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INTRODUCTION
AAC was invented in mid-1923 in Sweden. It is also known as Autoclaved Cellular
Concrete (ACC) or Autoclaved Lightweight Concrete (ALC). Production process of
AAC is fairly simple. It is made with made with a mixture of fly ash, lime, cement,
gypsum, an aeration agent and water. Aeration process, imparts it a cellular light-weight
structure. AAC products are precast in various sizes and provide structure, insulation,
and fire and mold resistance.
AAC products are offered in various shapes and sizes including but not limited to
blocks, wall panels, floor and roof panels, and lintels. Use of Autoclaved Aerated
Concrete (AAC) blocks in construction industry in India offers interesting proposition
for various segments in the society. For a project developer it means faster and lower
cost construction. For environmentally conscious it means eco-friendly products and for
those who occupy buildings built with AAC blocks it means better safety and lower
energy costs for cooling or heating. Primary raw material for AAC is fly ash.
Thousands of tonnes of fly ash is generated by thermal power plants everyday
and its disposal is a cause of concern. Moreover, using fly ash does not harm the
environment at all. In fact using fly ash takes care of issues related to disposal of fly ash.
Therefore by using fly ash to produce AAC products provides a sustainable, economic
and environment friendly option. At the end it all translates to a better world for future
generations.
CHAPTER 2
COMPARISION BETWEEN AEROCON BRICKS AND
CLAY BRICKS
Comparison between Parameter
Autoclaved Aerated
Concrete
(AAC)
blocks
and
clay
bricks Serial
AAC Blocks
Clay Bricks
Soil Consumption
One sq ft of carpet
area with clay brick
walling will consume
25.5 kg of top soil
Fuel Consumption
CO2 Emission
Labour
Production Facility
Tax Contribution
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8
9
10
11
12
State-of-the-art factory
facility
Contributes
to
government taxes in
form
of
Central
Excise, VAT and
Octroi
Size
625 mm x 240 mm x
100-300 mm
Variation in Size
1.5 mm (+/-)
Compressive Strength 3.5-4 N/m2
Dry Density
550-700 kg/m3
Fire Resistance (8" Up to 7 hours
wall)
Cost Benefit
Reduction in dead
weight leading to
savings in steel and
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One sq ft of carpet
area with clay bricks
will consume 8 kg of
coal
One sq ft of carpet
area will emit 17.6 kg
of CO2
Unorganized sector
with rampant use of
child labour
Unhealthy working
conditions due to
toxic gases
Does not contribute
to government
exchequer
225 mm x 100 mm x
65 mm
5 mm (+/-)
2.5-3 N/m2
1800 kg/ m3
Around 2 hours
None
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concrete
Approx.30%
and cooling
Energy Saving
heating
None
Aerocon blocks are available in various sizes and shapes.They are available in
three types; Infill blocks, Jumbo blocks and Thermal blocks. They are included
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into the category of Green Building materials because they dont emit VOC
(Volatile Organic Compounds) which cause environmental pollution.
Apart from being eco-friendly these blocks are also light weight with high
thermal insulation, fire resistance, sound insulation, have strength and durability,
have consistent quality control and gives a perfect finish with dimensional
stability. Buildings constructed out of these blocks ensure long term
sustainability and save a lot of water during the construction.
Excluding the eco-friendly characteristics of these blocks, they are also used in
construction for various other reasons. There are a number of problems involved
in acquiring the sand and bricks and also the prices of these basic materials are
hiking up. As the traditional construction materials have a higher price the
initiation of Aerocon blocks acts as better substitutes with affordable prices. Due
to these reasons the Aerocon blocks are in great demand.
Hence, it is one of the revolutionary materials that can be used to make the world
a better, greener and cleaner place to live in. It is a revolutionary material that
combines the unique properties such as durability and strength, low weight, very
simple construction technology and excellent environmental performance.
CHAPTER 3
DESIGN CONSIDERATIONS
3.1 General considerations
AAC masonry components(block units) can be used to build load bearing or non load
bearing walls.
O-block units used to build pilasters.
U-block units used to build bond beams and lintels.
Control joints on AAC reinforced walls must be placed at maximum 16 ft. o.c.
3.1.1 Installation Guide
Check foundation.
Receiving and distribution of AAC wall units.
Tools
Equipment
Other materials
Installing O-block for pilasters in first course
Lay the first course over a semi-dry cement mortar levelling bed- to 2 thick.
Corner blocks are laid first and the first course should be completed before
second course installation.
Once corner blocks are placed apply thin bed mortar, to the vertical joints for
other blocks.
Thin bed mortar 1/16 inch to 1/8
These are vertical joints taken through the full wall thickness, and from bottom to
top.
3/8 to thick.
Maximum spacing between control joints should be 15 ft.
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For subsequent courses use only thin bed mortaring on all joints between AAC
blocks.
Minimum overlapping of vertical joints between layers should be 4.
Metal strip ties should be placed every two courses at 1) connection of
secondary walls to main walls 2) connection of walls to concrete columns.
V-shaped metal strips should be set at every two courses unless there are two
pilasters on both sides of control joints and less than 2 from the joint.
Once the wall is built fill the gap using backer rod and seal with caulking.
Fill up pilasters by pouring concrete.
Install temporary supports before putting U-blocks in place apply thin bed mortar
to the vertical joints.
Once U-block are set, place rebars according to construction drawings and with
concrete.
For electrical conduits and piping installation, a chase is cut using an electrical
router or a chasing tool.
When required depth of chase is bigger than maximum depth recommended,
additional O-blocks are used to lodge the pipes or interrupt wall continuity.
After installation, the chase are filled with repair mortar or cement sand mortar.
3.1.11 Renders
Surface patching: Rasp block joints and other areas where AAC surface is out of
plane.
Surface must be cleaned using a scrub brush and any loose or damaged material
be removed.
A rubber float is commonly used to smooth the wall surface.
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Fiber glass mesh: This should be installed directly over one layer of render in all
control joints, around windows, doors and utility locations.
3.1.12 Finishes
AAC masonry walls can be finished with stucco , acrylic texture coats, or a
combination of both, also laminated stones, ceramic or clay tiles, concrete pieces
and ornamental products.
Fig.3.1.12.1: Finishes
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3.2.3 Cement
53-grade Ordinary Portland Cement (OPC) from reputed manufacturer is required for
manufacturing AAC blocks. Cement supplied by mini plants is not recommended due
to drastic variations in quality over different batches. Some AAC factories might plan
their captive cement processing units as such an unit can produce cement as well as
process lime. Such factories can opt for major plant clinker and manufacture their own
cement for AAC production. Cement is usually stored in silos.
3.2.4 Gypsum
Gypsum is easily available in the market and is used in powder form. It is stored in silos.
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CHAPTER 4
PRODUCTION PROCESS
poured into individual containers using screw conveyers. Once required amount of each
ingredient is filled into their individual containers control system releases all ingredients
into mixing drum.
Mixing drum is like a giant bowl with a stirrer rotating inside to ensure proper
mixing of ingredients. Steam might also be fed to the unit to maintain temperature in
range of 40-42o C. A smaller bowl type structure used for feeding Aluminium powder is
also attached as a part of mixing unit. Once the mixture has been churned for set time, it
is ready to be poured into molds using dosing unit. Dosing unit releases this mixture as
per set quantities into molds for foaming.
Dosing and mixing process is carried out continuously because if there is a long
gap between charging and discharging of ingredients, residual mixture might start
hardening and choke up the entire unit. In modern plants, entire dosing and mixing
operation is completely automated and requires minimum human intervention.
This entire operation is monitored using control systems integrated with
computer and CCTV cameras. As with any industrial operation, there is provision for
human intervention and emergency actions integrated inside the control system.
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4.1.3 Cutting
During this process, the pre-cured block goes through cutting and shaping, into different
size & shapes as per requirements. The high workability and large variety of sizes make
AAC production more suitable for massive production with higher mechanization.
Cutting can be done mechanically or manually. With a cutting machine, the production
efficiency and dimensional accuracy is easily achieved.
4.1.5 Grouping
Grouping could be the last step of AAC production (in some AAC plant, the AAC will
be further processed into panels after leaving autoclaves). After the cured AAC leaves
the autoclaves, inspection and packaging is done.
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Gypsum
Lime
OPC
Raw material
Water
Flyash
Weight
Weight Batched
Slurry
Batched
Quantity
Batched
Pouring
Mixture
to mix ingredients
Aluminum
Aluminum
CHAPTER 5
ANALYSIS
5.1 Market
Shelter is third skin, according to a German Concept, which implies its importance next
to human Skin and Clothing. This also shows the attachment of human race to this
fundamental requirement.
Building Material accounts for major component of the construction cost. Depending
on the location they can contribute to 60 - 70 % of the cost of construction. With the
ever increasing population, the demand for housing increases. This directly creates
demand for this prime commodity of building.
Add to the above fact the nearby area of this project site is undergoing a major
infrastructure revolution. As Residential, Commercial, IT companies, and Industrial
establishments are coming in, we can conclude that the Blocks unit will prosper and
flourish in this environment.
There is a central government gadget notification mandating government
departments and CPWD to use 100% Fly Ash based Bricks in their all constructionsdirectly of through contractors. This factor will help the marketability of this product
immensely.
Fly Ash policy of the Government also mandates that 20% of Fly ash Generated by a
power plant must be given free of cost to SME sector on a priority basis.
Just for a rough estimate of CERS, for an annual production of average size
AAC plant, that is 100000CM/Annum, we are likely to get around 12500 CERs on full
capacity Production. At present market rate of 11.5 Euros per CER and @ Rs. 60 per
Euro, we can expect to get additional revenue on CER. But we must expect to take a
cut of around 20 to 30% of CERs, if we want to forward sell the CERs and get the
CDM part sponsored by the buyer.
Grade (%)
Gr-I
(0.045
square
hole
sieve
Gr-II
left
30
45
15
25
5.0
10.0
SiO2
45-55
40
SO3
Degree of
amount)
(0.080 square hole sieve left
fineness
Ignition loss
amount)
Reference : The fineness can be 0.045 or 0.080 square sieve left amount.
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Lime (8-25%)
Item
Grade
1st Gr.
Super Gr.
2nd Gr
A(CaO+MgO)Quality Fraction %
90
75
65
MgO
Quality Fraction %
SiO2
Quality Fraction %
CO2
Digestion temperature
5-15
60-90
10
15
10
15
20
Quality Fraction %
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Cement (6-15%)
SiO2
Al2O3 Fe2O3
CaO MgO
C3S
C2S
C3A
C4AF
21-23
5-7
64-48 4-5
44-59
18-30
5-12
10-18
3-5
Gypsum/Plaster (3-5%)
CaSO4
70%
MgO
2%
Chloride
0.05%
10-15%
Type and recommendation for supply depend on raw materials and mix formula
Metal Content
Approx.
>=65%
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Powder
CHAPTER 6
INDIAN STANDARD FOR AAC BLOCKS
Bureau of Indian Standard Code no- 2185(Part-3):1984 discusses in details regarding the
AAC blocks specifications in India. The prime requirements for AAC blocks (of ISI
standards) in India as per the above said code are as follows.
400,500 or 600mm
Height
200,250 or 300mm
Width
100,150,200 or 250mm
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Density
In
Dry
Condition
Compressive Strength
Mininum
Thermal
Conductivity
In
Dry
Condition
Grade 1
Grade 2
N/mm^2
N/mm^2
W/m.k
Kg/m^2
A
451
550
to
2-0
1-3
0-21
551
650
to
4-0
3-0
0-24
651
750
to
5-0
4-0
0-30
751
850
to
6-0
5-0
0-37
851
1000
to
7-0
6-0
0-47
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CHAPTER 7
ADVANTAGES AND DISADVANTAGES
7.1 Advantages of using Autoclaved Aerated Concrete blocks
7.1.1 Lightweight
AAC blocks are about 50% lighter than clay bricks of equivalent size. This translates
into less dead weight of buildings and allows entire structure to be lighter therefore
reducing amount of steel and concrete used in structural components like beams,
columns and roof/floor slabs.
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7.1.6 Longevity
AAC does not lose strength or deteriorate over time. Buildings constructed with AAC
do not require routine repairs that are required for buildings using clay bricks.
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The production cost per unit for ACC is higher than other ordinary concrete.
Number of manufacturer is limited. So, cost will drastically increase in places far
from the manufacturer and need to travel a long distance.
Construction with autoclaved aerated concrete may will need special permission.
Environmentally friendly
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CHAPTER 8
CONCLUSION
As a construction system, AAC provide significant environment and other
benefits for the building owner. The short and long term effect of using AAC
compared to many other materials results in lower energy consumption, reduced
operating costs, greater safety and comfort, and a healthier and more trouble
free building. These features provide a better investment for building owner and
for environment.
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8.1 REFERNCES
Advances in Cement Technology
Edited by S.N.Ghosh
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