Manufacturing

Siporex is produced by a highly complex and advanced manufacturing process in our factory under the careful control of chemists and engineers. Siporex is made either as steel reinforced panels using moulds 6 meters long, 1.5 meters wide and 600 mm deep or as non-reinforced blocks using moulds 6 meters long, 1.5 (or 1.2) meters wide and 600 mm deep. A schematic diagram of manufacturing process shown below.

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The basic raw materials are sand, water, aluminum powder and cement. The sand is ground to required fineness in a ball mill before mixing with other raw materials and water to form slurry to which a trace of aluminum powder is added as expanding agent.
All Siporex panels are reinforced with steel. Steel coils are straightened, cut and spot-welded into mats, where crossbars provide anchorage to the longitudinal reinforcements. Siporex blocks are not reinforced.
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After dipping the welded mats in a homogenized anti-corrosion mix for rust protection, they are dried and assembled into cages and set accurately in the moulds before the slurry is poured in.
Regulated amount of aluminum powder gives accurate control of density of the final product. Moulds are only partly filled with slurry which then expands in a controlled reaction to fill the moulds.
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When the mass is sufficiently hard, the moulds are stripped and the cake is wire-cut to close tolerances into panels and blocks using high-precision cutting technology. These are then steam cured under high pressure in autoclaves for up to 15 hours.
This completes the chemical process, resulting in a unique crystal structure of calcium silicate hydrate and ensuring a stable and inert product giving AAC outstanding qualities not found in other products.
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After cooling to ambient temperature, the panels are demoulded and milled to required profile as necessary. All Siporex panels are singled out for proper marking, and if required, dry cut and stacked for further handling and storage. The blocks are demoulded, strapped, marked and stored on wooden pallets.
The finished goods inspection programme ensures the products quality. The material is now ready for loading and delivery.
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Manufacturing Diagram

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