NON-AUTOCLAVE AERATED

LIGHTWEIGHT CELLULAR CONCRETE

PLANT AND KNOW-HOW FOR LIGHWEIGHT
CELLULAR CONCRETE PRODUCTION
www.ecocon.ae

 I consider that ECOCON engineers have

acheived the substantial progress in developing non-autoclave aerated concrete technology and presently I do not see anybody who
is able to compete ECOCON in this particular
field.
Dr. Marcel Bikbau - professor, Member of Russian
Natural Sience Aademy,
General Director of Moscow Institue of
Materials and Effective Technologies

CONTENTS
INTRODUCTION

03

ECOCON PRODUCTS

04

ECOCON PLANT

05

ECOCON CONSTRUCTION SYSTEMS

06

ECOCON SPARES

07

SUCCESS STORY THAT COMES FROM DREAM

2008 - 2010
Scientific studies, laboratory tests and cerification
of plants Russia and Belarus

2012

ECOCON Group has

established in the UAE

been

2013

ECOCON WORLD CLASS PRODUCTS & SERVICES

In 2013 during Big 5 Intenrational

COnstruction Exhibition in Dubai,
ECOCON technology has gained
Gaya Award - main award for the
most green and innovative product
in the Middle East and Nothern
Africa

2014
The first fully fledged ECOCON Production facility has been launched in
Al Ghail Industrial Area in Ras Al Khaimah (UAE).

2014 - 2016
Successfull development of ECOCON technology in the UAE and worldwide. Recogintion and
acceptance of ECOCON products by the UAE certification and government authorities.
Construction of ECOCON plants in Ukraine, Saudi Arabia and Oman.

TODAY ECOCON IS A GLOBAL

LEADER IN DEVELOPMENT OF
TECHNOLOGY OF PRODUCTION
ECOCON AND APPLICATION OF NON-AUTOCALVE AERATED LIGHWEIGHT
CELLULAR CONCRETE

ECOCON PLANT

CELL-GENERATING
POWDER (CGP)

MIXERS AND
APPLICATION TOOLS

KNOW-HOW
TRANSFER, TRAINING

The heart of ECOCON Technology

is a plant that produces
non-autoclave aearted
lightweight cellular concrete
products, such as: masonry blocks,
dry mix for preparation of
lighweight concrete in-situ,
cladding and facade thermal
panels, decorative elements and
others. The design and
engineering of plant is produced
in a way that ensures durability,
low maintenance cost and
simplicity of equipment.

CGP is a specially designed

complex chemical additive that
initiate a chemical reaction that
produces aeration of ECOCON
mixture.

The mobile ECOCON high-rotary

speed mixers are used for
preparation of lighweight celluar
concrete in-situ and delivering the
mixture to place of application.

ECOCON shares all expirience and

new developments with
customers, ensuring the
continious operations and
business success. All new
developments and inventions
made by ECOCON engineers are
becoming a valuable domain to
all users of ECOCON technology.
Know-How Book provided to
custoemrs by ECOCON includes all
technological secrets and allows
customer to run the plant
independently.

Raw materials of ECOCON plant

are available everywhere . They
are: ordinary portland cement and
ordinary construction sand. Dune
sand, stone dust, fly ash can be
used as raw materials as well.

CGP has different components

that calculated in accordance with
available raw materials.
ECOCON has developed special
CGP formals allowing production
of lighweight cellular concretes
with various technical specifications such as: dry density,
compressive strength, drying
shrinkage.

FAST-TRACK SPARES
ECOCONs service doesnt stop the
moment when the plant is
erected: in-house engineering
department provides a wide
range of spare parts for all
ECOCON equipment. ECOCON
offers FAST-TRACK service,
combined with highly competitive rates.

03

ECOCON DRY MIX FOR PRODUCTION

LIGHTWEIGHT CONCRETE IN-SITU
ECOCON Dry Mix is a two-components dry
powder for producing non-autoclave
lightweight cellular concrete in-situ by
simple mixing with water.
ECOCON Dry Mix production is based on
usage of scientific innovations in nano-technologies in line with innovative selection
and processing of raw materails.
ECOCON Dry Mix is used for construction of
lightweigh floor screeds, filling walls and
partitions, road and pipeline bedding

MASONRY UNITS (BLOCKS)

ECOCON Lightweight Blocks are used in virtually all areas of the construction
industry, such as housing, industrial and agricultural construction, the construction of schools, hospitals, administrative and public buildings, etc. ECOCON block
is an economical and efficient building material whose properties allow to
quickly construct buildings for various purposes.
In addition, ECOCON blocks can be used for restoration or reconstruction of old
buildings (due to low weight) or half-timbered houses (due to simple processing). In world practice, cellular concrete has long been used in the renovation of
old buildings, while building their height.

ECOCON PLANT PRODUCT PRODUCTION

AND APPLICATION DIAGRAM
KNOW - HOW ADDITIVE
cell-generating
powder (CGP)

To customers for
cosntruction of
floor screeds,
filling walls,
roads and
pipelines
bedding

4 THERMAL FACADE & CALDDING

PANELS

RAW MATERIALS
chemicals

sand
(filler)

cement

fibre

water

Dry Line Processing

Storage
Construction
Adhesives
(limited qty)

Packing

ECOCON
Dry
Mix

Wet Processing & Cutting Line

5
2

Masonry Units
(400 - 800 kg/m3)

Cladding &
Facade
Panels

Superlight
blocks
(250 kg/m3)

Final curing at storage (15 - 25 days)

Cutting Process

To customers

SUPER-LIGHT BLOCKS & PANELS

ECOCON Superlightweight Blocks (less than 275 kg/m3) can be perfectly applied
as filler (hoardy) blocks for pre-cast panels production. The perfect thermal
insulation of superlight blocks allow to avoid usage of expensive and fire
dangerous polysterene.

ECOCOCN Thermal Panels are kind of block with

thickness up to 100 mm. Panels can be applied
for thermal insulation of RCC structures and fire
protection of elevator shafts, staircase shafts,
steel structures and construction of fire
protected walls and partitions

To customers for
execution
masonry works
To customers for
facade and
cladding works

Decorative
elements

BUILDING DECORATIVE
ELEMENTS

ECOCON decorative elements are produced by

special processing of lighweight concrete
massives that gives them required shape and
form. Due to their light weight, reasonable
strength and special way of finishing ECOCON
decorative elements are excellent replacement
to heavy RCC or expensive GRC (GRP)
structures.

ECOCELL Construction System

(construction with pre-cast
sandwich panels with ECOCON
superlight concrete infilling)

ECOCON Construction System

(combination of LGS and
lighweight concrete)

This diagram is for ECOCON plant E-P type. Other designs and
configuration of the plant may change the diagram.

04

ECOCON PLANT E-N TYPE

DESCRIPTION
ECOCON E-N Plant is designated for
production of lighweight cellular concrete
blocks with 600 - 800 kg/m3 density and
minimum comressive strength 2.0 - 4.0
Mpa. These blocks can be used for
construction of thermal-insulated
bearing and non-bearing walls and
partitions.

12

4
9

RAW MATERIALS

13

ADVANTAGES
affordable price

10

11

possibility to use raw materials locally

available

5
14

low electricity consumption

* - moisture content of filler should not be more

than 10%

pre-planned expansion possibility

15

13

14

14
17

14

13

13

Ordinary Portland Cement is used as binding

material. Any type of sand (dune sand, ordinary
construction sand), stone dust, fly ash and other
neutral materials are used as filler*. Cell
Generating Powder is based on alluminum
powder with addition special chemicals that
initiate and control the aeration (expansion)
process.

1 - Sand Receiveing Hopper

2 - Sand Transporter
3 - Cement Silo with Accessories
4 - Cement Vertical Conveyor
5 - Cement Receiving Hopper
6 - Primary Curing Chambers
7 - Manipulator for lifting and moving moulds
8 - Retrieving carrageway
9 - Reserve space for expansion
10 - Primary cutting machine
11 - Main cutting machine
12 - Secondary curing chambers
13 - Distribution carrageways
14 - Distribution trolleys
15 - Vibrating table
16 - Weghting, mixing and filling station
17 - Final curing area

PRODUCTION CAPACITY
Plant:

E-N-1/1 E-N-1/2 E-N-2/3

Blocks

80 m3

120 m3

240 m3

Production capcity is given for 24-hours

production cycle for blocks with dimension 200 x
200 x 600 mm

Manipulator for lifting mould

Mould on the trolley

DELIVERY
The plant will be produced, delivered , erected
and tested in 6 months period down payment
for planning and engineering. The plant will
be packed and deliveredin 3 containers.

Cutting complex control panel

OTHER REQUIREMENTS
Production area ..................... 1,500 m2
Total land plot ...................... 5,000 m2
Power connection ................... 200 kW
Water consumption ................ 150 l/day
Working shift .............................. 6 - 8 people**

** - including forklift operator and storage

workers

Filling Station

Automatic Cutting Complex: a) main cutting machine; b) primary

cutting machine

05

ECOCON PLANT E-P TYPE

2

3
4

25

11 - Primary cutting machine

12 - Main cutting machine
13 - Wastage removal conveyor
14 - Reserve space for expansion
15 - Secondary curing chambers

1 - Cement Silo
2 - Pipes for cement loading
3 - Sand Vertical Conveyor
4 - Sand Silo
5 - Cement Receiving Hoppe
6 - Intermediate silo
7 - Wet mixer
8 - Primary curing chambers
9 - Retrieving carrageway
10 - Mould manipulator

24

10

11

12

13

14

15

23

16
7

22

21
16

20
Dry mixer for mixing
components

DESCRIPTION
ECOCON E-N Plant is designated for
production of lighweight cellular concrete
blocks with 250 - 800 kg/m3 density and
minimum comressive strength 1.0 - 4.0 Mpa.
Except of this the plant will produce special
dry mix for preparation of lighweight
cellular concrete in-situ by simple mixing it
with water (filling of walls, making floor
screeds, road basements, etc.)
The high quality of products is achieved due
to application of specially deisgned and
produced rotary, high-rpm speed mill that
provides milling of all materials up to nano
dimensions.

19
17

21 - Packing machine
22 - Rotary mill
23 - Weight batch hopper
24 - Screw conveyors
25 - Steel structures
26 - Final curing area

16

ADVANTAGES

A -Weight batch hopper;

B - Rotary mill

RAW MATERIALS

manufacturing of different types of products

possibility to use raw materials locally
available
high level of automation
pre-planned expansion possibility

Plant:

23

18
17

E-P-1/2

Blocks

120 m

Dry Mix

40 t

Ordinary Portland Cement is used as binding

material. Any type of sand (dune sand, ordinary
construction sand), stone dust, fly ash and other
neutral materials are used as filler*. Cell
Generating Powder is based on alluminum
powder with addition special chemicals that
initiate and control the aeration (expansion)
process.

Touchscreen control panel

* - moisture content of filler should not be

more than 10%

PRODUCTION CAPACITY
E-P-2/3
240 m

DELIVERY
The plant will be produced, delivered ,
erected and tested in 9 months period
down payment for planning and
engineering. The plant will be packed
and deliveredin 5 containers.

OTHER REQUIREMENTS
3

80 t

Production capcity is given for 24-hours

production cycle for blocks with dimension 200 x
200 x 600 mm

Dry mix packing station

16

17

16 - Distribution carrageways
17 - Distribution trolleys
18 - Vibrating table
19 - Mould with trolley
20 - FIlling station

Production area ..................... 1,500 m2

Total land plot ...................... 5,000 m2
Power connection ................... 200 kW
Water consumption ................ 150 l/day
Working shift .............................. 6 - 8 people**
** - including forklift operator and storage
workers

Silos with steel

structures

06

BENEFITS OF USING ECOCON

WELLCOME TO ECOCON
When Customer enters ECOCON he
will have uncountable benefits and
peace of mind knowing that ECOCON
is the only manufacturer of this type of
equipment that has operated with the
same name and principles for over 5
years from product innovation to
production of the most cost effective
machinery.
Our plants are designed in such way
that will result in increased profits to
our customers. Equipment is designed
to be user friendly and our plants
require less personnel to run.

SMART SORCING
ECOCON uses only components of the
highest quality, all of which are
sourced from internationally
recognized brands. This not only
ensures that ECOCON provides the
highest quality components but also
has a strong network of suppliers
throughout the world reducing lead
times and offering superior customer
support.

SERVICES
ECOCON offers a comprehensive
solutions ranging from full turn-key
project for specific output requirements
to individual or specific product
solutions.
Our customers have the freedom to
decide whether they wish to pursue a
full turn-key plant or more target
specific plant options. ECOCON
technical expertise is always available to
respond to your needs.
ECOCON will work within your budget.
In some cases ECOCON can even
provide assistance for non ECOCON
auxillary equipment .
In most cases ECOCON can offer
assistance in many languages (English,
Arabic, Russian, and French).

AFTER SALES SUPPORT

With a Service Support team of
highly qualified technical operatives
and service engineers, ECOCON will
ensure that all your after sales
requirements are met with total
professionalism and quality.

SPARE PARTS
ECOCON carries a large stock of all
ECOCON genuine spare parts and
consumables. In order to reduce plant
down time ECOCON can offer soonest
dispatch on the most items

ENIVIRONMENTAL
CONSIDIRATIONS
ECOCON takes environmental
responsibility seriuosly. Our plant is
certified by EPDA (Environmental
Protection Agency). We have
implemented the program of
reducing electricity and water
consumption and maintain the
wastage free facility.

ECOCON Industries L.L.C.

ECOCON Technologies F.Z.C
ECOCON General COntracting L.L.C.
Tel.: +971 4 4542418
Fax: +971 4 4542419
1104, JBC2, JLT, P.O. Box: 36408,
Dubai, United Arab Emirates
Email: info@ecocon.ae
www.ecocon.ae
www.facebook.com/ecocongroup
07