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Aerocon Blocks
55
AAC BLOCKS
Autoclaved Aerated Concrete
What an AAC Block is made of:
Composition
- Fly Ash/Sand(69%)
- Cement(8%)
- Lime(20%)
- Gypsum(3%)
- Aluminium(0.08%)
How are AAC Blocks manufactured?
Manufacturing
Raw Material Preparation
STEP 1
The preparation of raw material consists of mixing fly ash with water to form fly ash slurry so that the fly ash can be mixed with other raw materials such as cement, gypsum, and aluminum powder in the required proportion.
Dosing and Mixing
STEP 2
- This process is an important one as the quality of the final product is dependent. The ratio in which the raw materials are to be added is decided based upon the required final product.
- Fly ash is pumped into a container. Once the desired weight is poured in, pumping is stopped.
- Similarly, lime powder, cement, and gypsum are poured into individual containers using conveyors.
- Once the required amount of each ingredient is filled into their individual containers control system releases all ingredients into the mixing drum.
- Once the mixture has been churned for a set time, it is ready to be poured into molds using the dosing unit.
Casting, Rising and Curing
STEP 3
- Before casting, molds are coated with a thin layer of oil in order to ensure that green-cake does not stick to molds.
- Aluminum reacts with CaOH and water and releases hydrogen gas.
- The bubble size is 2- 5mm. This is the reason behind the lightweight and insulating properties of the AAC block.
- When the rising process is over, green-cake is allowed to settle and cure.
- Usually rising and the pre-curing process takes around 1-4 hours.
- AAC is cured in a large pressure vessel called an autoclave. An autoclave is normally a steel tube of 3m diameter and 45 meters long.
- Steam is fed into the autoclaved at high pressure, typically reaching a temperature of 180°C.
Demoulding and Cutting
STEP 4
- Once it had achieved cutting strength, it is de-molded and cut as per requirements.
- Generally, market available sizes of AAC Blocks are:
- 600 x 200 x 100
- 600 x 200 x 150
- 600 x 200 x 200
Comparison Chart
Here are the average market prices for an AAC block:
Size-cost comparison
Properties of AAC Block
Properties
Uses of AAC block
Applications
1.External and internal walls
2. Multi-storey construction
3. Kitchen surfaces
4. Residential , industrial and commercial building
Advantages and Disadvantages
Advantages!
ADVANTAGES
- Three times lighter than clay brick therefore the overall cost is less.
- Bigger size, less joints, therefore the process takes lesser time.
- Less mortar gets used.
- Water absorption is less than 10%
- Fire resistance
- Thermal Efficiency
- Neatly trimmed
- Less labour and transportation cost.
- Eco- friendly
Disadvantages :(
DISADVANTAGES
- Dangerous to use in load-baring structures.
- Improper installation can cause cracking of blocks which will affect the final finish of the building.
- It cannot be used below plinth level.
- Preferred mostly for high rise buildings.
- Should be handled with care as it is a porous material.
Steps to use AAC bricks in construction
Methods of construction
Step 1 - Layout wall lines.
Step 2 - Start the leveling bed.
Step 3 - Set the first corner block.
Step 4 - Mix thin-bed mortar.
Step 5 - Set second corner block.
Step 6 – Repeat for additional corners.
Step 7 - Fill-in completion of level course.
Step 8 - Install lintels as required.
VIDEO!!
VIDEO!!
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SOUMYA YASHFEEN TANISHQA RITHVIKAA VARUN