost construction. For environmentally conscious it means eco-friendly products and for those who occupy buildings built with AAC blocks it means better safety and lower energy costs for cooling or heating. Primary raw material for AAC is fly ash. Thousands of tones of fly ash is generated by thermal power plants everyday and its disposal is a cause of concern. Moreover, using fly ash does not harm the environment at all. In fact using fly ash takes care of issues related to disposal of fly ash. Therefore by using fly ash to produce AAC products provides a sustainable, economic and environment friendly option. At the end it all translates to a better world for future generations.

Features of AAC products:

Lightweight

AAC blocks possess a cellular structure created by the unique manufacturing process. Millions of tiny air cells impart AAC blocks very light weight structure. Density of these lightweight blocks usually ranges between 550 –700 kg/m3. Yes, AAC blocks are lighter than water and literally float on water.

Ease of Use

AAC blocks are very easy to work with. These blocks can be cut or drilled sing normal tools used with wood. Since AAC is steam-curried, it is ready to be used as soon as it comes out of autoclave. It does not shrink or warp once it is removed from autoclave.

Versatility

AAC can be used to make any design, be it carving or irregular shapes. Moreover it can be manufactured invarious shapes and sizes to suit intended purpose.

Long Life

AAC does not rot or deteriorate over time. Structures built with AAC have a long life and retain good finish even after decades.

Eco-friendly

AAC has excellent thermal insulation property leading to lower energy requirements for heating and cooling. AAC serves as one stop solution for structure, insulation, and fire protection. Use of AAC eliminates use of different materials for structure, insulation, and fire protection as these requirements are met by only using AAC. By using AAC, separate materials are not required to meet these requirements leaving to lower energy footprint of abuilding. Using AAC is a must for any green building project. AAC is manufactured with industrial waste like fly ash and pond ash. AAC manufacturing process requires less energy is non-polluting and does not produce any waste products.

Thermal Insulation
Cellular structure of AAC creates millions of tiny air pockets. These air pockets give AAC very good insulating properties. Better insulation translates to lower cost for heating and cooling.

Fire Resistance

AAC offers amazing fire resistance. 8” wall made from AAC blocks can resist fire for up to seven hours.

Sound Insulation

Tiny air pockets created during production of AAC stop sound from travelling one end of the wall to another. Sound insulation of a wall built using AAC is much higher than a wall of similar thickness built using other materials. Some AAC companies even offer special AAC products produced specifically for sound insulation.

Weather Resistance

AAC does not decay, rust, deteriorate or burn. AAC has been found to be earthquake resistant. AAC structures are known to maintain structural integrity in heavy rains, extremely low temperature and salty air.

Pest Resistance

Primary raw material used to manufacture AAC is fly ash. Fly ash (or pond ash) is an inert material and does not allow termites or other pests to survive.

Advantages of using Autoclaved Aerated Concrete

Lightweight

AAC blocks are about 50% lighter than clay bricks of equivalent size. This translates into less dead weight of buildings and allows entire structure to be lighter therefore reducing amount of steel and concrete used in structural components like beams, columns and roof/floor slabs.

Easy workability

AAC is very easy to work with and can be cut accurately reducing the amount of waste generated.

Single product solution

Buildings constructed with AAC do not require separate insulation products reducing construction cost, energy footprint and environmental impact of buildings.

Environmental impact

Manufacturing of AAC does not have high energy requirements. Moreover since AAC is light weight, it also saves energy required for transportation and leads to reduced CO2 Emissions by transport vehicles. Since AAC is made from fly ash – an industrial waste product – generated by thermal power plants, it offers a low cost and sustainable solution for today and tomorrow. AAC is a requisite for green buildings.

Easy transportation

It is easy to transport AAC as it does not suffer from high transit breakage usually associated with clay bricks.

Longevity

AAC does not lose strength or deteriorate over time. Buildings constructed with AAC do not require routine repairs that are required for buildings using clay bricks.

Thermal Insulation

AAC offers excellent thermal insulation. This reduces recurring cost of energy required for heating and cooling. Better thermal insulation also allows usage of smaller HVAC than required conventionally.

Shorter Project Duration

Buildings can be built with AAC 50% faster compared to clay bricks. This translates to lower project completion times benefiting project developers.

Fire Resistance

Due to high fire resistance offered by AAC, structures made from AAC have higher rate of survivability in case of fire.

Sound Insulation

Sound absorption properties of AAC make it ideal material for reducing ambient noise. AAC is well-suited for establishments like hospitals and offices situated in noisy areas.

High survivability

Millions of air pockets in AAC cushion structure from major force and prevents progressive collapse of a building. AAC structures are known to maintain structural integrity despite of heavy rains, extremely low temperature and salty air.

Contribution to Nation

AAC factories create many jobs directly and indirectly creating a social impact. Along with that they pay Excise Duty and VAT contribution to national economy.

Production Process

Raw Material Preparation and Storage Section:

The first step of AAC production is grinding of silica rich material (sand, fly ash, etc) in ball mills. For different materials, different processing is adopted, such as dry grinding (into powder), wet grinding (into slurry) or mixed grinding with quicklime (CaO). There are two methods for mixed milling. One is dry mixing to produce binding material, and the other method is wet mixing. Since most quicklime is agglomerate, it should be crushed and then grinded. Gypsum is normally not ball milled separately. It is grinded with fly ash or with quicklime, or it could be grinded with the same miller for quicklime in turn. Other supplementary and chemicals are also have to be prepared. Raw material storage assures the continuous production and material stability. The continuous production guarantees the non-stop & on-time supply, and the material stability guarantees the quality of products, since the raw material might come from different sources, with different qualities. Raw material preparation & storage is the pre-step for proportioning batching. This pre-step guarantees the raw material meet the standard for AAC production, and it is also finishes the storage, homogenization and aging process. It is the basic process that assures the smooth production and production quality.

Dosing and mixing Section:

Maintaining ratio of all ingredients as per the selected recipe is critical to ensure consistent quality of production. This is accomplished by using various control systems to measure and release the required quantity of various raw materials. A dosing and mixing unit is used to form the correct mix to produce Autoclaved Aerated Concrete (AAC) blocks. Fly ash/sand slurry is pumped into a separate container. Once the desired weight is poured in, pumping is stopped. Similarly lime powder, cement and gypsum are poured into individual containers using screw conveyers. Once required amount of each ingredient is filled into their individual containers control system releases all ingredients into mixing drum. Mixing drum is like a giant bowl with a stirrer rotating inside to ensure proper mixing of ingredients. Steam might also be fed to the unit to maintain temperature in range of 40-42º C. A smaller bowl type structure used for feeding Aluminum powder is also attached as a part of mixing unit. Once the mixture has been churned for set time, it is ready to be poured into molds using dosing unit. Dosing unit releases this mixture per set quantities into molds for foaming. Dosing and mixing process is carried out continuously because if there is a long gap between charging and discharging of ingredients, residual mixture might start hardening and choke up the entire unit. In modern plants, entire dosing and mixing operation is completely automated and requires minimum human intervention. This entire operation is monitored using control systems integrated with computer and CCTV cameras. As with any industrial operation, there is provision for human intervention and emergency actions integrated inside the control system.

Casting, Foaming and Pre-curing Section:

Once the desired mix is ready, it is poured into moulds. These moulds can be of various sizes depending on the production capacity of a manufacturing unit. Once mix is poured into moulds, it is ready for pre-curing. After casting, the slurry in molds will be in the pre-curing chamber to finish foaming and hardening. Foaming and hardening actually starts when the slurry is fed into molds, which includes gas-forming expansion and perform curing to achieve certain strength, which is enough for cutting. Pre-curing is always done under set temperature; hence it is also called as heating-room-pre-curing. Pre-curing is not a complicated process, but should avoid vibration. Operators must keep eyes to monitor the slurry change during foaming and provide feedback to dosing, mixing and casting operators. Pre-form defects (cracking, sinking, etc) mainly occur during the process.

Cutting Section:

During this process, the pre-cured block goes through cutting and shaping, into different size & shapes as per requirements. The high workability and large variety of sizes make AAC production more suitable for massive production with higher mechanization. Cutting can be done mechanically or manually. With a cutting machine, the production efficiency and dimensional accuracy is easily achieved.

Horizontal Cutting

Vertical Cutter

 Autoclaved Curing Section:

 After cutting into the desired sizes & shapes, ‘green’ AAC blocks are transferred into autoclaves. Autoclaves are used for steam curing under pressure. AAC must be pre-cured and steam cured to finish the physical and chemical changes, and then to achieve enough strength for desired usage. A batch of AAC blocks is steam cured for 10-12hours at a pressure of 12 bars and temperature of 190°C. In hot and humid conditions, AAC blocks undergo last stages of hydro-thermal synthesis reaction to transform into a new product with required strength and various physical performances. Autoclaved curing imparts inherent properties and performance of AAC.

Grouping Section:

Grouping could be the last step of AAC production (in some AAC plant, the AAC will be further processed into panels after leaving autoclaves). After the cured AAC leaves the autoclaves, inspection and packaging is done.

Comparison between Autoclaved Aerated Concrete (AAC) blocks and clay bricks:

Technical Comparison:

PARTICULARS CONVENTIONAL RED BRICKS AAC BLOCKS
Strength 30-40 Kg/cm2 35-40 Kg/cm2
Shape & Size Non Uniform & Irregular Uniform & Regular
Water Absorption 40 – 45 % 15 – 20 %
Breakage / Wastage 8 – 10 % Nil – 0.5 %
Mortar Consumption High Less
Density 1500 – 1700 Kg/M3 550 – 650 Kg/M3
Nos. of Bricks for per Cubic Meter 592 Nos [9x4x3inch] 67 Nos.[25x9.6x4inch]
Mortar Joint Thickness 15– 18 mm 8 – 10 mm
Plaster Thickness 15– 20 mm 10 – 12 mm