Visit Our Case Study of Karad AAC Plant

We received our first plant reviving project during the time we were registering Viaduct as a company. The Karad AAC Plant was an Indian based AAC blocks manufacturing plant that wasn’t running optimally and was about to be shut down by the owners. It wasn’t even able to achieve the daily aggregate of 33 cu.m/ per day.

The viaduct team conducted its erection process and ended up discovering a huge lot of unused AAC liquid. The good thing was that none of it was in the machines as it could have made them unusable after being stagnant for this long.

The erection process itself experienced immense troubles as the plant was considerably obsolete in a sense where the machinery and equipment somehow were never used in the right manner.

The plant’s state somehow spoke of operations being conducted without much care and supervision. The team discovered many problems with the plant layout, along with malfunctioning electrical connections, Improper installation of machines, flawed track setup, faulty autoclave machine and boiler. 

Upon realising the fact that more than 70% of this plant has to be completely revamped and upgraded in an efficient manner, they conducted a meeting with the core team and finalised on a particular working process and ethic which will be followed across the whole plant and for all its troubles.

The team finally decided to work section-wise and started dedicating time in a more uniform manner to assure the proper working of each section of the plant.

The team started working on the slurry making area in the plant simply to  follow a more systematic method of working. This system is beneficial as even the hidden faults can be highlighted this way with more manpower scouring the particular area.

The main problem with the first section was extremely slow slurry making which is the first stage of the whole AAC block manufacturing process, and this drawback can create a huge setback when it comes to daily aggregate production.

The team noted that a misaligned chute and a lazily covered pit were the main reasons for the slow slurry making process. After correctly aligning the slurry chute, placing the screw conveyors and covering the pit, the team was confident that they had rectified the problem in this section,  but then they came upon what is known as the brain of the plant, the main motor. 

This motor was facing additional problems as it tended to choke up every 10-15 minutes. This was posing further problems for the physical  help as they had to spend additional labour hours behind the main motor. This motor was the main motor used in the making of slurry and was giving severe indications of an impending mechanical problem.

The team got back to investigating the problem and aimed at figuring out the underlying mechanical problem as fast as time permits. We have one of the best engineers on our team and a mechanical problem should not have stopped our operations this way and after several investigative techniques,

we found that there was no mechanical problem with the motor and it was just a faulty connection that was giving rise to the repeated choke ups helped us gain our pace once again with this plant.

The team rectified this error, cleared all the choked butterfly valves, and automated the whole process of mixing aluminium in the slurry, giving the plant a top level upgrade which fastened the whole process quite a bit! 

Our team then shifted to the cutting lines to solve the problem this plant faced there. The whole horizontal cutting line was dismantled and was reassembled but at a height of 60mm this time. Our team also worked on the tinting grid as it was not in shape and was also not aligned properly. 

Apart from this it was also missing the stoppers that send the required amounts of solution. Our team of expert engineers fixed all the underlying problems and got it to workable conditions in record time!

The team then moved on to the tracks and the side plates which is a more extensive mechanical work. 

The fact that none of the plates were in working condition made it even difficult for the team to overcome this issue but we have a team made of the best and we overcame this with the help of our sharpened team of engineers. 

A similar situation was going on with the boiler which was not in a very good condition. After tinkering a few changes and making the boiler a little more sustainable than what it used to be, our team finally reached the point to have a trial run to check if our team hit the mark. 

At the time of our trail run, everything looked good to go, but the moment we started our trial run, our team experienced a hiccup. The moment the boiler was started, its IDFD failed and the whole plant lost its electricity.

Our team had approached the higher management for the blueprints  of  the electrical layout at the plant at which we got a negative answer. 

This being one of the most cumbersome and time consuming matters, our team put their all in creating a mock blueprint of  the electrical layout of the plant and then stepped in our expert engineers once again to save the day and the plant. 

 

 

This took an additional 2 days of working 18-19 hours from our pocket, but Viaduct was finally able to get this plant to optimal running conditions.

Viaduct brought the Karad plant back from the dead! The owners of this plant had completely lost hope and were a call away from selling it, at which point viaduct stepped in to save them the trouble. Our team consists of the best from each corner of the plant and we are absolute that there isn’t any problem that the team viaduct can’t figure and solve. 

It took a total of 45 days, a team of 7 individuals with 3 of them being the country’s best engineers to revamp the Karad AAC blocks plant. The overall plant was in a very bad condition and more than half of the blueprints were missing but we proved our expertise in the AAC industry by overcoming all the problems and bringing it back to its older production capacities.
We at Viaduct aim at aiding every AAC block manufacturer facing trouble in the market and carry the expertise to bring back any form of obsolete plants, back to their best production capacities!