AAC BLOCK

AERATED AUTOCLAVED
CONCRETE (AAC) BLOCKS
AERATED AUTOCLAVED CONCRETE (AAC) BLOCKS

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 Abstract

Autoclaved Aerated Concrete (AAC) is an ultra-light concrete

masonry product. It can weigh as little as 1/5 as much as ordinary
concrete due to its distinct cellular structure featuring millions of tiny
pockets of trapped air. This cellular structure gives AAC a number of
exceptional physical characteristics. AAC consists of basic materials
that are widely available. These include sand, cement, lime, fly ash,
gypsum, aluminium powder paste, water and an expansion agent.
Silica sand, the raw material used in the greatest volume in AAC, is
one of the world's most abundant natural resources. The finished
product is up to five times the volume of the raw materials used, with
an air content of 70% to 80% (depending on the required strength and
density.) Due to this large increase in volume, AAC is very resource
efficient.

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 Literature review

From most of literature it was observed that

AAC blocks are relatively new material in construction industry.
Despite of drastic growth in manufacturing of AAC blocks, market
share of AAC blocks is very small as compared to red clay bricks. As
on the basis of soil consumption of AAC blocks, it has zero soil
consumption. Primary raw material for AAC blocks is fly ash. Fly ash
is industrial waste generated by coal based thermal power plants. Clay
bricks of one sq. ft carpet area consume 25.5 kg of top soil. AAC
block consumes 1 kg of coal whereas Clay bricks consume 8 kg of
coal. AAC Blocks with CO2 emission is 2.2 kg per sq. ft area as
compared to clay. Brick which emits 17.6 kg per sq. ft of CO2. Hence
its environment friendly too. In market AAC Blocks are available in
sizes 600/625 X 200/240 X 100-300 mm whereas clay bricks are
available in sizes 225 X 100 X 65 mm. Experiment shows that
compressive strength of AAC is 3-4 N/m2 whereas clay brick have
2.5-3 N/m2. This means high compressive strength of AAC blocks
over Clay Bricks. On the basis of density of both the blocks, AAC
have 500-700 Kg/m3 whereas clay bricks have 1800 kg/m3 which
indicates light weight nature of AAC blocks over clay bricks. Due to
this, dead weight of the structure is reduced to far more extent and
hence the structural members pass on reduced sizes and reduced
reinforcement; this indicates economy attained by the structure
constructed using AAC Blocks. AAC Blocks is also for better
material providing 30% more insulation and sealing from the
environment.

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Experimental studies: -
Size of different brick taken in analysis: -
Clay brick = 200mm x 100mm x 100mm
AAC block = 300mm x 200mm x 100mm
Density of different brick: -
Density of clay brick = 5.5 KN/m3
Density of AAC block = 19 KN/m3
Load efficiency analysis
A) Assumptions The buildings have the following criteria:
1) Building is 3 storey (G+2) high and floor area 16m x 12m.
2) Building is framed concrete structure.
3) Building is residential and has layout as shown
4) The building is design for static loading or say for gravity load i.e.
Dead load & Live load

On comparing the loadings of each building blocks with clay brick

loading.
RESULT: - The results which we have found out from our analysis
are: -
Total reaction comparison: -
Type Clay bricks AAC blocks
Total reaction 12514KN 9471KN

Area of footing required: -

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Type Clay bricks AAC blocks
Area of footing 61.18m2 46.30m2

Reinforcement comparison of Columns: -

Type Clay bricks AAC blocks
Column 5473kg 4650kg
reinforcement

Reinforcement comparison of Beams: -

Type Clay bricks AAC blocks
Beam reinforcement 4300 kg 3350kg

Reinforcement comparison of Footings: -

Type Clay bricks AAC blocks
Footing 325.13 kg 131.45 kg
reinforcement

Brick work comparison: -

Type Clay bricks AAC blocks
No. Of bricks/blocks 29100 bricks per 9750 blocks per floor
floor
CONCLUSION
Through our analysis and comparison, we have managed to find
many clear conclusions. Total savings while choosing AAC blocks
are as follows: -
Total reaction of AAC block is 24% less as compare to clay bricks.
In brick work, AAC blocks are used 66.5% less as compare to clay
bricks than 66.5%.

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 Area of footing there is 24.3% of saving n footings there is 24.3%
savings while using AAC blocks over clay bricks.
For reinforcement in footings, there is a saving of 45.5 % for AAC
blocks as compare TO CLAY BRICKS In column reinforcement
there is 15% of steel saving in AAC blocks as compared to clay
bricks.
There is 15 % and 17% of savings in columns and beams
respectively for AAC blocks over clay bricks.
This was the only savings which we could clearly see but while using
AAC blocks over clay bricks, more savings would be seen in per unit
rate of AAC blocks and very less use of plastering and mortar while
brickwork, as compared to Clay Bricks. AAC blocks proved to be the
best constructional material amidst other bricks having just a much
selected few disadvantages.

All the above points are taken from the various research papers published

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 Introduction

Since Roman times, lightweight aggregates and foaming agents have

been employed to reduce the weight of concrete. However, unlike
these foamed or light aggregate mixes, true aerated concrete relies on
the alkaline binder (lime & cement) reacting with an acid to release
gases, which remain entrained in the material.
The Autoclaved Aerated Concrete (AAC) material was developed in
1924 in Sweden. It has become one of the most used building
materials in Europe and is rapidly growing in many other countries
around the world.
AAC is produced from the common materials lime, sand, cement and
water, and a small amount of rising agent. After mixing and
moulding, it is then autoclaved under heat and pressure to create its
unique properties. AAC has excellent thermal insulation and acoustic
absorption properties. AAC is fire and pest resistant, and is
economically and environmentally superior to the more traditional
structural building materials such as concrete, wood, brick and stone.
Aerated concrete is either a cement or lime mortar, classified as
lightweight concrete, in which air-voids are entrapped in the mortar
matrix by means of a suitable aerating agent. Broadly speaking
aerated concrete falls into the group of cellular concrete (microporous
being the other). The prominent advantage of aerated concrete is its
lightweight, which economises the design of supporting structures
including the foundation and walls of lower floors. It provides a high
degree of thermal insulation and considerable savings in material due
to the porous structure.
AAC Blocks is a unique and excellent type of building material due to
its super heat, fire and sound resistance, AAC blocks are lightweight
and offers ultimate workability, flexibility and durability. Its main
ingredients include sand, water, quicklime, cement and gypsum. The
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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.

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9
 Advantages of AAC

 Resistant to Fire

The AAC Blocks are resistant to fire between a certain limit of time.
It is from a 2 hours minimum time to 6 hours maximum time limit.
However, their resistance to fire hazards is dependent on thickness of
the AAC Blocks. In the constructions where fire safety is given
highest importance. Moreover, holding fire from spreading is a very
good and positive thing in safety procedures.

 Resistant to Pests and Insects

The AAC Blocks are resistant to pests and insects. This a big plus that
helps in building maintenance. This is because the AAC Bricks
inorganic material. This in turn reduces damage to constructions.
They prevent the termites from entering the buildings. Thus, offering
protection and saving huge loss to constructions. Indeed, it a very
special quality and most required protection offering complete
protection against pests.

 Sound Proof In Nature

The AAC Blocks are sound proof in nature. This is due to their
porous nature, which absorbs sounds up to certain decibel levels. This
specialty in them offers peaceful working and living conditions. The
AAC Bricks can absorb sound to a range or limit of 45 decibels,
which is considered very good in busy city squares. Moreover, in
constructions such as hotels, hospitals, public auditoriums and studios
and similar such buildings they offer complete sound proof
environment, which is so useful for effective sound protection.

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  Resistant To Earth Quakes

The AAC Blocks are resistant to earthquakes. The natural property it

is made from is light in weight. This in turn increases the stability in
the building structures. Usually, the impact of the earthquake is
directly on the weight of the building. The AAC Bricks used in the
construction of high-rise buildings, including single unit constructions
are most reliable and safe.

 Quick Construction work

The AAC Block help in quick construction work, thereby reducing

time and constructions costs. In AAC Bricks it is easy to use ordinary
tools for cutting the walls for electrical work, including drilling of
holes. Even, band saws can be used in cutting and alignment of the
AAC Bricks. As they are large in size, the advantage is that few joints
are there in the constructions. Thus, enabling quick construction,
including strong structural support to the building. Therefore, the
work time during installation of AAC Blocks is reduced due to a
smaller number of AAC Bricks. This results in less time used for
masonry and plastering work. So, the construction work is done ahead
of time.

 Long Lasting in Nature

The AAC Blocks are long lasting in nature. Thus, offering the
building extra life span. The material in AAC Bricks of high quality
with superior strength it gives the building construction. This results
in more structural strength and strong staleness to the building. The
material used in AAC Bricks is from non-biodegradable product. It
does not attract mould, thus keeping the interior environment clean
and durable. There is no chance given to damage or deterioration of
the construction quality.

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  Cost Effective

The AAC Blocks are highly cost effective in nature. Thus, offering
cost saving and less investment on the construction work. In
comparison to clay bricks its weight is less than 80 per cent. This
considerably reduces dead weight. Furthermore, the reduction in dead
weight by such a huge margin results in reduction of cement and steel
usage for construction. This saves plenty of money on money.

 Versatile in Nature
The AAC Blocks are very versatile in nature. Their appearance is
very attractive. This gives the building structure beauty. The AAC
Bricks can adapt to architecture of any shape or size. A good mason
or a construction worker can design and construct most beautiful
buildings with them.

 Non – Hazardous
The AAC Blocks are Non-toxic in nature. They cannot be damaged
from smoke from pollution and smoke of the chimney in factories.
The best part of AAC Bricks is that it does not attract pests at all. This
is most welcome part in its nature.

 In Thermal Insulation
In thermal insulation the AAC Blocks have insulating qualities. The
thermal conductivity level of the AAC Bricks keeps the room
temperature warm during winter. In summer, it is cool and nice. At
the end of the day it offers huge savings on air conditioning load,
which means less power bills.

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  Moisture Resistance
The pollution and moisture from ecological surroundings usually
bring huge amount of damage and disfigure the buildings. It is prime
concern of buildings owners and construction work. In this area, the
AAC Blocks scores. It is highly resistant to humidity and dampness
from rain water and water in the soil. The AAC Bricks are porous in
nature. The smaller pores in it evenly distribute the water in them.
Thus, water absorption is kept to a minimum level. This enhances the
use of them in all type environmental surroundings.

 Environmentally friendly to natural surroundings

The AAC Blocks are environmentally friendly to natural
surroundings. The material of the AAC Bricks is non-toxic. It does
not pollute the air, including land and water as well. The waste dust
from the cutting process at the time of manufacturing them is given
added strength and it again used for manufacturing new bricks and
blocks. Even in construction work there is 0.1 per cent waste material
generation. This is bare minimum. Moreover, the energy consumed in
the production of AAC Blocks process is just a small quantity that can
be measured in fractions. Whereas, the production of other materials
it is much higher. There is no emission of pollution in the
manufacturing process. It does not create by-products or waste
products that are toxic. It is made from naturally raw material. The
beauty in it is that the finished product is three times the volume of
the raw material, which is used. It is most environmentally friendly
and resource efficient.

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  Light In weight
The AAC Blocks are light weight. It is the biggest feature, which is
helpful in transport and during construction work as well. The cellular
structure of the AAC Bricks created during its manufacture makes it
easy to carry around manually in small numbers. The light weight
nature is imparted from the several million tiny air cells in it. The
density of each Airbrick’s is usually between 550 to 650 kg/m³.
Indeed, it is lighter than water. Unbelievable!

 Perfect in Shape and Size

The AAC Blocks are perfect in shape and size. It is manufactured
under technical dimensions that require standard design. Therefore,
The AAC Bricks provide a uniform design in all constructions.
Therefore, the economical applications are plenty. The internal walls
can be plastered with direct application of POP. Thus, eliminating the
need of masonry work and plastering.

 High Compressive Strength

The AAC Blocks have a compressive strength of an average (3-4.5)
N/mm³. This is superior to most types of light weight blocks.
Moreover, it is 25 per cent stronger than other products of the same
density.

 Hight Resistance to Penetration of Water

The AAC Blocks offer high resistance to penetration of water in it.
This is possible due to a large number of pores in it. Itis also that their
cellular and discontinuous micro structure is much superior to the
normal clay brick. Thus, the external surface of AAC Brick walls
provides superior resistance to moisture penetration than the
traditional clay bricks.

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  Conduction of Heat Is High
Making of AAC Blocks conduction of heat is high in comparison to
CLC and Clay and Bricks. It is because of the usage of lime, gypsum
and aluminium powder in the raw material during manufacturing
process. The strength in AAC Bricks becomes less when made with
concrete chamber. With auto claves, the strength to AAC Bricks
becomes maximum. Finally, there is another big disadvantage in AAC
Blocks. Their absorption water is high. It is evident from the several
million pores in it. This facilitates their expansion in water, which can
bring cracks in the structure. This includes air gaps. Therefore, in long
exposure to moisture, the material begins to disintegrate. The strength
in AAC Bricks is reduced when it wet. You may also consider the
environmental conditions before using AAC Blocks and Bricks in
building construction.

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16
Compared with conventional concrete, AAC still has advantages,
 It uses less material--important for concrete, since Portland
cement is one of the most energy- and carbon-intensive building
materials.
 Despite the energy-intensive autoclaving process, manufacturers
say it takes about 50% less energy to make, because of the lower
Portland cement content by volume (we're haven't found anyone
to challenge those claims, but are still looking for data).
 It's lighter, which cuts down on transportation costs and fuel use.
 It's a better insulator, with a steady-state R-value just a hair
above R-1 as opposed to something more like R-0.2 (neither of
these factors in thermal mass, which we'll get to later).
 Air leakage is minimal.
 AAC also has excellent soundproofing properties.
 It can also be used as a firebreak.

DRAWBACK
 Some disadvantages of AAC blocks and panels are that they do
contain Portland cement, they are made in so few places which
means more transportation cost and using gas resources.
 Builders must learn how to use them since the mortaring is
different, some of the blocks are made to European standards
and have to be cut.
 They are porous so must have stucco or cladding on the exterior
to keep out water. For load-bearing, AAC may need rebar
reinforcement.

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 Properties of aerated concrete
Physical properties
Microstructure
In aerated concrete, the method of pore-formation (viz.,
gas release, or foaming) influences the microstructure, and thus its
properties. The material structure of aerated concrete is characterised
by its solid microporous matrix and macropores
The porous system of aerated concrete is also classified in terms of
pore size distribution functions as artificial air pores, inter-cluster
pores and inter-particle pores and the distribution of pores in the
matrix has bearing on its properties
Mechanical properties
The specimen size and shape, method of pore-
formation, direction of loading, age, water content, characteristics of
ingredients used and method of curing are reported to influence the
strength of aerated concrete. Density reduction by the formation of
large macropores is found to cause a significant strength drop.
Generally, compressive strength increases linearly with density.
Values of compressive strength for different densities.

Functional properties
Water absorption and capillarity
Aerated concrete being porous, there is a strong
interaction between water, water vapour and the porous system and
there exists various moisture transport mechanisms. In the dry state,
pores are empty and the water vapour diffusion dominates, while
some pores are called in higher humidity regions. Capillary suction
predominates for an element in contact with water. These mechanisms
make it difficult to predict the influence of pore size distribution and
water content on moisture migration

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 Durability
AAC mainly consists of tobermorite, which is much
more stable than the products formed in normally cured aerated
concrete, and hence it is durable. However, aerated concrete has high
porosity, allowing penetration by liquids and gases. This may lead to
the damage of the matrix. At higher degrees of saturation, the sample
becomes brittle and cracks completely.
Thermal conductivity
Thermal conductivity depends on density, moisture
content and ingredients of the material [3,10,51,54]. As thermal
conductivity is largely a function of density, it does not really matter
whether the product is moist cured or autoclaved as far as thermal
conductivity is concerned. The number of pores and their distribution
are also critical for thermal insulation.

Fire resistance
In practice, the re-resistance of aerated concrete is more
than or as good as ordinary dense concrete and hence its use does not
involve any risk of spread of flames. An important reason for such
behaviour is that the material is relatively homogeneous, unlike
normal concrete where the presence of coarse aggregate leads to
differential rates of expansion, cracking and disintegration.

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MANUFACTURING OF
AAC BLOCK

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How AAC is made

Autoclaved aerated concrete is a precast product manufactured by

combining silica (either in the form of sand, or recycled fly ash),
cement, lime, water, and an expansion agent - aluminium powder, and
pouring it into a mould. Once added to the concrete, the aluminium
powder reacts with the silica, resulting in the formation of millions of
microscopic hydrogen bubbles. The hydrogen bubbles cause the
concrete to expand to roughly five times its original volume. The
hydrogen subsequently evaporates, leaving a highly closed-cell
aerated concrete. The now aerated concrete is cut into blocks or
panels which are then steam and pressure cured in an autoclave.

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RAW MATERIALS USED IN AAC

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 PRODUCTION PROCESS

Autoclaved aerated concrete is quite different from dense

concrete (i.e.: “normal concrete”) in both the way it is produced
and in the composition of the final product.

Autoclaved aerated concrete is cured in an autoclave - a large

pressure vessel. In air Crete production the autoclave is
normally a steel tube some 3 metres in diameter and 45 metres
long. Steam is fed into the autoclave at high pressure, typically
reaching a pressure of 800 kPa and a temperature of 180 °C.
Autoclaved aerated concrete can be produced using a wide
range of cementitious materials, commonly: Portland cement,
lime and pulverized fuel ash (PFA) OR Portland cement, lime
and fine silica sand. The sand is usually milled to achieve
adequate fineness. A small amount of anhydrite or gypsum is
also often added.

Autoclaved aerated concrete is of much lower density than

dense concrete. The chemical reactions forming the hydration
products go virtually to completion during autoclaving and so
when removed from the autoclave and cooled, the blocks are
ready for use.
Autoclaved aerated concrete does not contain any aggregate; all
the main mix components are reactive, even milled sand where
it is used. The sand, inert when used in dense concrete, behaves
as a pozzolana in the autoclave due to the high temperature and
pressure.
The autoclaved aerated concrete production process differs
slightly between individual production plants but the principles
are similar. It is a mix that contains cement, lime and sand; these
are mixed to form slurry. Also present in the slurry is fine
aluminium powder - this is added to produce the cellular

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structure. The density of the final block can be varied by
changing the amount of aluminium powder in the mix.
The slurry is poured into moulds that resemble small railway
wagons with drop-down sides. Over a period of several hours,
two processes occur simultaneously:

The cement hydrates normally to produce ettringite and calcium

silicate hydrates and the mix gradually stiffens to form what is
termed as "green cake". The green cake rises in the mould due to
the evolution of hydrogen gas formed from the reaction between
the fine aluminium particles and the alkaline liquid. These gas
bubbles give the material its cellular structure.

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25
Price comparison of a 25m long and 2m high
wall of AAC BLOCK AND RED BRICK

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 MORTAR IN BRICKS
Size of brick= 230*115*85

Size of brick= 240*125*95 (including mortar)

Ratio = 1:6
1 m^3 volume =0.24*0.125*0.95

 Volume of 1 brick = .240*.125*.095 =0.0285

 No. of bricks in 1 m^3 =1/.0285 =850 bricks
 Volume of 1 brick Without mortar = 0.23*0.115*0.05
=0.02248
 Volume cover by 35 bricks in 1m^3 = 35*0.002248 + 0.7868
 Volume of mortar in 1m^3 =1-0.7868 =0.213
 Dry vol increases 33% = 0.213*1.33= 0.283m^3

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 MORTAR IN AAC
Size
Without mortar 600*200*200 = 0.024
With mortar 610*210*210 = 0.026
 No of AAC blocks = 1/0.026= 38.46
 Volume without mortar= .024*38.46=.923
 Volume of mortar = 1-0.923 = 0.077
 Dry value = 0.102
70% reduction in mortar

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CALCULATION OF NUMBER OF BRICKS
 c-c distance between column is 3048mm = 10 ft
 column = 230*230
 inner distance between two columns= 2818
 length of bricks=240mm
 width of bricks=125mm
 thickness of bricks=95mm
CALCULATION OF BRICKS
 Total no. of bricks in a block= 2818/125 =22.5
 No. of layers of bricks, since height of all is 2m
=2000/95
- =21 layers

 Total no. of bricks in a block=21*22.5 =472.5

 Total no. of blocks 7+1 blocks
 No. of bricks
= (7*472.5) +(3.404/125*21)
=3307.5+571.87
=3879.37
 Price of one brick=5rs
=Rs19396.85

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 CALCULATION OF NUMBER OF ACC BLOCKS
Dimensions: -
600*200*200
Blocks: -
 c/c dist between two columns=3048mm =10feet
 Column=230*230mm
 Inner dist. between two columns=2818mm
Blocks dimensions
 L=600mm
 B=200mm
 T=200mm
 No. of blocks in a layer=2818/200=14.09

 No. of layers in all =2000/200

=10 layers
 Total no of blocks in a block = 10*14.09= 1409
 No. of layers in all =2000/200
=10 layers
 Total no of blocks in a block = 10*11.35
=113.5
 Total no. of blocks= 7+1 blocks
 No. of bricks
(7*140) +(3904/200*10)
= (980) +(170)
=1150
 Price on the block 35/pc
=Rs 40250

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Reference
 https://www.buildinggreen.com/news-article/autoclaved-
aerated-concrete-aac-will-us-ever-lighten
 Autoclaved Aerated Concrete as a Green Building Material
Stefan Schnitzler October 2006
 https://www.google.co.in/?gws_rd=cr&ei=X6X3UremGIqJrAeJ
44CAAg#q=RAW+MATERIALS+USED
+Inactivates
 Structure and properties of aerated concrete: a review N.
Narayanan, K. Ramamurthy Building Technology and
Construction Management Division, Department of Civil
Engineering, Indian Institute of Technology Madras, Chennai
600 036, India, Received 7 January 1999; accepted 13 April
2000
 Shaikh Alim et al., International Journal of Advance Research,
Ideas and Innovations in Technology.
 A STUDY ON MATERIAL PROPERTIES OF AUTOCLAVED AERATED
CONCRETE (AAC) AND ITS COMPLEMENTARY WALL ELEMENTS: THEIR
COMPATIBILITY IN CONTEMPORARY AND HISTORICAL WALL SECTIONS

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