Autoclaved Aerated Concrete Blocks

Autoclaved Aerated Concrete Blocks
Name : Sayabanna
Reg. No. : 14ETCE001020
Department : Civil Engineering

Programme : B. tech
Guide : Harshad R. Parate
1
Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
1. Introduction.
Autoclaved aerated concrete(AAC)

 It is a type of precast concrete composed of natural raw materials
giving great benefits and better energy efficient performance
 AAC is a derivative of fly ash that is combined with cement, lime and
water and an aerating agent
 AAC is lightweight, precast building product
 AAC blocks contains 80% air
2
1. Introduction cont…..
 AAC is also known as Autoclaved Cellular concrete (ACC), Autoclaved
Lightweight Concrete (ALC), Autoclaved Concrete, Cellular
Concrete, Porous Concrete, Aircrete, Hebel Block
 AAC is available in blocks and panels of various sizes
3
2. History
 In 1880 a German researcher Michaelis was granted a patent on his
steam curing processes
 Czech Hoffman successfully tested and patented in 1889 the method

of “aerating” the concrete by carbon dioxide
 Americans Aylsworth and Dyer used aluminium powder and calcium

hydroxide to attain porous cementitious mixture for which they also
received a patent in 1914
 Swede Axel Eriksson made a serious next step towards developing

modern AAC when in 1920 he patented the methods of making
aerated mix of limestone and ground slate
4
3. Aim of the Seminar
 To Study the properties, manufacturing, advantages of AAC
blocks and compare with normal clay bricks
5
4. Objectives
 To study the literature survey
 To study the properties of AAC blocks
 Manufacturing process of AAC blocks
 To study the advantages and limitations of AAC blocks
 To study the applications of AAC blocks
 Comparing AAC blocks with Conventional blocks
6
4.1. Literature Survey
 Presented by: Ritu Patel, Shreya Mevada, Yogita Patel, Jalpa Patel,
Kamini Sharda,
7
4.1. Literature Survey cont..
 Presented by: Ritu Patel, Shreya Mevada, Yogita Patel, Jalpa Patel,
Kamini Sharda,
8
4.2. Physical Properties of AAC blocks
 Light weight
 Thermal insulation
 Fire resistance
 Durability and moisture resistance
 Toxicity and breath ability
 High load bearing capacities
 Excellence sound insulation
9
4.2. Properties of AAC blocks
Density 551-650kg/cum
Compressive strength Minimum 30kg/cm2
Thermal conductivity 0.162W/mK (avg.)
Resistance to fire 2-6 hours
Drying shrinkage 0.1%
Design gross density 850kg/cum
10
4.3. Manufacturing
4.3.1. Materials Used
Fly ash Lime
Cement
11
4.2. Manufacturing
4.3.1. Materials Used
Silica Sand
Aluminium Powder
12
4.2. Manufacturing
13
4.3.2. Manufacturing
Codes Specifications
BIS 2185(part 3) Specification of

material
BIS 6041 Construction of AAC
masonry
BIS 6441(part 1-9) Testing procedure
BIS 6072, 6073 Autoclaved reinforced

panels
14
4.3.3. Sizes of AAC
 The standard block size is 200mm height by 600mm long. Block

thickness can range 50mm to 300mm, but for residential construction
the most common block widths are used are 100mm, 150mm and
200mm
 Standard panel size is 600mm wide by 75mm thick with length

ranging from 1200mm to 3000mm
15
4.3.3. Sizes of AAC blocks
16
4.3.4. Other modes of AAC
 AAC U-Blocks
17
 AAC Lintels
18
 AAC Wall Panels
19
 AAC Floor Panels
20
 AAC Roof Panels
21
4.3.1. Advantages of AAC
22
23
 Improved thermal efficiency reduces the heating and cooling load in
buildings
 Light weight saves cost & energy in transportation, labour expenses

Larger size blocks leads to faster masonry work
 Environmental friendly : it helps to reduce at least 30% of

environmental waste as opposed to going with traditional concrete
There is a decrease of 50% of greenhouse gas emissions
 Reduction in dead load
 blocks are also termite, pest, mold and fungus resistant and hence
greatly improve the indoor air quality
24
4.3.1. Advantages of AAC cont…..
 Uniform sizes leads to thin surface finishes
 Delays transmission of heat
 Material available through out the year i.e. no seasonal variation
 Totally inert material – no salt leaching, hence less maintenance cost
 Quick assembly : Since it is a lightweight material and easy to work

with, the assembly is much quicker and smoother
 Accuracy: The panels and blocks made of autoclaved aerated concrete

are produced to the exact sizes needed before they even leave the
factory
25
4.3.2. Limitations of AAC
 Production cost per unit for AAC is higher than other ordinary
concrete
 Brittle nature: they need to be handled more carefully than clay bricks
to avoid breakages
 Contractors are less familiar with the product
 Consistency in quality and colour may be difficult to obtain
 Unfinished exterior walls should be covered with an exterior

cladding to protect them from wear and tear
 Skilled labours are required

26
4.3.3. Case Study
International Journal of Scientific & Engineering Research Volume 4,
Issue 1, January-2013 1 ISSN 2229-5518
 Size of block
 200mm*200mm*200mm
 Dry density
 597.42 kg/cum
27
4.3.3. Case Study Cont..
 Water absorption
 36.08%
 Compressive Strength
 3.2 MPa
 Flexural strength
 0.44 MPa
28
4.4. Applications of AAC blocks
 Hospitals
 Industrial buildings
 Auditorium and Theaters
 Education Institute construction
 Medical and Clinics
 Cold storage
 Hotel and restaurants

29
4.4. Applications of AAC blocks
 Firewalls
 Pipeline and culvert installation
 Retaining wall
 Sound absorption for partition walls
 Fire proofing panels
 Tunnel lining
30
4.5. Comparison with Clay bricks
 AAC blocks are one third lighter than conventional clay bricks, thereby
reducing the dead weight of the structure drastically
 Light weight structure decreases construction cost due to reducing

steel, Cement and Excavation
31
4.5. Comparison with Clay bricks cont…
 AAC blocks are 7 times bigger than the size of the conventional bricks.
Bigger size means less number of joints
 Less joints results in lesser quantity of mortar for building and there is
overall 60% reduction in use of Mortar
32
4.5. Comparison with Clay bricks cont…
 AAC blocks have uniform shape and texture, which gives even surface
to the walls. There is overall 35% reduction in the cost of plastering
33
4.5. Comparison with clay bricks cont…
Parameter AAC blocks Clay bricks
Soil consumption Uses fly ash which is waste 1 sq ft of carpet area with clay
product of the thermal power brick walling will consume 25.5
plant. kg of top soil.
Fuel consumption One sq ft of carpet area with AAC One sq ft of carpet area with clay
blocks will consume 1 kg of coal bricks will consume 8 kg of coal
Co2 emission One sq ft of carpet area will emit One sq ft of carpet area will emit
1.5 kg of CO2 12.0kg of CO2
Compressive Not less than 3 N/mm2 3-5 N/mm2

strength
34
Parameter AAC blocks Clay bricks
Dry density 551-600 kg/m3 1920 Kg/m3
Consumption of 0.77 bags of cement / Cum 1.44 bags of cement/ Cum

cement mortar
Thermal 0.12 w/m-k 0.8 w/m-k

conductivity
Cost benefits Reduction in dead weight leading None

to savings in steel and concrete.
35
36
5. Conclusions
 AAC is the one of the most sustainable building materials today
 AAC is a technological revolution
 It provides convenience to build
 Economics of construction
 Long lasting and strong
 Eco-friendly
 Comforts of living
 AAC is used in wide range of commercial, industrial and residential

applications
37
6. References
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
2. International Journal of Chemical, Environmental & Biological

Sciences (IJCEBS) Volume 1, Issue 2 (2013)
3. http://civil.srpec.org.in/files/Project/2013/4.pdf
4. https://www.slideshare.net/indiablockmachine/aac-the-wonder-
building-material
5. https://www.slideshare.net/sraruna/autoclaved-aerated-concrete-
47254059
6. “Google Images” for Images
38
39

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Autoclaved Aerated Concrete Blocks

Department : Civil Engineering

Autoclaved aerated concrete(AAC)

 AAC is lightweight, precast building product

 AAC blocks contains 80% air

 AAC is available in blocks and panels of various sizes

 Czech Hoffman successfully tested and patented in 1889 the method

 Americans Aylsworth and Dyer used aluminium powder and calcium

 Swede Axel Eriksson made a serious next step towards developing

 To study the properties of AAC blocks

 Manufacturing process of AAC blocks

 To study the advantages and limitations of AAC blocks

 To study the applications of AAC blocks

 Comparing AAC blocks with Conventional blocks

 Durability and moisture resistance

 Toxicity and breath ability

 High load bearing capacities

 Excellence sound insulation

Compressive strength Minimum 30kg/cm2

Thermal conductivity 0.162W/mK (avg.)

Resistance to fire 2-6 hours

Drying shrinkage 0.1%

Design gross density 850kg/cum

BIS 2185(part 3) Specification of

BIS 6072, 6073 Autoclaved reinforced

 The standard block size is 200mm height by 600mm long. Block

 Standard panel size is 600mm wide by 75mm thick with length

 AAC Wall Panels

 AAC Floor Panels

 AAC Roof Panels

 Light weight saves cost & energy in transportation, labour expenses

 Environmental friendly : it helps to reduce at least 30% of

 Reduction in dead load

 Delays transmission of heat

 Material available through out the year i.e. no seasonal variation

 Totally inert material – no salt leaching, hence less maintenance cost

 Quick assembly : Since it is a lightweight material and easy to work

 Accuracy: The panels and blocks made of autoclaved aerated concrete

 Contractors are less familiar with the product

 Consistency in quality and colour may be difficult to obtain

 Unfinished exterior walls should be covered with an exterior

 Skilled labours are required

 Auditorium and Theaters

 Education Institute construction

 Medical and Clinics

 Hotel and restaurants

 Pipeline and culvert installation

 Sound absorption for partition walls

 Fire proofing panels

 Light weight structure decreases construction cost due to reducing

Compressive Not less than 3 N/mm2 3-5 N/mm2

Dry density 551-600 kg/m3 1920 Kg/m3

Consumption of 0.77 bags of cement / Cum 1.44 bags of cement/ Cum

Thermal 0.12 w/m-k 0.8 w/m-k

Cost benefits Reduction in dead weight leading None

 AAC is a technological revolution

 It provides convenience to build

 Long lasting and strong