# AAC Block Plant Manufacturer in India | Maruti Hydraulics — Since 1991

> Maruti Hydraulics Limited — India

![Maruti Hydraulics Limited](/images/logo-light-bg.webp) 

India's Top Construction Machinery Manufacturer

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# AAC Block Plant Manufacturer in India — Maruti Hydraulics Limited Since 1991

Maruti Hydraulics Limited (MHPL) is an ISO 9001:2015 certified AAC block plant manufacturer in India, headquartered in Nashik, Maharashtra. Founded in 1991, the company manufactures complete turnkey Autoclaved Aerated Concrete (AAC) block plants from 150 CBM/day to 1200 CBM/day — the widest capacity range offered by any single Indian manufacturer. Maruti Hydraulics commissioned India's largest AAC plant at 1200 CBM/day in 2024, built India's first complete SCADA-controlled batching system in 2023, and was the first Indian manufacturer to export an AAC plant to Nepal in 2016.

Maruti Hydraulics Limited — India's leading ISO 9001:2015 certified AAC block plant manufacturer since 1991\. Turnkey plants from 150 to 1200 CBM/day. India's first SCADA batching system (2023), first Nepal export (2016), India's largest 1200 CBM/day plant (2024). Factory-direct from Nashik, Maharashtra.

## AAC Plant Capacity Range — 150 to 1200 CBM/Day

| Capacity     | Land Required  | Team Size | Suitable For               | Market Radius |
| ------------ | -------------- | --------- | -------------------------- | ------------- |
| 150 CBM/Day  | 1.0–1.5 acres  | 18–22     | Entry-level commercial     | 80–120 km     |
| 200 CBM/Day  | 1.5–2.0 acres  | 22–28     | Small regional market      | 100–150 km    |
| 300 CBM/Day  | 2.5–4.0 acres  | 30–38     | Mid-size commercial        | 150–200 km    |
| 500 CBM/Day  | 4.0–6.0 acres  | 40–55     | Large regional plant       | 200–300 km    |
| 800 CBM/Day  | 6.0–8.0 acres  | 55–75     | Industrial scale           | 300–500 km    |
| 1200 CBM/Day | 8.0–12.0 acres | 75–100+   | Mega plant / group captive | Pan-India     |

## 9 AAC Plant Subsystems — All Manufactured In-House

* **[Raw Material Storage Silos](/products/aac-raw-material-storage)** — Fly ash, cement, lime, and gypsum silos from 30 to 200 tonnes with aeration pads, level indicators, and pneumatic conveying.
* **[Raw Material Preparation System](/products/aac-raw-material-preparation)** — Ball mills, slurry tanks, vibration screens for sand slurry preparation and fly ash conditioning.
* **[SCADA Batching System](/products/aac-batching-system)** — India's first fully automatic SCADA-controlled batching system (2023). Gravimetric dosing to ±0.1% accuracy. PLC + SCADA HMI with recipe management.
* **[Tilting & Demoulding Machine](/products/aac-tilting-machine)** — Hydraulic tilting of pre-cured AAC mould cake for wire cutting. Handles mould sizes up to 6.2 m × 1.5 m × 0.65 m.
* **[Wire Cutting Machine](/products/aac-wire-cutting-machine)** — Simultaneous horizontal and vertical wire cutting. ±1.5 mm block dimension tolerance. Invented by Maruti Hydraulics in 2007 — India's first.
* **[Autoclave](/products/aac-autoclave)** — SAE 516 Gr 70 pressure vessels, 12 bar / 190 °C steam curing. Diameters 2 m to 3.2 m, lengths 26 m to 42 m. IBR approved and hydraulically tested.
* **[Industrial Boiler](/products/boiler)** — Coal, biomass, and gas-fired steam generation. Supplied in partnership with Thermax. Skid-mounted with pre-heaters for full AAC plant integration.
* **[Finished Block Handling System](/products/aac-finished-block-handling-system)** — Conveyor belts, tilting cradles, and pallet systems for finished block transport and stacking after autoclave discharge.
* **[AAC Separator](/products/aac-separator)** — Pneumatic and mechanical block separation after autoclave discharge without edge damage.

## AAC Block Manufacturing Process — Step by Step

1. **Raw Material Batching:** Fly ash, cement, lime, gypsum, aluminium powder, and water are weighed by SCADA batching system and mixed into homogeneous slurry.
2. **Mould Filling & Pre-Curing:** Slurry is poured into steel moulds. Aluminium reacts with lime to generate hydrogen gas, expanding the mix. Pre-curing 2–4 hours.
3. **Tilting & Demoulding:** Hydraulically tilted 90°, green cake separated onto cutting rack.
4. **Wire Cutting:** Simultaneous horizontal and vertical wire cutting to ±1.5 mm tolerance.
5. **Autoclave Curing:** 12 bar / 190 °C steam curing for 10–12 hours — permanent silicate bond formation.
6. **Handling & Dispatch:** Cured blocks separated, conveyed, palletised, shrink-wrapped, dispatched to sites.

## Industry Firsts — Verified by Maruti Hydraulics

* **2007 — India's First Wire Cutting Machine:** Invented India's first wire and blade cutting machine (1.1 CBM) for lightweight concrete blocks — a technology now standard in every AAC plant in the country.
* **2023 — India's First Complete SCADA Batching System:** Built India's first fully automatic SCADA-controlled batching and mixing system — eliminating human error in batch proportioning.
* **2024 — India's Largest AAC Plant:** 1200 CBM/day plant replacing German Siporex machinery operating since 1973\. India's oldest AAC facility became its most modern.
* **2016 — First Indian Export to Nepal:** First Indian manufacturer to commission an AAC block plant in Nepal — a 300 CBM/day turnkey installation.

## Turnkey Services — From Feasibility to Commissioning

* **Feasibility Study & DPR:** Market analysis, land evaluation, financial projections, ROI analysis, and Detailed Project Report (DPR) for bank financing.
* **Plant Layout Design:** Custom equipment arrangement, material flow optimisation, civil drawing package, PEB factory building design.
* **Equipment Manufacturing:** All 9 subsystems fabricated at ISO-certified Nashik facility — no outsourcing.
* **Installation & Commissioning:** Mechanical, electrical, and pneumatic erection plus 30-day on-site technology transfer.
* **After-Sales Support:** Spare parts within 36 hours across India, remote SCADA diagnostics, annual maintenance contracts.

## Frequently Asked Questions — AAC Block Plant

### What is the capacity range of Maruti Hydraulics' AAC block plants?

Maruti Hydraulics manufactures AAC block plants from 150 CBM/day to 1200 CBM/day. Standard sizes are 150, 200, 300, 500, 800, and 1200 CBM/day. India's largest AAC plant at 1200 CBM/day was commissioned by Maruti Hydraulics in 2024.

### Does Maruti Hydraulics provide turnkey AAC plant installation?

Yes. Maruti Hydraulics provides complete turnkey services: feasibility study, plant layout design, equipment manufacturing at the ISO-certified Nashik factory, installation, commissioning, 30-day on-site technology transfer, and long-term after-sales support including spare parts within 36 hours across India.

### What is the cost of an AAC block plant in India?

AAC plant investment varies by capacity and site-specific requirements. Maruti Hydraulics provides detailed project reports (DPR) with capacity-matched equipment quotations. Contact +91-253-2308131 for a customised DPR.

### Which IS standard applies to AAC blocks manufactured in India?

AAC blocks must comply with IS 2185 Part 3:2005 — Specification for Concrete Masonry Units: Autoclaved Cellular or Aerated Concrete Blocks. Key parameters: dry density 400–900 kg/m³, compressive strength ≥2 MPa (Grade D 500), moisture content ≤35%. Maruti Hydraulics' plants are configured to produce IS 2185-compliant blocks.

### Can Maruti Hydraulics supply both the factory building and the AAC plant machinery?

Yes — Maruti Hydraulics designs and erects Pre-Engineered Buildings (PEB factory sheds up to 90 m clear span) and then equips the same building with the complete AAC block plant line under one contract. Single vendor, single project manager, zero coordination gaps between civil structure and machinery.

## Contact Maruti Hydraulics — Get a Free Plant Feasibility Report

**Maruti Hydraulics Limited**

Gat No. 592, Nashik-Pune Highway, Nashik, Maharashtra 422101, India

Phone: [+91-253-2308131](tel:+912532308131)

Email: [info@marutihydraulics.com](mailto:info@marutihydraulics.com)

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