1.1 General Background: Seminar Report 2021
1.1 General Background: Seminar Report 2021
CHAPTER 1
INTRODUCTION
Bricks are one of the most important building materials in the India. In recent years, with
expanding urbanization and increasing demand for construction materials, brick kilns
have grown to meet the demand. It has directly or indirectly caused a series of
environmental and health problems. At a global level, environmental pollution from
brick-making operations contributes to the phenomena of global warming and climate
change. Also, extreme weather may cause degradation of the brick surface due to frost
damage. Global warming and Environmental pollution is now a global concern. Various
types of blocks can be used as an alternative to the red bricks, to reduce Environmental
pollution and Global warming. AAC blocks may be one of the solutions for brick
replacement. Similar to foam concrete, Autoclaved Aerated Concrete (AAC) is one of the
certified green building materials, which can be used for commercial, industrial and
residential construction. It is porous, non-toxic, Perusable, renewable and recyclable.
AAC was developed in 1924 by a Swedish architect, who was looking for an alternate
building mate-rial with properties similar to that of wood having good thermal insulation,
solid structure and reac-tion. It is one kind of new type green warm preservation wall
material formed easy to work with, but without the disadvantage of combustibility, decay
and termite damage. As AAC Block uses fly ash, sand as main raw material, cement, lime
as accessory materials, aluminium powder as forming agent, it refers to foaming through.
Chemical through raw materials grinding, batching and mixing, pouring and foaming,
quiet stop and cutting, autoclave curing processes. It has lightweight, high strength, good
durability, heat preserva-tion, sound insulation, fire proofing, impervious, good anchoring
properties.
Significant research studies have been conducted on the development of new construction
materials using different kinds of material. However, the application of these construction
materials in real con-struction is limited. Therefore more research is needed to study the
actual behaviour or performance of new construction materials under field conditions to
encourage their practical applications. Many research studies had been conducted
utilizing various new construction materials. Most of these re-search works focused on
the physical and mechanical properties of construction products. Some of those studies
attempted to investigate the durability performance of several construction materials
including AAC block like material. However, more research studies are needed to
confirm the beneficial effects of new construction material. In this context, research work
has been started to investigate Cost effectiveness by using AAC Blocks for building
construction. This paper highlights different aspects of using AAC block masonry
construction. Findings of comparative statistical analysis of cost effectiveness of using
AAC block instead of traditional bricks are presented in this paper.
AAC (Autoclaved Aerated Concrete) was invented in the mid-1920s by the Swedish
architect and inventor Johan Axel Eriksson. AAC is one of the major achievements of the
20th century in the field of construction. It is a lightweight, precast building material that
simultaneously provides structure, insulation, and fire and mold resistance. AAC Blocks
is a unique and excellent type of building ma-terials due to its superb heat, fire and sound
resistance. AAC block is lightweight and offers ultimate workability, flexibility and
durability.
Main ingredients include fly ash, water, quicklime, cement, aluminium powder and
gypsum. The block hardness is being achieved by cement strength, and instant curing
mechanism by autoclav-ing. Gypsum acts as a long term strength gainer. The chemical
reaction due to the aluminium paste provides AAC its distinct porous structure, lightness,
and insulation properties, completely different compared to other lightweight concrete
materials. The finished product is a 2.5 times lighter Block compared to conventional
Bricks, while providing the similar strengths. The specific gravity stays around 0.6 to
0.65. This is one single most USP of the AAC blocks, because by using these blocks in
structural buildings, the builder saves around 30 to 35 % of structural steel, and concrete,
as these blocks reduce the dead load on the building significantly.
AAC is a long proven material. AAC block is used in a wide range of commercial,
industrial and residential application and has been in use in EUROPE over 90 years, the
Middle East for the past 40 years and in America and Australia for 25 years. It’s an
estimate that AAC now account for over 40% of all construction in UK and more than
60% of construction in Germany. In India production of AAC block started in 1972. This
unit is proposed to manufacture AAC Blocks by consuming the Fly-Ash as one of the
prime raw material. Fly-Ash, a major raw material with 70% proportion in AAC Blocks,
an indispensable by-product of Thermal Power Plants, is an environmental threat across
the globe. Power plants are facing an ever increasing challenge of disposal of this
polluting agent.
Infill Blocks
The size of the Infill Aerocon brick is 600X600 mm and the thickness varies in the ranges
of 75,100,125,150,200 mm. The main advantage of Infill blocks is that they can easily
replace 60% of the concrete in roof slabs and thus help in saving significant amounts of
concrete, steel, labour, water, plaster etc. These blocks are especially suitable for building
roofs in large column-free constructions.
• Jumbo blocks
Jumbo blocks are typically in the size of 600X300 mm, and thickness ranges from
75,100,125,150, to 200 mm. The unique large size of Jumbo Aerocon bricks results in the
usage of much fewer bricks and hence less mortar is required. These bricks are more
suitable for non-load bearing walls, multi-storied buildings etc.
• Thermal blocks
These blocks are also called as Aerocool thermal blocks whose size and thickness is 300
x 200 mm and 50 mm respectively. These blocks are ideal for roofing since they delay the
transmission of heat flow and also help interiors remain warm during winters and cool
during summers.
• Light-weight:
The typical aircrete arrangement of Aerocon bricks resulted in light-weight blocks. Their
weight is only one third the densities of clay bricks which make them simple to handle
on-site. Reduced weight of the brick decreases the dead weight on the structure; hence
Aerocon bricks are perfect for low load bearing soil and for seismic zones. Even for
building additional floors in an accessible building, Aerocon blocks are ideal choice as
their less weight will not affect the strength of the structure. Using Aerocon bricks from
the foundation stage of the building helps to save considerable amounts of concrete and
steel.
• Fire resistance:
Walls build by means of Aerocon bricks, with a minimum thickness of 100mm can resist
fire for up to four hours which make them the safe choice in construction. Especially for
industries and companies, which are susceptible to fire accidents, these blocks are of
much help.
• Sound insulation:
One more remarkable characteristic of Aerocon bricks is their sound insulation. A good
quality Aerocon brick can reduce the sound transmission up to 42 decibels. Apparent
manufactures of Aerocon bricks do have a sound transmission class rating for their
blocks, which made them perfect for wall construction in hotels, auditoriums, hospitals,
etc., where sound insulation is quite essential.
• Thermal insulation:
Due to the closed cell structure of the Aerocon blocks, they afford outstanding thermal in-
sulation. They help interiors to stay cooler during summer and warmer during winter
which further aid the user to save electricity bills and thus help in conserving natural
resources.
Aerocon bricks made with elevated weight ratio help in building stronger and
economicalv structure. As they remain unaltered by the environmental conditions they
ensure longer life for the building.
The autoclaving process used in the manufacturing of Aerocon bricks gives ideal
dimensions to the blocks along with low tolerances. Dimensionally ideal blocks help in
building uniform, thin walls with faultless finish.
General considerations
AAC masonry components (block units) can be used to build load bearing or non load
bearing walls.
1. Installation Guide
Check foundation.
Receiving and distribution of AAC wall units.
2. Installation requirements
Tools
Equipment
Other materials
Installing O-block for pilasters in first course.
Lay the first course over a semi-dry cement mortar levelling bed- ½” 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 ½” thick.
Maximum spacing between control joints should be 15 ft.
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 –
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.
Before pouring concrete place rebar and anchor bolts according to construction
drawings.
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.
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.
Fiber glass mesh: This should be installed directly over one layer of render in all
control joints, around windows, doors and utility locations.
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.
CHAPTER 2
RAW MATERIALS
Sand
Fine aggregate are basically sand consists of crushed stone with maximum particles
passing through a 4.75 mm sieve.
Aluminium
Aluminium is an expansion agent. When the raw material reacts with aluminium powder,
air bubble introduced due to reaction between calcium hydroxide, aluminium and water
and hydrogen gas is released. Aluminium powder is used at a rate of by volume.
Aluminium power reacts with calcium hydroxide and water to form hydrogen. The
hydrogen gas forms and doubles the volume of raw mix creating gas bubbles up to 3 mm
(1/8 inch) in diameter. At the end of the foaming process, the hydro-gen escape into the
atmosphere and is replaced by air.
Quartz sand
The sand which is used to increasing the strength of blocks. Before the sand is used for
manufacturing it should be tested. In sand the silica content, moisture content and residue
is to be checked. The silica content should be below 98% and residue ranges from 98 –
100 %.The wastages should not be more. Moisture content 0.06%.some cases the sand is
not to be used.
Calcined gypsum
Gypsum is easily available in the market and is used in powder form. Gypsum is easily
available in the market and is used in powder form. It is stored in silos. Gypsum is a very
soft mineral composed of calcium sulfate dehydrate. It has the chemical formula of
CaSO4.2H2O gypsum is almost PH neutral. It is colorless to white, may be yellow, blue.
And it is translucent, very soft, and water-soluble. Nearly 20 kg of gypsum is used for
3.024 m3 mould.
Lime (mineral)
Cement
Portland cement is generally preferred. Mostly India cement where used in manufacturing
of auto-claved aerated concrete blocks. Cement is a binding material, used to binding the
ingredients. The amount of cement is used for 3.024m 3 mould is 440 kg – 450 kg. Initial
and final setting time of the cement is checked. It ranges from 165 – 180 minutes. Cement
is a binder, a substance used in construction industry that sets and hardens and can bind
other materials together Color- White Density of cement -1440kg/m 3 Type - OPC Grade
53 Compressive strength – 53 MPa.
Water
Potable water should be used which should conform with the general requirements of the
concrete.
Fly ash
Fly ash is waste industrial product used for reduction of construction cost. The density of
fly ash ranges from 400-1800 kg/m3. It provides thermal insulation, fire resistance and
sound absorption. The type of fly ash used is of Class C with contains 20% lime (CaO)
and loss of ignition not be more than 6%. A byproduct of thermal power plants and is an
important raw material in the manufacture of AAC. Fly ash is a byproduct from burning
pulverized coal in electric power generating plants. Fly ash is the best known and one of
the most commonly used pozzolans. The amount of fly ash is used in manufacturing of
AAC blocks is 1150 – 1160 kg for 3.024m3. The factor for waste slurry and pure slurry is
150 & 550 (for blocks), for lintels 200 &700.
CHAPTER 3
MANUFACTURING PROCESS
Step 1: Raw Material Preparation
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 aluminium powder in the required proportion.
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.
Aluminium is about 0.08% of total dry materials in the mix and the water ratio is 0.6 -
0.65.
1. Fly ash is pumped into a container. Once the desired weight is poured in, pumping
is stopped.
2. Similarly, lime powder, cement, and gypsum are poured into individual containers
using conveyors.
3. Once the required amount of each ingredient is filled into their individual
containers control sys-tem releases all ingredients into the mixing drum.
4. Once the mixture has been churned for a set time, it is ready to be poured into
molds using the dosing unit.
1. The molds could be of various sizes depending upon the required quantity of mix.
2. Before casting, molds are coated with a thin layer of oil in order to ensure that
green-cake does not stick to molds.
3. Aluminium reacts with Calcium Hydroxide and water and releases hydrogen gas.
This leads to the formation of tiny cells causing the slurry mix to expand.
4. Such expansion may be thrice its original volume. The bubble size is about 2- 5
mm. Thus, this is the reason behind the lightweight and insulating properties of
the AAC block.
5. When the rising process is over, green-cake is allowed to settle and cure.
6. Usually rising and the pre-curing process takes around 60-240 minutes.
7. Autoclave Aerated concrete is cured in an autoclave – a large pressure vessel.
8. 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 pressure of 800kPa to
1200 KPa and a temperature of 180°C.
1. Once it had achieved cutting strength, it is de-molded and cut as per requirements.
2. Generally, market available sizes of AAC Blocks are 600 x 200 x 100, 600 x 200
x 150, 600 x 200 x 200.
Step 5: Curing
For this block normal water curing cannot be done has it will increase the weight of the
block by fill-ing up the pores in the block so to increase the strength of the block in short
period of time and also to reduce the block weight steaming curing is done. Generally
curing is done to reduce the heat induced inside the concrete and to increase the strength
of concrete.
In industries the aerated concrete block production process, autoclave steam curing is a
must, and this process determines the strength and performance of products. In the
manufacturing process, a correct autoclave curing system can achieve light brick masonry
strength requirements and ensure excel-lent performance, it can also make the
manufacturing process smoother. Inside the autoclaving the block hardens and increases
in strength and reduces in weight by vapouring the water present inside the block this also
induces expansion of voids. But in this project a steel drum consisting of a tray is used for
steam curing here the blocks are placed on top of the tray and the lower portion of drum
consists of water the drum is heated by means of burning wood at the bottom, the top of
the drum is sealed with lid in this the pressured cannot be maintained properly but it
produces steam equal to the autoclave in this the block dries up hardens and reduces
weight this also increase the voids of block, but only thing is the production of gel is for
short period of time the curing process is done for about 6-8 hours before that the block
demoulded is first pre cured by placing in sun and then placed inside the curing chamber.
CHAPTER 4
Initial rate of absorption (IRA) test was conducted, in accordance with ASTM C 67. The
specimen was kept in a tray containing distilled water up to a depth of 25 mm from the
bottom of the tray for 60 Seconds. Later, the specimen was removed from the tray and
weighed, thus the initial rate of absorp-tion is obtained.
Dry Density
This test was carried out on blocks samples collected randomly in and around Bangalore
City. IS: 2185- (Part I) 1979 specifications were followed to conduct this test. The density
of AAC ranges from 250 to 1,800 kg/m3, as compared to 2400-2600 kg/m3 for
conventional concrete. Therefore, the weight of a structure built with foam concrete
would undoubtedly be reduced significantly, leading to tremendous savings in the use of
reinforcement steel in the foundations and structural members. AAC blocks are ideal for
the entire building structure and possess high structural integrity. The product is light
weight and easy work ability means that it is very quick to install on site, thereby saving
in steel, cement, and mortar and plastering costs.
Water Absorption
The blocks were tested in accordance with the procedure laid down in IS: 2185 (Part I)-
1979. The code specifies two methods to be adopted, by 5 hour boiling water test or the
24 hour cold water immersion test. The latter method was adopted. Water absorption for
blocks should not be greater than 20% by weight up to class 12.5 as per IS: 1077- 1992
specifications.
The compressive strength of the block is the main contributing factor for the strength of
masonry. IS:2185 (Part-I)-1979 specifies the minimum compressive strength. The
minimum compressive strength for a non-load bearing unit is 1.2MPa while that for a
load bearing unit, it varies from 1.6MPa to 5.6 MPa. This test was conducted as per the
specification laid in the IS: 3495-1992.
The test specimen was placed centrally on two roller supports and load was applied
through another roller, taking care not to cause local failure. The transverse load was
applied at a uniform rate not exceeding 300 N/min through the central roller. The
individual breaking load was recorded and flexural strength was calculated using pure
bending equation. Stress-Strain Characteristics Strain measurements were carried out on
the block specimens with a uniaxial compressive load applied parallel to its length in a
600kN UTM. Steel plates were placed on the specimens to facilitate uniform
compression.
The strains were measured using a demountable mechanical strain gauge of 100mm
gauge length. The relative deformation of the studs mounted on the specimen was
measured using a digital dial gauge of least count 0.001mm.
Compressive strength
Thermal conductivity
CHAPTER 5
The use of recycled industrial waste (fly ash), non-toxic ingredients, no emitting gases,
and fewer energy consumptions makes the ACC Blocks eco-friendly and sustainable.
2. Lightweight
The AAC Blocks are 3 to 4 times lighter than bricks, 30% lighter than that of concrete
which helps in reducing the dead load of the building, thereby allowing construction of
taller buildings.
Tiny air pores and thermal mass of blocks provide excellent thermal insulation, thus
reducing heating and air conditioning costs of a building.
4. Fire Resistant
5. Acoustic Performance
As the AAC block is porous in nature, the sound absorption quality is superior. It offers
sound attenuation of about 42 dB, blocking out all major sounds and disturbances which
makes it ideal for schools, hospitals, hotels, offices, multi-family housing and other
structures that require acoustic insulation.
AAC blocks can be easily cut, drilled, nailed, milled and grooved to fit individual
requirements.
7. Seismic Resistant
Lightweight blocks reduce the mass of a structure, thus decreasing the impact of an
earthquake on a building. Non-combustible nature provides an advantage against fires,
which commonly accompany earthquakes.
8. Faster Construction
Construction of AAC Blocks reduces the construction time by 20%. As different sizes of
blocks help reduce the number of joints in wall masonry. The lighter weight of the blocks
makes it easier and faster to transport, place and construct the masonry.
CHAPTER 6
CHAPTER 7
CONCLUSION
The use of fly ash in Aerocon panels and substituting them for wood and metal makes
them an eco-friendly product. The panels have high thermal and acoustic insulation
properties and are resistant to fire, water and termites. They have wide applications in
construction of Pre-Fab houses, high rise buildings, shelters etc... Compared to
conventional building products, they take much less construction time, they are reusable
and can be easily relocated. In difficult terrains where other materials are not suitable this
product becomes the favoured option for construction. The design of the product makes it
suitable for application in seismic and cyclone prone zones.
These are suitable for walls in RCC framed building. It helps in reducing dead load of
structure. The workability of AAC helps to eliminate waste on the jobsite. Density of
AAC block is 1/3 that of tra-ditional clay brick Compressive strength of AAC blocks is
comparatively more than traditional clay brick. Cost of construction reduces by maximum
up to 20 % as reduction of dead load of wall on beam makes comparatively lighter
members. Use of AAC reduces overall labour and material costs. Utilization of fly ash
leads to the reduction in the cement consumption in the product which results in reduction
of greenhouse gases. As both side face of AAC block wall are plane, thickness of plaster
is very less, and so there is substantial reduction up to 50% in requirement of cement and
sand for plaster work. The energy consumed in the production process emits no pollutants
and creates no by-products or toxic waste products. Superior thermal insulation of the
blocks reduces the need to turn on the air conditioner which in turn helps in saving
electricity costs.
CHAPTER 8
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May 2020.
3. Kulbhushan K., Kumar S., Chaudhary R., Ahmad S., Gupta S., & Chaurasia R.
(2018). A Contextual Analysis of the Advantages by Using Lightweight Concrete
Blocks as Substitution of Bricks, International Research Journal of Engineering
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