INTRODUCTION
AAC blocks are a lightweight, precast,
foam concrete building material. AAC blocks were invented in the mid-1920s and
since then has become the most widely used building material in Europe, Asia,
America and Africa. AAC blocks are best for foundations, inner leaves of cavity
walls, dwelling partitioning walls, plus inside, external, and firewalls in
both load-bearing and non-load bearing designs. These building blocks are
proven as being highly efficient for both house construction and for commercial
and industrial buildings. In addition to the versatility and energy efficiency
properties, AAC blocks are characterized by their ease of working and
construction. AAC blocks can easily be sawn even with a hand saw to meet the
required size of a block. This results in greater construction speed which can
deliver cost savings. Notable savings can also be made in speedy weatherproofing, reduce scaffolding costs, and less on-site waste. In addition, when
using the thin-bed joint application, you use up to 5 times less mortar. Our
AAC blocks are 33% lighter compared to traditional bricks and depending on
project design, savings up to 20% in structural costs can be achieved, due to
reduction of dead load.
AAC
blocks come in 4 standard sizes:
600mm x 200mm x
100mm
600mm x 200mm x
150mm
600mm x 200mm x
200mm
600mm x 200mm x
225mm
MANUFACTURING
PROCESS
●
RAW MATERIAL PREPARATION
Autoclaved Aerated
Concrete (AAC) is produced by mixing pulverised fly ash, cement, gypsum, lime,
water and a small quantity of aluminium powder.
●
BATCHING PLANT
A fully automated
batching plant enables accurate dosing, weighing, and mixing of all the raw materials.
The mixture is then poured into moulds, where chemical reactions cause it to
rise like a cake.
●
CUTTING
After the cake has
attained sufficient strength, it is removed from the mould and cut with wires
onto blocks with precision accuracy.
●
AUTOCLAVING/CURING
After cutting, the AAC
blocks are hardened by autoclaving in a saturated steam atmosphere at a temperature of approx. 180–190-degree C. It is this steam curing that creates
the unique crystalline structure and lends AAC its excellent qualities in
comparison to building materials that are not steam cured.
●
SORTING AND PACKING
After autoclaving the
blocks are packed and are then ready for dispatch to the construction site.
●
RECYCLING
The product waste is placed back into the production process
making it a totally recyclable product.
ADVANTAGES
●
SUPERIOR STRENGTH
AAC blocks have a
compressive strength of 3-5 MPa. The high load-bearing strength makes them an
ideal choice for external and internal walls, load and non-load bearing walls,
partition walls and fire-break walls.
●
LIGHTWEIGHT
AAC blocks are 33%
lighter than other construction materials, therefore, resulting in a reduction in
freight and construction costs.
●
ENERGY EFFICIENT
AAC blocks have excellent
thermal insulation properties that retain heat during winters and repel the
extreme heat during summers, leading to a significant reduction in heating and
cooling costs.
●
LARGE SIZE
Larger size blocks lead
to faster masonry work.
●
ACCURACY
AAC blocks are produced
to the exact sizes needed before leaving the factory. There is less need for
on-site trimming. Since the blocks fit so well together, there is less use of
finishing materials such as mortar.
●
PEST RESISTANT
There are no toxic gases
or other toxic substances in AAC blocks. It neither attracts rodents or other
pests nor can it be damaged by such.
●
LONG-LASTING
The life of AAC blocks is
extended because they are not affected by harsh climates or extreme weather
changes. They will not degrade under normal climate changes.
●
FIRE RESISTANCE
The porous structure of
AAC blocks give them superior fire resistance and make them non-combustible.
●
SOUNDPROOF
AAC blocks soundproofing
properties make them an ideal choice for hotels, hospitals, schools, commercial
and residential buildings.
●
COST-EFFECTIVE
AAC blocks are cost-effective as they are lightweight, large in size, have good workability, etc.
Depending on project design, savings up to 15-20% in structural costs can be
achieved when our blocks are used as compared to other construction materials.
●
ENVIRONMENT FRIENDLY
AAC blocks are primarily
composed of fly ash and thus help in reducing pollution. These blocks are a
green building product as there is no pollution or waste material in the
manufacturing process.
AAC BLOCKS V/S TRADITIONAL CLAY BRICKS
|
SR
NO |
PARAMETER |
AAC
BLOCKS |
RED
CLAY BRICKS |
|
1. |
Size |
600x200x100-300 mm |
230x75x150 mm |
|
2. |
Accuracy |
Variation 1.5 mm (+/-) |
Variation 5 mm (+/-) |
|
3. |
Compressive Strength |
3-5 MPa |
1.5-2 MPa |
|
4. |
Mortar Consumption per cum with 1:6 |
0.5 Bag of cement |
1.35 Bag of cement |
|
5. |
Chemical Composition |
Fly-ash is used approx. 60% which reacts with binders (lime and
cement) to form AAC which is an inert material |
Soil is used which contains many inorganic impurities like
sulfates which result in efflorescence |
|
6. |
CO2 Emission per square foot |
2.2 kg |
17.6 kg |
|
7. |
Dry Density |
550-650 kg/m3 (Oven Dry) |
1900 kg/m3 |
|
8. |
Fire Resistance |
Up to 7 hours |
Up to 2 hours |
|
9. |
Cost-Benefit Factor |
Depending upon project design, savings up to 20% in structural
costs can be achieved due to reduction of dead load |
None |
|
10. |
Energy Saving |
Up to 30% savings can be achieved in heating and cooling costs
due to excellent insulation properties |
None |
|
11. |
Plastering Material |
Exception dimensional accuracy allows for a final 6 mm skin coat |
Traditional 3 coat plaster is required |
|
12. |
Breakages |
3% |
15% |
|
13. |
Environmental Impact |
A green building product as there is no pollutant or discharge
in the manufacturing process |
Erosion of fertile topsoil is a crime against nature. |
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