Sand-lime brick, also known as calcium silicate brick, is a type of building material made by mixing sand, lime, and water. The mixture is then molded under high pressure into the desired shape and cured in an autoclave, which is a special high-pressure steam chamber. During the curing process, the lime reacts with the silica in the sand to form a strong, durable, and fire-resistant brick.

Sand-lime bricks are known for their excellent thermal insulation properties, making them ideal for use in construction projects that require high levels of energy efficiency. They are also resistant to moisture and erosion, making them suitable for use in coastal areas or in buildings that are exposed to harsh weather conditions.

Overall, sand-lime bricks are a sustainable and environmentally friendly building material that can help reduce carbon emissions and energy costs in construction projects.

The carbon footprint of sand-lime bricks can vary depending on several factors, including the specific manufacturing process, the energy sources used, and the transportation of raw materials and finished products.

However, on average, the carbon footprint of producing one ton of sand-lime bricks is estimated to be around 200-300 kg of CO2 emissions. This is significantly lower than the carbon footprint of traditional clay bricks, which can range from 800-1000 kg of CO2 emissions per ton.

One reason for the lower carbon footprint of sand-lime bricks is that the manufacturing process requires less energy and produces fewer emissions. For example, the autoclave used in the curing process can be powered by renewable energy sources such as solar or wind power, which further reduces the carbon footprint.

Overall, sand-lime bricks are considered to be a more sustainable and eco-friendly alternative to traditional clay bricks, thanks to their lower carbon footprint and superior insulation properties.

The carbon footprint of fired clay bricks can vary depending on several factors, including the specific manufacturing process, the energy sources used, and the transportation of raw materials and finished products.

On average, the carbon footprint of producing one ton of fired clay bricks is estimated to be around 800-1000 kg of CO2 emissions. This is due to several factors, including the energy-intensive nature of the manufacturing process, the use of fossil fuels such as coal or natural gas to fire the kilns, and the transportation of raw materials and finished products.

To reduce the carbon footprint of fired clay bricks, manufacturers can take several steps, such as using more energy-efficient kilns, switching to renewable energy sources, and using locally-sourced raw materials to reduce transportation emissions.

Overall, while fired clay bricks are a durable and long-lasting building material, their high carbon footprint makes them less environmentally friendly compared to alternative building materials such as sand-lime bricks or earth-based construction materials.

Experience the ultimate in sand-lime brick production with Titan Machinery’s cutting-edge brick making plants. Our state-of-the-art technology, custom designs, and uncompromising commitment to quality ensure the production of the finest sand-lime bricks on the market.

At Titan Machinery, we’re all about making top-notch sand-lime bricks equipment. That’s why we develop and build the most innovative machines and systems for sand-lime brick production, along with complete production plants. We cover everything you need for a modern manufacturing process, making sure every system works together perfectly. When everything’s running like clockwork, you get the highest quality products. Check out our plants and systems for making the best sand-lime bricks around.

A combination of fly ash, bottom ash, quicklime, and a small amount of gypsum or other binding agent may be used.

The process of manufacturing autoclaved fly ash bricks involves mixing the raw materials together, compressing them into the desired shape, and then curing them in an autoclave at high pressure and temperature. 

The advantages of using autoclaved fly ash bricks include their environmental friendliness, as they utilize waste materials that might otherwise be discarded, their insulating properties, and their high durability. Additionally, because the production process does not involve firing in a kiln, the energy consumption and associated carbon emissions are reduced.

The quality of finished sand lime products is primarily influenced by the storage, mixing, and dosing of sand and lime raw materials. To ensure the best possible plant layout, Titan Machinery can provide all the required components.

Our facility includes different systems such as sanding, sieving, and bunkering system, silo, transport and dosing system, premixer, reactor, remixer, color mixing unit, and an electric control system. We use traditional raw materials such as sand and lime, as well as a green alternative like fly ash, to provide our customers with a wider range of products to choose from.

Sand and lime of different types, needed for various recipes, are stored separately. The raw materials are sorted and transported to the pre-mixer, where they are precisely dosed and mixed with water. We use electronically controlled weighing technology and continuous moisture measurement to create a homogeneous mixture, producing the perfect sand lime brick according to the provided recipe.

The core element in our premixing system is a Titan intensive mixer or high-speed mixer which gives us the following advantages:

• Homogeneous distribution of all materials in the mix combined with a uniform coating of binding material (lime) on the sand
• Intensive and uniform wetting of the lime with water
• The sand grains are activated on their entire surface to form calcium silicate.
• The mixer breaks down clay agglomerates that hinder the formation of high-density calcium silicate with fine pores.
• Lime agglomerates are effectively separated.
• Our mixers ensure a uniform brick structure when light aggregates or fly ash are mixed in.
• Our mixing process yields outstanding and reproducible quality.

Our electric control system ensures an automatic production process and comes with hardware, software components, and control panels. The individual areas communicate with each other via Profinet or Ethernet, and the setting of the control panels takes place in the immediate vicinity of the machine or system components.

To start the production process, the ready mix is transported to the reactors using conveyor belts and bucket elevators. In the reaction vessel, a chemical reaction takes place involving water, converting the anhydrous lime to calcium hydroxide. This process usually takes about two hours. Once the reaction is complete, the mix is withdrawn through the reactor discharge and fed to the re-mixer, also known as the double-shaft mixer, using a conveyor belt.

The double-shaft mixer, also known as the remixer, is positioned between the reactor and the press. It comes equipped with an automated water dosing unit to achieve the ideal pressing humidity of the mixture right before pressing. The system and processes are designed to be airtight to prevent dust formation.

During remixing we use intensive mixers which gives us the following advantages:

• Our mixers reliably separate any agglomerates in the reactor material.
• We have accurate control of moisture levels for precise pressing.
• Our mixer design ensures a continuous material stream from the reactor to the brick removal stage on the press.
• No streaking occurs when pigments are mixed into the mixture.
• Our mixer adapts to changes in pressing output, such as those associated with different brick sizes, by adjusting the mixing power.

Our mixer control system is precisely calibrated to the processes in your plant. This ensures that the appropriate amount of sand lime brick mass is fed to each press’s remixer, even when handling various mixtures or products.

Colored bricks.

Due to we use intensive mixer as a remixer it is possible to expand your product range and increase your sales by offering custom colors to your customers by using separate color unit which includes automatic pigment dosing.

If your customers require a special color for their sand-lime bricks, the mixed materials are transported to our color mixing plant via conveyor belts. In addition to the mixer, the color mixing plant includes the following components:

• A scale for the sand-lime brick mass
• A lifting and emptying device for powdered colors
• A color scale
• A water dosing unit
• An emptying tub

The mix is dyed with the desired color within the system, accurately dosed using the emptying tub on a conveyor belt, and then transported to the sand-lime brick press for production. Our intensive mixing system ensures consistent and precise coloring, allowing you to meet your customers’ color specifications.

Unleash the Power of Titan Machinery Presses at the Heart of Your Sand-Lime Brick Plant!

The secret to producing high-quality sand-lime bricks lies in our hydraulic presses. The presses are the core of every sand-lime brick production plant, and we have developed the Titan Machinery range of presses to ensure the production of high-quality sand-lime bricks for our customers.

Our presses are hydraulic and designed with a classical four-pillar design features four vertical pillars arranged in a square or rectangular pattern, with a hydraulic cylinder and ram located at the center. This design provides strong and stable support for the pressing process, allowing for high precision and control in shaping and forming materials. This design guarantees longevity and high product quality. They are equipped with state-of-the-art construction and electric control systems that provide an individual and modern sand-lime brick production for our customers. Our presses can produce both solid and perforated bricks, colored sand-lime bricks, and sand-lime bricks with undergrips. With our presses, customers can expect precise dimensions and a uniform brick compressive strength, achieved through automatic and precisely tuned filling of the machine. This ensures that the pressure is constant at each stroke, resulting in uniform brick compressive strength.

Our presses are designed to be easily maintained, ensuring longevity, rich product variety, and the highest quality sand-lime bricks. We have also designed this area of the plant for even more cost-effectiveness and efficiency. Scattered waste that accumulates in the press area represents valuable and reusable raw material, which is returned to the mixer via the spillage return.

Discover the Titan Series: Our High-Performance Presses for Sand-Lime Brick Production!

TITAN 600S

Looking for a sand-lime brick press that’s tailored to your specific production requirements? Meet our hydraulic TITAN 600S press, the smallest yet powerful press in the Titan range. With an impressive capacity of up to 5,720 bricks per hour, this press delivers uncompromised quality and longevity.

TITAN 900S

Titan Machinery’s star performer, the TITAN 900 press, is an unparalleled force in the sand-lime brick industry. It boasts a staggering capacity of up to 10,000 bricks per hour with a jaw-dropping maximum force of 1000 tons. Not only does it produce bricks at lightning speed, but it also features a compact design that takes up minimal floor space. This makes the TITAN 900S an ideal choice for plant upgrades as it can effortlessly replace lower-performing machines while integrating seamlessly into existing setups.

TITAN 900SH

Introducing the TITAN 900SH, the perfect solution for producing large format sand-lime bricks of the highest quality. With its specially designed frontal discharging gripper, it can handle larger formats with ease, making it the go-to choice for producing high-quality bricks in large sizes. Upgrade your production capabilities with the TITAN 900SH.

TITAN 900DH

The double press TITAN 900DH utilizes upper and lower punches that are powered by hydraulics to apply pressure to the raw material from two opposite directions. This process results in the attainment of uniform and exceptionally high strength throughout the brick’s entire cross-sectional area. This machine is capable of producing sand-lime bricks that are up to 250 mm in height, as well as small-format facade brickwork and blanks for the cleaving and embossing system, all of which exhibit excellent compressive strength.

TITAN 1300DH

The TITAN 1300DH double-action press is the largest in the standard range. It is necessary to use it in cases where very large products need to be produced, which may later be subjected to cutting. This press has very large dimensions and requires high ceilings in the room where it is installed. The maximum height of the products is 250 mm.

The circulation of the hardening wagon is a critical aspect of a sand-lime brick plant that significantly impacts the quality of the final product. Proper internal transport and handling are essential to produce flawless sand-lime bricks.

We can provide various hardening wagon logistics solutions, including traversers, hardening wagons, transport systems, incremental drives, steel rope systems, and an electric control system with product tracking. Additionally, we offer scraper and hardening wagon brushes for the cleaning systems.

In our sand-lime brick production plants, we transport the empty hardening wagons of the press using a traverser for empty wagons that can accommodate one to two wagons. The gripper automatically removes the pressed sand-lime brick blanks from the press and stacks them on the empty hardening wagon. A traverser, which can carry up to six hardening wagons, then transports the full wagons from the press tracks for autoclaving. After autoclaving, another traverser collects the hardening wagon with the hardened bricks from the autoclave and transports them to the packaging area.

You can choose between an incremental drive or a “locomotive” drive when equipping the traverser. Contact our team of experts to discuss the best option for your plant.

The process of sand-lime brick production involves the use of autoclaves, which are high-pressure steam chambers used to give the bricks their final strength. Blanks are loaded onto hardening wagons and placed in the autoclaves. The sand-lime bricks acquire their final strength at a temperature of about 200°C and a steam pressure of 16 bar, and the hardening time depends on the size and density of the bricks. Typically, the hardening process takes around eight hours.

During the hardening process, the structures of lime, sand, and water formed during the manufacturing process convey the solid structure of the sand-lime brick. The hot steam atmosphere releases silicic acid from the surface of the quartz sand grains, which then binds to the binder to form hydrated lime crystalline binder phases (CSH phases). These phases grow on the grains of sand and interlock them firmly, creating the final solid structure of the sand-lime brick.

The autoclave section includes various systems such as the feed water treatment system, steam generating system, steam distribution system, autoclave with drainage, and condensate recovery system. Waste heat recovery is an essential aspect of this section, given that the hardening of the material in the autoclave consumes the most steam. To maximize efficiency and effectiveness, several autoclaves are often operated in a staggered manner. This increases the amount of steam required, but also allows for the recovery of waste heat through condensate re-use or by using steam generated for autoclaving to preheat the feed water or heat the building.

To meet the high-quality demands of our finished sand-lime bricks, we prioritize sensitive and product-specific handling throughout the entire production process. Titan Machinery has developed portal grabber systems and grouping systems that are tailored to meet our product-specific requirements, ensuring that only the highest quality bricks are produced and packaged flawlessly. Apart from the synchronized conveyor and hardening wagon logistics, the packaging system also plays a critical role in the production of flawless sand-lime bricks.

Our modular packaging systems are designed to meet the specific packaging requirements of each customer. We offer various packaging modules such as palette magazines, palette transport and conveyor equipment, and marking stations. Once the palettes loaded with the hardened bricks are fed to the packaging system, we use a combination of vertical and horizontal strapping and foiling to secure and protect the package during transport, as well as to provide an advertising space. The marking station can also add lettering to the foiled brick packages.

At Titan Machinery, we’re committed to meeting your unique sand-lime brick production needs. That’s why our experts are ready to work with you to customize our Titan range of presses to match your plant specifications. Whether you require modifications for performance, size or capacity, we’ve got you covered. Let’s collaborate and design the ideal sand-lime brick press for your business.

We understand that every project is unique, and the size of the sand lime bricks production plant will depend on your specific needs. Our team of experts is here to help you plan the ideal plant size and number of reactors based on your ideas and requirements.

Achieving the perfect mix for sand lime bricks!

Revitalizing Sand Lime Brick Plants: Upgrading for Efficiency and Quality

To remain competitive in the market, it is important to keep sand lime brick production plants up to date with the latest technology. Titan Machinery offers modernization solutions for existing plants to improve efficiency, product quality, and reduce operating costs.

Our experts will assess your current plant and provide a customized modernization plan that meets your specific needs. This could include upgrading or replacing outdated equipment, integrating new control systems, or improving energy efficiency.

Upgrading your plant can provide numerous benefits, including increased production capacity, improved product quality, reduced energy consumption, and minimized maintenance costs. Our goal is to provide you with a modernized plant that meets your production goals and delivers a significant return on investment.

Upgrade your sand-lime brick production plant with our TITAN hydraulic presses! These presses are the centerpiece of our production line, guaranteeing high-quality bricks with precise dimensions and uniform compressive strength. Our experts recommend using the TITAN 900S press, which can be easily integrated into your existing plant, replacing lower performance machines quickly and effectively.

With our TITAN presses, you can now expand your product assortment and manufacture solid and perforated bricks, colored sand-lime bricks, and bricks with undergrips. By upgrading to our proven technology, you can improve your product quality, increase production efficiency, and significantly expand your product portfolio in one swift move. Don’t just keep up with the competition, stay ahead of the game. Contact us today to build up your competitive edge!

Sand lime brick technology is a modern method of producing bricks that offers several advantages over traditional brick-making methods. Here are some of the main advantages of sand lime brick technology:

1. High Strength: Sand lime bricks are known for their high strength and durability. This is due to the high density of the bricks, which makes them resistant to wear and tear.
2. Energy Efficient: The sand lime brick manufacturing process requires less energy than traditional clay brick-making methods. This is because the bricks are cured using steam and pressure, which is more energy-efficient than firing clay bricks in a kiln.
3. Environmentally Friendly: The sand lime brick manufacturing process is environmentally friendly because it produces fewer emissions and consumes less energy than traditional brick-making methods. Also, sand lime bricks can be recycled and reused after demolition.
4. Consistent Quality: Sand lime bricks are made in a controlled environment, which ensures consistent quality and reduces the risk of defects.
5. Versatile: Sand lime bricks can be used in a wide range of building applications, including load-bearing walls, partition walls, facades, and insulation.
6. Low Cost: Sand lime bricks are relatively inexpensive to produce, especially when compared to other building materials such as concrete blocks and clay bricks.
7. Fire Resistance: Sand lime bricks are highly fire-resistant, making them an ideal choice for buildings in areas prone to wildfires or other fire hazards.
8. Sound Insulation: Sand lime bricks provide excellent sound insulation, which is beneficial for buildings located in noisy areas.

Overall, sand lime brick technology offers several advantages over traditional brick-making methods, making it a popular choice for builders and architects around the world.

• Compressive strength: from 75 to 300 kgf/cm².
• Bending strength: from 16 to 40 kgf/cm² for solid bricks of type O and U, and from 8 to 24 for hollow bricks of type U.
• Volume weight (preferably) ranges from 1300 kg/m³ to 1900 kg/m³.

Silicate bricks are divided into porous products, up to 1500 kg/m³, and dense products, over 1500 kg/m³, based on their average density.

Other characteristics include:

• Thermal conductivity: from 0.38 to 0.87 W/(m·°C).
• Frost resistance: from 15 to 50 cycles.
• Expressed by the marks F15, F25, F35, F50 (F15 is excluded for face products).
• Water absorption: from 6% to 16% of the weight of dry bricks.
• Vapor permeability: 0.11 mg/(m·h·Pa).
• Fire resistance: class NF.
• Total specific activity of natural radionuclides not exceeding 370 Bq/kg.
• Price per unit (wholesale) starts at 5.6 rubles.
• The price depends on the product characteristics, color, porosity, purpose, and the manufacturer’s location. 
• Sound insulation: over 64 dB.
• Maximum number of floors for buildings is not limited.