Successful upgrade from AAC blocks to panels in Mongolia

The advantages of autoclaved aerated concrete are gaining increasing international recognition and are also
very well known in Mongolia. MAK Euro Block, the market leader in Mongolia, is now expanding its portfolio
with the so-called AAC Reinforcement System from Hess AAC Systems. This reinforcement system enables the
manufacturer to produce loadbearing AAC elements in addition to AAC blocks, thus expanding the product
range to all essential components for small houses. A large part of the Mongolian population lives in tents,
which is why the local government has now indicated its interest in the product range offered by the MAK
company. The extreme climate in Mongolia makes AAC the material of choice.

For an outsider, it is difficult to visualize the production conditions and associated challenges in Mongolia. Also, considering that the country has little more than 3 million inhabitants living in an area of 1.5 million km² (more than 4 times the size of Germany), one does not immediately expect to find large concrete production facilities in the region. And yet, several Mongolian companies were already producing AAC blocks as early as 20 years ago. However, the quality and dimensional accuracy of these products did not always meet the advantages expected from AAC as a building system. This situation has now changed. From the onset, Hess AAC Systems supported MAK Euro Block in the construction of their production plant. It was not only the high-quality systems and machines, but also the introduction of efficient quality assurance that set MAK Euro Block apart from other manufacturers. Standards such as those established in Europe did not exist at that stage, which is why Hess AAC Systems brought the European DIN EN standards to Mongolia. The technically complex documents were translated and officially recognized by the relevant local authorities. 

MAK Euro Block therefore adheres to self-imposed guidelines and has at the same time influenced AAC application in the whole country. 

Construction of small houses in Mongolia
The MAK company has predominantly been focussing on copper and coal mining but is continuously expanding its portfolio into the construction sector. MAK Euro Block now produces 900 m3 of AAC per day and operates four autoclaves. Hess AAC Systems will soon deliver a fifth one, which will enable MAK to increase production by another 25%. 
MAK’s vision of achieving steady growth is being put into practice and since the plant can be expanded to 1,600 m3/day with the existing core of the factory, further growth is pre-programmed. This expansion is more than appropriate for the local market, as construction companies are happy to accept the high-quality offered by AAC blocks and slabs. A large part of the Mongolian population still lives in tents and politicians are consequently very interested in building small houses. It is therefore no surprise that the government is in favour of the activities of MAK Euro Block and the product expansion made possible with the Hess reinforcement system.

Based on the local conditions, AAC is obviously very suitable for house construction in Mongolia, which explains its growing demand in the market. Extreme weather conditions require the right choice of material Mongolia is located in the Central Asian highlands, which is why it has one of the most extreme climates in the world. The temperatures in summer average +20°C, but in the long winter they can drop to -25°C. In addition, temperature fluctuations between day and night can be as high as 32°C in some places. This is why the excellent thermal insulation provided by AAC is a welcome feature. The cold winters further shorten the time span in which construction can take place. This brings about yet another advantage of AAC: the lightweight material can be transported very easily, even in large sizes. And also, AAC can be handled and installed with simple methods and, above all, very fast. Since MAK Euro Block can now also produce reinforced panels, it is in a position to offer all essential components for small houses from its own product range.

The AAC Reinforcement System for reinforced slabs

MAK Euro Block is the only company in Mongolia that is even capable of producing reinforced AAC slabs. As the future was considered when the plant was initially built, the AAC Reinforcement System was integrated quickly and easily. The expansion was carried out during ongoing operations, so production was not restricted. The Hess Reinforcement System allows the insertion of a reinforcement cage into the AAC product. Longitudinal and transverse bars of reinforcing steel are welded together, coated with a corrosion protection and lowered into the material directly after casting via a support frame. After fermentation of the AAC, the holding frame is unlocked from the reinforcement cage and the reinforcement cage remains in place. Only then is the product cut into its final shape. Due to the reinforcement, the end product can absorb not only compressive forces but also high tensile forces due to bending and can therefore be used as a load-bearing element. It is not possible to see from the outside which reinforcement cage is placed in which product, which is why the introduction of an efficient control system and optimal coordination with existing processes is also part of the expansion by Hess AAC Systems.

Training and equipment for quality assurance
The reinforcement cage is designed in such a way that the transverse bars serve for anchoring and stability and the longitudinal bars for the transmission of tensile forces. The consistent and reliable quality of this cage forms the basis for the stability of the final product. Therefore, when integrating the AAC Reinforcement System in the plant, a tension bench was installed to check the quality of the reinforcing steel. In addition, a system to check the welded
joints was provided. In order to verify the absorption of the tensile forces by the reinforced AAC, a system for carrying out bending tests was also set up. 
Last but not least, Hess AAC Systems trained the employees of MAK Euro Block on the subject of reinforcement. Among other aspects, they worked together with structural engineers to raise awareness of the practical application after production. 
AAC is gaining increasing recognition and popularity worldwide
The low self-weight of the material, the very good workability, and the thermal insulation properties - the advantages of AAC are becoming increasingly well known internationally. Particularly in climatically challenging areas such as Mongolia, AAC manufacturers have a strong market advantage and MAK Euro Block has taken an important step with the addition of the AAC Reinforcement System. From floors and ceilings to walls, the Mongolian company can now offer all basic components including load-bearing elements for house construction.
Hess AAC Systems has now been working with the Mongolian company for more than a decade and will continue to contribute to strengthening MAK Euro Block’s market position in the future.